Rotary Atomizer Sealing Element for Gap Contamination
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Solution Overview
Problem
Rotary atomizers face issues with cleaning liquids and coating agents penetrating into the annular gap between the bell cup and the shaping air ring, leading to contamination during the coating process due to incomplete sealing, which complicates automated cleaning and can result in painting defects.
Innovation Solution
A mechanically acting, elastically deformable sealing element is used to seal the gap between the bearing unit and the shaping air ring, preventing external media and particles from entering and ensuring effective cleaning without liquid accumulation during automated cleaning processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If automated cleaning is performed by spraying cleaning liquid directly at the atomizer, then cleaning effectiveness is improved, but cleaning liquid penetrates into the annular gap between the bell cup and shaping air ring causing contamination
Solution Approach 1:
A sealing element is introduced as an intermediary component between the bell cup and shaping air ring to prevent cleaning liquid from penetrating into the annular gap. The sealing element acts as a barrier that allows automated cleaning to proceed effectively while blocking the harmful infiltration of cleaning liquid into the gap space.
Solution Approach 2:
The sealing element is designed as a flexible component that can deform elastically to maintain effective sealing contact. This flexibility allows the sealing element to adapt to slight variations in positioning and maintain the seal under different operating conditions, preventing cleaning liquid penetration while allowing for thermal expansion and mechanical tolerances.
2Ease of manufacture
If the annular gap is left open for normal operation, then ease of assembly and manufacturing is improved, but cleaning liquid and coating agent can penetrate into the gap during cleaning operations
Solution Approach 1:
The sealing element is designed as a flexible component that can deform elastically to maintain effective sealing contact. This flexibility allows the sealing element to adapt to slight variations in positioning and maintain the seal under different operating conditions, preventing cleaning liquid penetration while allowing for thermal expansion and mechanical tolerances.
Solution Approach 2:
The sealing element's elastic deformability allows it to change its physical state in response to pressure variations. During cleaning operations, the element deforms to block the gap; during normal operation, it maintains a balanced state that prevents leakage while allowing for operational tolerances and thermal effects.
3Reliability
If a rigid seal is used to prevent liquid penetration, then sealing effectiveness is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The sealing element is designed as a flexible component that can deform elastically to maintain effective sealing contact. This flexibility allows the sealing element to adapt to slight variations in positioning and maintain the seal under different operating conditions, preventing cleaning liquid penetration while allowing for thermal expansion and mechanical tolerances.
Solution Approach 2:
The sealing element is made from elastomeric material that combines the benefits of flexibility and sealing effectiveness. This material choice provides both the necessary compliance to accommodate manufacturing tolerances and the elastic recovery to maintain sealing contact, achieving reliable sealing without complex mechanical structures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The sealing element effectively prevents contamination by sealing the gap radially inward, allowing for direct spraying of cleaning fluid during automated cleaning, ensuring a clean coating process and preventing interference from external media or particles during both cleaning and operation.
Implementation Method 1
A mechanically acting, elastically deformable sealing element is used to seal the gap between the bearing unit and the shaping air ring
Implementation Method 2
a turbine loaded with compressed air and mounted on air bearings and carries a bell disk which rotates at high speed during the coating operation
Implementation Method 3
It is also possible to blow out the shaping air jet at an angle to the axis of rotation of the bell cup or even in a radial direction, the so-called Coanda effect is used
Implementation Method 4
a turbine loaded with compressed air and mounted on air bearings and carries a bell disk which rotates at high speed during the coating operation
Implementation Method 5
Coating agent (e.g. paint) is fed to the bell cup through an internal paint tube, whereby the coating agent is carried outwards by centrifugal forces
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The rotary atomizer component comprises a bushing-shaped shaft cover (25) made of material softer than material of bearing shaft, which covers the bearing shaft when mounted partially in area of annular gap between the bell cup (4) and the atomizer casing. Independent claims are included for the following: (1) rotary atomizer; (2) method for coating installation using paint robot with rotary atomizer; and (3) method for cleaning rotary atomizer.