Brake Disc Laser Cladding With Multi-Stage Powder Extraction
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Solution Overview
Problem
Current methods for producing coated brake discs are complex and not suitable for series production, leading to inefficiencies in resource usage and operator safety due to excess coating material not being effectively managed during the laser deposition welding process.
Innovation Solution
A multi-stage suction device is integrated into the coating system, comprising a first suction unit generating a vertically oriented flow and a second suction unit with a collar to collect excess material from the peripheral section, significantly reducing residual powder on the brake disc and improving operational safety by minimizing the need for personal protective equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laser deposition welding is used to coat brake discs, then wear resistance and thermal stability are improved, but excess coating material is generated causing contamination and safety issues
Solution Approach 1:
The patent extracts and removes excess coating material from the working space using a suction device with multiple suction units. The first suction unit removes excess material from the general working area, while the second suction unit with collar specifically targets excess material at the peripheral section of the brake disc, effectively taking out the harmful factor generated during laser deposition welding.
Solution Approach 2:
The suction device acts as an intermediary between the laser deposition welding process and the environment. It mediates the harmful effect of excess coating material by capturing and removing it before it can contaminate the production line or expose operators to dust, thus protecting both the environment and personnel.
2Device complexity
If conventional single-stage extraction is used, then device complexity is reduced, but excess material removal is insufficient leading to contamination
Solution Approach 1:
The extraction system is segmented into multiple independent suction units with different functions. The first suction unit handles general excess material removal from the working space, while the second suction unit with collar specifically addresses peripheral section contamination. This segmentation allows each unit to be optimized for its specific task, achieving thorough material removal despite increased system complexity.
Solution Approach 2:
Different regions of the working space are treated with different suction approaches. The first suction unit provides general extraction throughout the workspace, while the second suction unit with collar provides localized extraction at the peripheral section where excess material accumulates. This local quality approach ensures comprehensive coverage with targeted effectiveness.
3Device complexity
If manual handling and single-stage extraction are used, then operator equipment is simplified, but operator safety is compromised due to dust exposure
Solution Approach 1:
The multi-stage suction device serves as an intermediary protective barrier between the dust-generating laser deposition process and the operators. It actively captures and removes excess coating material and dust particles from the working space, preventing operator exposure and reducing the need for extensive personal protective equipment.
Solution Approach 2:
The suction device operates autonomously to maintain a clean working environment during laser deposition welding. It continuously removes excess material and dust without requiring manual intervention, thereby protecting operators while simplifying their equipment needs.
4Manufacturing precision
If complex production processes are used for coated brake discs, then coating quality is improved, but productivity and automation suitability deteriorate
Solution Approach 1:
The multi-stage suction device provides self-service by automatically removing excess coating material during the laser deposition welding process. This eliminates the need for complex manual cleaning operations and downstream processing, thereby maintaining high coating quality while significantly improving productivity and suitability for automated series production.
Solution Approach 2:
The suction device operates continuously throughout the laser deposition welding process, maintaining a clean working environment and preventing excess material accumulation. This continuous action ensures consistent coating quality while enabling uninterrupted production flow, thereby improving both quality and productivity.
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 system achieves nearly complete removal of excess material, reducing the burden on downstream processes and environmental protection measures, enabling more efficient and automated production with reduced operator exposure to dust, thus enhancing the suitability for industrial-scale production.
Implementation Method 1
a first suction unit is provided for a first of the suction stages, which generates a vertically oriented flow in the working space
Implementation Method 2
a second suction unit is provided for a second of the suction stages, wherein the second suction unit comprises a collar which is assigned to a peripheral section of the base body and sucks off excess material there
Implementation Method 3
generating a laser beam through the nozzle to heat the powder and/or substrate to coat the substrate with the powder
Implementation Method 4
heat the powder and/or substrate to coat the substrate with the powder
Implementation Method 5
The coating of brake discs can be carried out, for example, using the so-called EHLA process (extreme high-speed laser cladding). Generally, the present disclosure refers to a thermally induced deposition on a substrate
Data Source
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AI summary
The invention relates to a production facility for producing brake discs and to a device for coating brake discs, in particular using laser cladding. The device comprises a base (12) with a housing (14) which forms a work area (22), a workpiece support (26) in the work area (22), said workpiece support (26) being designed to receive a main part of a brake disc, a coating head (32) which is designed to produce a coating on the main part, in particular by a thermally induced deposition of a powder material, a handling device which produces relative movements between the workpiece support (26) and the coating head (32), and a suction device for suctioning excess material out of the work area (22), said suction process being carried out in multiple stages.