Automatic Sprayer Cleaning System for Coating Booths
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Solution Overview
Problem
Current automatic cleaning systems in coating facilities are inadequate for thoroughly cleaning multiaxial spraying robots due to short cleaning times and incomplete drying, leading to finishing defects and increased personnel exposure to hazardous solvents.
Innovation Solution
An automatic cleaning process that utilizes programmed production stoppages for extended cleaning sequences, including dedicated rinsing and drying stations, allowing for comprehensive cleaning of all sprayer surfaces without human intervention, using a combination of solvent jets and mechanical brushes for effective paint removal and air flow for drying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If cleaning operations are performed manually by operators during production stoppages, then cleaning can be performed with flexible timing, but personnel are exposed to harmful solvent vapors and cleaning quality is inconsistent
Solution Approach 1:
The cleaning system performs automatic cleaning of the sprayer without human intervention. The sprayer is cleaned by automated solvent application and drying processes, eliminating the need for operators to manually clean equipment and exposing them to harmful solvent vapors.
Solution Approach 2:
Manual mechanical cleaning by operators is replaced with an automated system that uses solvent jets and air drying. The cleaning process is transformed from a manual operation to an automated sequence controlled by the plant control system.
2Manufacturing precision
If cleaning time is extended to improve cleaning quality, then more thorough cleaning is achieved, but production efficiency decreases
Solution Approach 1:
The sprayer is cleaned during scheduled production stoppages before the next painting operation begins. This preliminary cleaning ensures the sprayer is thoroughly cleaned without impacting ongoing production, as cleaning occurs during already-planned downtime for color or vehicle changes.
Solution Approach 2:
The cleaning process is integrated into the continuous production cycle by utilizing existing production stoppages. The sprayer is cleaned automatically during these stoppages, and the system is ready for immediate use when production resumes, maintaining continuous operational efficiency.
3Area of stationary object
If a rinsing box is used for drying the sprayer, then space inside the booth is reduced, but drying effectiveness is insufficient
Solution Approach 1:
The drying function is extracted from the rinsing box and implemented as a separate dedicated drying station. This separation allows the rinsing box to be optimized for space efficiency while the dedicated drying station provides effective drying through controlled air flow, resolving the conflict between compactness and drying performance.
Solution Approach 2:
The cleaning system is segmented into distinct functional zones: a rinsing box for solvent application and a separate drying station for air drying. This segmentation allows each component to be optimized for its specific function - the rinsing box for compact solvent delivery and the drying station for effective moisture removal.
4Productivity
If cleaning is performed during changeover periods, then production continuity is maintained, but cleaning time is insufficient for thorough cleaning
Solution Approach 1:
The sprayer is cleaned in advance during scheduled production stoppages before the next painting operation. This preliminary cleaning ensures thorough cleaning is completed before production resumes, maintaining both production continuity and cleaning quality.
Solution Approach 2:
The automated cleaning system operates continuously during production stoppages without requiring operator intervention. The cleaning sequence is executed automatically, ensuring consistent thorough cleaning while maintaining production schedules and continuity.
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
Ensures thorough and reproducible cleaning of all sprayer surfaces, reducing finishing defects and operator exposure to solvents, while maintaining production efficiency and economic profitability.
Implementation Method 1
The drying station (4) makes it possible to dry the liquid solvent applied on the surfaces of the sprayer (86) to prevent the solvent from dripping on the surfaces to be painted
Implementation Method 2
a ventilation system is used to generate a vertical stream of air directed from top to bottom, which makes it possible to guide the drops of paint toward the filtration system
Implementation Method 3
This water or powder reserve is intended to absorb the drops of paint from the overspray
Data Source
AI summary
The invention relates to an automatic cleaning process, carried out during cleaning sequences during which all or at least part of an element to be cleaned is cleaned, each element to be cleaned being positioned inside a controlled atmosphere booth belonging to a coating facility. The cleaning sequences of the element(s) are programmed during imposed production stoppages of the facility.The invention also relates to a drying station, intended to be positioned inside a booth with a controlled atmosphere belonging to a coating facility, this drying station being dimensioned to receive all or part of a spraying robot, comprising a moving arm at the end of which a handle and a sprayer attached on the handle are provided.