Coating Device Longitudinal Spray Hollow Body Complexity
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Solution Overview
Problem
Existing arc wire spraying systems for coating components, particularly hollow bodies, have high structural complexity due to the need for 90° deflection of the spray jet, which complicates the design and reduces coating quality.
Innovation Solution
A coating device with a separate distribution device and spray device, where the spray jet is directed longitudinally, eliminating the need for deflection, and utilizing a rotary distributor disk with ceramic surfaces and adjustable speed to optimize particle delivery and surface contact, along with a suction device for overspray management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the spray jet is deflected by 90° to achieve radial alignment in hollow bodies, then the coating can be applied to the inner surfaces, but the structural complexity increases significantly
Solution Approach 1:
The device is divided into functionally separate components: a spray device that generates the spray jet in a simple longitudinal direction, and a separate distribution device that handles the deflection and radial alignment. This segmentation allows each component to be optimized independently, reducing overall structural complexity while maintaining coating capability for hollow bodies.
Solution Approach 2:
The distribution device acts as an intermediary element between the spray device and the hollow body surface. It receives the spray jet from the spray device and transforms its direction to achieve radial alignment, eliminating the need for complex integrated deflection mechanisms while maintaining the required coating geometry.
2Device complexity
If the spray jet is directed longitudinally without deflection, then the structural design is simplified, but the coating coverage on hollow bodies is reduced
Solution Approach 1:
By separating the spray generation function from the distribution function, the system achieves simple longitudinal spray direction while using the distribution device to provide the necessary radial alignment and coverage for hollow bodies.
Solution Approach 2:
The distribution device incorporates a rotary-driven distribution disk that dynamically adjusts the spray jet direction radially. This dynamic mechanism enables the system to maintain simple longitudinal spray geometry while achieving comprehensive coverage on rotating hollow body components.
3Manufacturing precision
If a rotary distributor disk is used to deflect the spray jet, then the coating uniformity is improved, but the device complexity increases
Solution Approach 1:
The distribution device is segmented into a rotary-driven distribution disk and a stationary spray device. This segmentation allows the complex rotary mechanism to be isolated and optimized for uniformity while the spray device remains simple and dedicated to generating the spray jet.
Solution Approach 2:
The rotary distribution disk changes the spatial parameters of the spray jet by rotating at controlled speeds, transforming the longitudinal spray into radially aligned coating patterns. This parameter change approach achieves uniform coating distribution without requiring complex mechanical deflection mechanisms.
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 solution simplifies the structural design, improves coating quality by ensuring efficient particle delivery and surface contact, and enhances thermal resilience and surface quality, allowing for effective coating of complex geometries with reduced constructive effort.
Implementation Method 1
an electric arc is generated between the two wire ends by means of high electrical voltage, which melts the wire material
Implementation Method 2
the droplets of molten coating material are discharged by means of pressurized air supplied through the hollow interior of the torch shaft
Implementation Method 3
the particles of the spray jet of melted coating material hit the distributor disc, they are first caught by it and moved on a circular path. However, the centripetal forces that can be transmitted in this way are limited by the static friction between the particles and the surface of the distributor disc. If the static friction is exceeded, the particles - following their tangentially directed inertial forces - are moved in the direction of the surfaces to be coated
Implementation Method 4
a suction device for removing the overspray that occurs during coating
Data Source
Figure 1
Figure 2
AI summary
The device has a hollow part, with a spray of a coating material, through which a directional spray of coating material is created. The spray is provided from the distributor device (7) and causes the diversion of the spray on the coated surface of the component. An independent claim is included for a method.