Automated Flame Spray Metallizing for Precise Mold Component Repair
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Solution Overview
Problem
Manual metallization of mold components in glass container manufacturing results in inconsistent quality and precision due to the manual nature of the process.
Innovation Solution
A metallizing system and method that automates the metallization process using a metallizing workstation with a rotatable workpiece spindle, a metallizer station with a movable flame spray torch, and a material handler to precisely apply a metallized layer of metal onto worn workpieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual metallization is used, then ease of operation is improved, but manufacturing precision deteriorates
Solution Approach 1:
The patent replaces the manual mechanical system with an automated robotic system. The robotic arm equipped with a metallization torch automatically positions and moves the torch along the workpiece surface, eliminating manual manipulation while achieving consistent, precise metal deposition. The system uses computer-controlled motion to maintain optimal torch-to-workpiece distance and traversal speed, ensuring uniform coating thickness and quality across all metallized surfaces.
2Manufacturing precision
If automated metallization is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The robotic system is designed with multi-functionality to justify the increased complexity. The same robotic arm and torch assembly can perform metallization on various workpiece geometries and materials by simply reprogramming the motion paths and adjusting torch parameters. The system integrates multiple functions including automated positioning, torch control, material feed, and quality monitoring into a single coordinated platform, making the complexity worthwhile through versatile application capability.
Solution Approach 2:
The patent introduces an intermediary control system that mediates between the operator and the complex robotic metallization process. This control interface allows operators to set parameters and monitor progress without needing to understand the underlying mechanical and electrical complexity of the robotic system. The intermediary layer abstracts the complexity, enabling easy operation while maintaining precise automated control.
3Device complexity
If manual metallization is used, then device complexity is reduced, but reliability deteriorates
Solution Approach 1:
The automated metallization system incorporates feedback mechanisms that continuously monitor the deposition process. Sensors detect variables such as torch-to-workpiece distance, deposition rate, and coating uniformity, automatically adjusting parameters to maintain consistent quality. This closed-loop control ensures reliable, repeatable results across multiple workpieces and operators, eliminating the variability inherent in manual processes while the systematic approach manages overall device complexity.
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
Improves process repeatability and quality of metallized mold components by reducing manual intervention, ensuring consistent and precise application of metal coatings.
Implementation Method 1
a flame spray torch configured to emit a flame and receive powdered metal material into the torch flame to create a thermal metallic spray
Data Source
AI summary
A metallizing system for metallizing worn workpieces to produce metallized workpieces is disclosed. The metallizing system includes a metallizing workstation, which includes a worktable configured to receive and rotate a worn workpiece, at which the worn workpiece is metallized into a metallized workpiece by being rotated through a thermal metallic spray of a flame spray torch. The metallizing system also includes a metallizer station, which includes a metallizer handler that carries a metallizing applicator. The metallizing applicator is movable towards and away from the worktable and the retained workpiece and includes the flame spray torch. The metallizing system automates the metallizing operation in that neither the worn workpiece nor the flame spray torch needs to be hand manipulated during metallizing of the worn workpiece. A method of metallizing a worn workpiece to produce a metallized workpiece is also described.