Atomizer Changing System for Hollow-Wrist Coating Robots
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Solution Overview
Problem
Existing atomizer changing systems for multi-axis hollow-wrist coating robots are time-consuming, expensive, and require manual intervention, leading to increased contamination risks and reduced efficiency in switching between different atomizers and coating mediums.
Innovation Solution
An atomizer changing system comprising a master unit with a central coupling plate and releasable connecting elements, allowing for fully automatic and rapid switching between different atomizers, including high-rotation and pneumatic types, while minimizing contamination and optimizing space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual conversion of atomizer is used, then flexibility to use different atomizer types is achieved, but setup time increases and productivity decreases
Solution Approach 1:
The atomizer system is divided into separable modules: the atomizer unit itself and the coupling plate with connecting elements. This segmentation allows the atomizer to be quickly detached and replaced without manual intervention, enabling rapid switching between different atomizer types while maintaining versatility.
Solution Approach 2:
The system employs dynamic, releasable connecting elements (clamping elements and locking elements) that enable the atomizer to be quickly attached and detached from the coupling plate. This dynamic connection mechanism allows for rapid atomizer replacement, significantly reducing setup time and improving productivity compared to fixed or manual conversion systems.
2Adaptability or versatility
If multiple painting robots are used for different atomizers, then atomizer versatility is maintained, but device complexity and cost increase
Solution Approach 1:
The coupling plate is designed as a universal interface with standardized master-side connecting elements that can accommodate different slave-side connecting elements for various atomizer types. This universal design allows a single painting robot to handle multiple atomizer types, eliminating the need for multiple specialized robots and reducing overall system complexity.
Solution Approach 2:
The coupling plate acts as an intermediary component between the robot's hollow wrist and the various atomizer types. It provides a standardized interface that mediates the connection between different atomizers and the robot, simplifying the overall system architecture and reducing device complexity compared to having multiple dedicated robots.
3Extent of automation
If central clamping element with external couplings is used, then tool changing capability is achieved, but space requirement increases and kinematics are negatively affected
Solution Approach 1:
The slave-side connecting elements are positioned within the hollow wrist structure, nesting the connection mechanism inside the existing robot geometry. This nesting approach allows for automated tool changing capability while minimizing the external space requirement and avoiding negative impacts on the robot's kinematics.
Solution Approach 2:
The connection system utilizes the internal volume of the hollow wrist by positioning coupling points and connecting elements within this three-dimensional space. This dimensional reorganization allows automated tool changing functionality to be integrated without increasing the external footprint or interfering with the robot's operational envelope.
4Strength
If metal components are used in atomizer changing system, then structural strength is ensured, but unwanted side effects occur under high voltage
Solution Approach 1:
The system employs composite material construction, combining non-conductive materials (such as plastic or composite alloys) with strategically placed conductive elements. The non-conductive portions isolate the high-voltage atomizer from the robot's metal structure, preventing unwanted electrical side effects, while the conductive elements provide necessary structural strength and grounding where required.
Solution Approach 2:
Non-conductive coupling plates and isolating elements act as intermediaries between the high-voltage atomizer and the robot's metal structure. These intermediary components electrically isolate the atomizer, preventing unwanted electrical discharge or interference, while still providing the mechanical connection and structural support needed for the tool changing system.
5Ease of manufacture
If open hose lines are used in slave unit, then connection simplicity is achieved, but contamination susceptibility increases
Solution Approach 1:
The hose lines are enclosed within protective flexible sheaths or thin-walled protective coverings that form a barrier against overspray contamination. These flexible protective layers maintain the simplicity of hose connection while preventing contaminants from entering the hose interior, thus protecting the coating material flow path.
Solution Approach 2:
Protective coverings and sealing elements act as intermediaries between the open hose connections and the contaminated painting environment. These intermediary protective layers shield the hose lines from overspray and contaminants while allowing the simple connection design to be maintained.
Data Source
AI summary
Described herein is an atomizer changing system, including a master unit and at least one slave unit, where the master unit has at least the following components: a releasable connecting element, surrounding a center of the master unit, for a nonpositive and positive connection (KS, FS) of the master unit to the slave unit, a coupling plate arranged in the center of the master unit and having a plurality of coupling points for supplying an atomizer that can be connected thereto with substances, energy and/or information, and an adapter for connecting the master unit to a hollow wrist of a coating robot; and where the slave unit has at least the following components: a coupling plate for connecting the slave unit to the master unit and to the atomizer; and a releasable connecting element for connecting the slave unit to the atomizer.