Atomizer Return System for Parallel Paint Change Cycles
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Solution Overview
Problem
Current painting systems using rotary atomizers face inefficiencies during color changes, including high cycle times, hazardous waste disposal, and introduction of volatile organic compounds (VOCs) due to the need for separate collection and cleaning processes, which hinder the parallel cleaning of atomizers and extend paint change cycles.
Innovation Solution
The implementation of a rotary atomizer with a return system that recirculates paint residues during color changes, allowing simultaneous flushing of residues and external cleaning, reducing cycle time and eliminating the need for separate collection hoppers, while using a flushing medium to prevent reaction between paint systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If paint residues are flushed into a collecting hopper or container, then paint residues can be collected, but the rotary atomizer must move to the collecting hopper which takes additional time and extends cycle time
Solution Approach 1:
The patent combines the paint residue collection function with the existing paint supply system by integrating a collection container into the paint supply line. This allows paint residues to be flushed into the collection container without requiring the rotary atomizer to move, enabling parallel operation of atomizer cleaning and new paint pressurization.
Solution Approach 2:
The patent performs preliminary pressurization of the new paint into the paint supply line before the actual paint change is needed. This preliminary action allows the system to be ready for immediate paint change, reducing the overall cycle time by overlapping preparation steps with production cycles.
2Reliability
If the rotary atomizer is moved to a collecting hopper for rinsing, then paint residues can be flushed out, but parallel cleaning of outer surfaces cannot be performed simultaneously
Solution Approach 1:
The patent segments the cleaning process into two independent parts: internal paint residue flushing through the paint supply line and external surface cleaning. This segmentation allows both cleaning operations to proceed simultaneously without interfering with each other, thereby improving overall cleaning efficiency and reducing downtime.
3Reliability
If separate installations such as solvent-flushed collection hoppers are used, then paint residues can be collected, but a great deal of maintenance and cleaning is required
Solution Approach 1:
The patent makes the paint supply line serve multiple functions: it supplies paint during normal operation and serves as a flush path for paint residue collection during color changes. This multi-functionality eliminates the need for separate dedicated collection hoppers, thereby reducing maintenance requirements while maintaining reliable paint residue collection.
4Ease of operation
If multicomponent reactive paint material is discharged into the paint booth, then flushing can be performed, but volatile organic compounds are introduced into the paint booth requiring further purification
Solution Approach 1:
The patent extracts the paint residue collection function from the paint booth environment by routing flushed paint residues through the paint supply line into a separate collection container located outside the paint booth. This extraction prevents volatile organic compounds from being introduced into the paint booth, eliminating the need for additional air purification steps while maintaining ease of flushing operation.
Data Source
AI summary
The disclosure relates to an atomizer for the application of a multi-component paint, with a master paint connection, a hardener connection, a mixer, a hardener line leading in the atomizer from the hardener connection to the mixer, a master paint line, which in the atomizer leads from the master paint connection to the mixer, and with a main valve for controlling the paint delivery, the main valve being arranged downstream of the mixer and controlling the flow of the multicomponent paint to an application element, in particular to a rotatable bell cup. The atomizer according to the disclosure is characterized by a first return connection for returning the multicomponent paint from the atomizer to a return system. For this purpose, the atomizer has a first return line which branches off in the atomizer between the mixer and the main valve and opens into the first return connection.