Automated Spray Machine for Concrete Articles
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Solution Overview
Problem
Existing machines for spraying paints or powders onto large, complexly shaped concrete or stone articles are inefficient, require long processing times, and lack automation, making them hazardous for operators and unable to handle multiple articles simultaneously, with inadequate handling and drying capabilities.
Innovation Solution
A machine with a combination of longitudinal and transverse guide systems, multiple spray heads, and vacuum-drying capabilities, allowing for precise and uniform coating of large, complexly shaped articles and simultaneous processing of multiple items, with integrated motor control and flexible hose systems for efficient movement and application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual spraying equipment is used, then operator flexibility is maintained, but processing time increases and operator safety deteriorates due to harmful work environment
Solution Approach 1:
The patent replaces manual mechanical spraying operations with an automated robotic system that includes a programmable controller, multiple spray heads with motors, and automated positioning mechanisms. This substitution eliminates operator exposure to harmful environments while significantly increasing processing speed and productivity.
Solution Approach 2:
The system incorporates automated material delivery through flexible hoses connected to powder containers, self-positioning mechanisms with motors and guides, and integrated control systems that autonomously coordinate spray heads, movement, and material delivery without human intervention during operation.
2Adaptability or versatility
If conventional spray machines are used, then simple structure is maintained, but they cannot handle large or complexly shaped articles
Solution Approach 1:
The patent divides the spraying system into multiple independent spray heads (at least two), each capable of independent positioning and operation. This segmentation allows the system to handle large and complexly shaped articles by targeting different surfaces simultaneously, while each individual spray head maintains a relatively simple structure.
Solution Approach 2:
The system incorporates three-dimensional movement capabilities with longitudinal guides, transverse guides, and vertical positioning mechanisms, allowing spray heads to access surfaces in multiple dimensions. This multi-dimensional approach enables handling of large and complexly shaped articles without requiring overly complex individual component structures.
3Productivity
If single-article processing is used, then machine simplicity is maintained, but productivity decreases
Solution Approach 1:
The patent merges multiple spray heads and their associated positioning systems into a single integrated machine platform with shared guides, motors, and control systems. This combination enables simultaneous processing of multiple articles or multiple surfaces of one article, increasing productivity while avoiding the need for separate simple machines for each task.
4Manufacturing precision
If fixed spray head mounting is used, then structural simplicity is maintained, but uniform spraying on complex surfaces cannot be achieved
Solution Approach 1:
The patent implements dynamic positioning systems with motors and guides that enable spray heads to move precisely along longitudinal and transverse axes and adjust vertical positions. This dynamic capability allows the spray heads to maintain optimal positioning for uniform coating on complex surfaces, while the motorized systems provide controlled, repeatable movement for precision.
Solution Approach 2:
The system incorporates programmable controllers that coordinate the movement and positioning of spray heads, likely using feedback mechanisms to maintain precise positioning and uniform spray application across complex surfaces, ensuring consistent coating quality.
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 machine enables efficient, uniform spraying and drying of paints or powders on large, complexly shaped articles, significantly reducing processing time and improving safety by automating the process and allowing for simultaneous treatment of multiple articles.
Implementation Method 1
at least one vacuum means, which creates a negative pressure in the support area for sucking up paints and powders dispersed in the environment
Implementation Method 2
at least one radiation means, which are oriented toward the support area for drying the paints once they have been sprayed onto the articles
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A machine (1) for spraying paints or powders (P) onto surfaces (S) of articles of manufacture (M) made of concrete or stone materials, comprisingfirst longitudinal guide means (2) adapted to be anchored to the ground and defining a lower support area (3) for an article (M) to be sprayed, a supporting structure (6) slidably mounted to the first longitudinal guide means (2), second transverse guide means (7) associated with the supporting structure (6), a first spray head (22) slidably mounted to the second guide means (7) and one or more reservoirs (23) for the products (P) to be sprayed operably connected to the first spray head (22). The second guide means (7) are comprised of transverse guides (15, 16, 17, 18) defining two longitudinal gaps (17, 20). The first head (22) is secured to a first substantially vertical post (24) fixed to a first carriage (25) that is designed to slide in the first gap (17), and third guide means (26) are associated with the first carriage (25) for guiding the first post (24) in a substantially vertical direction (V1), for spraying to occur in three mutually perpendicular directions. A second spray head is secured to a substantially vertical post (30) fixed to a second carriage (31) that slides in the second gap (20), and fourth guide means (32) are associated with the second carriage (31) for guiding the second post (30) in a substantially vertical direction (V2).