Coating Device Segmentation for Reduced Rotating Mass
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Solution Overview
Problem
Existing coating devices, such as arc wire spraying systems, have complex structures and high manufacturing and operating costs due to the need for a rotating feed device that must be firmly connected to the torch shaft, limiting their efficiency and simplicity.
Innovation Solution
A device where the distribution device for coating material is decoupled from the supply device, allowing for a simpler structure and reduced rotating mass, with a separate feed device that can supply wire segments tailored to the coating process, enabling temporary decoupling and reducing the need for a large rotary drive.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the feed device is firmly connected to the torch shaft to ensure continuous supply of coating material, then the reliability of coating material supply is improved, but the device complexity increases and manufacturing costs rise
Solution Approach 1:
The coating device is divided into two independent parts: a distribution device (torch shaft) that rotates during coating and a separate feed device that supplies wire segments. The distribution device receives pre-loaded wire segments and processes them independently, eliminating the need for a complex rotating feed mechanism while ensuring continuous material supply.
Solution Approach 2:
The feed device loads a specific quantity of wire segments into the distribution device before the coating process begins. This preliminary loading action ensures that the distribution device has sufficient coating material for the entire coating operation, eliminating the need for continuous feeding mechanisms during rotation.
2Reliability
If the feed device rotates with the torch shaft to maintain continuous coating material supply, then the reliability of coating is improved, but the use of energy increases due to larger rotating mass
Solution Approach 1:
The system separates the rotating distribution device from the stationary feed device. Only the lightweight distribution device rotates during coating, containing only the necessary wire segments for the coating operation. The heavier feed device remains stationary, dramatically reducing the rotating mass and energy consumption of the rotary drive.
Solution Approach 2:
Wire segments are pre-loaded into the distribution device before rotation begins. This eliminates the need for the feed device to rotate or supply material during the coating process, further reducing the functional requirements and mass of the rotating components.
3Productivity
If a large rotary drive is used to ensure continuous supply of coating material during rotation, then the productivity is improved, but the manufacturing cost increases
Solution Approach 1:
The coating system is segmented into a stationary feed device for loading and a rotating distribution device for application. The distribution device only needs to rotate lightweight wire segments and coating material, requiring a much smaller, less expensive rotary drive compared to systems that rotate the entire feed mechanism.
Solution Approach 2:
The feed device prepares and loads the required quantity of wire segments into the distribution device before the coating process starts. This preliminary preparation enables the distribution device to operate independently with minimal rotating mass, reducing the size and cost of the rotary drive while maintaining continuous coating capability.
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
This design results in a structurally simpler and cost-effective coating device with reduced energy costs and improved manufacturing efficiency, particularly suitable for internal coating processes, allowing for precise material supply and adaptable to different coating materials and projects.
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 coating material is melted and then atomized—usually by means of a compressed air or other gas stream—and transported to the surface to be coated
Data Source
Figure 1~3
Figure 4a~4d
AI summary
Process for coating a component, especially internally coating by means of a distribution device. Prior to coating a specific amount of coating material, e.g. in the form of wire segments is fed to the distribution device. The coating material is melted by means of an arc and is transported to the component in a gas stream. An independent claim is included for a component coating device.