Coating Jet Spray Angle Control via Partial Jets
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Solution Overview
Problem
In thermal coating processes, especially for internal combustion engine components, achieving a uniform surface coating is challenging due to deviations in the angle of incidence and velocity of the coating jet, often resulting in rejected parts despite correct process settings.
Innovation Solution
A method and device that adjust the spray angle of a coating jet by forming it from two partial jets with adjustable volume flows, allowing real-time correction of the spray angle during or between coating processes, using an image detection system to ascertain and adjust the angle without altering the particle distribution or energy content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the spray angle is not precisely controlled, then the coating quality becomes non-uniform, but increasing measurement and adjustment complexity is required to maintain precision
Solution Approach 1:
The system employs a camera to detect the actual spray angle and feeds this information back to a control unit, which automatically adjusts the spray angle to match the predetermined target angle. This closed-loop feedback mechanism maintains coating uniformity without requiring complex manual measurement and adjustment procedures.
Solution Approach 2:
The patent replaces complex mechanical angle measurement and adjustment systems with an optical detection system (camera) and automated control. Instead of using精密 mechanical gauges and manual adjustment mechanisms, the system uses image processing to detect spray angle and electronic control to adjust it, simplifying the overall device complexity while maintaining high precision.
2Manufacturing precision
If the spray angle deviates from the target angle, then coating quality deteriorates, but frequent monitoring and adjustment reduce productivity
Solution Approach 1:
The system enables continuous monitoring and adjustment of the spray angle during the coating process. The camera continuously detects the spray angle, and the control unit makes real-time adjustments to maintain the target angle, ensuring continuous high-quality coating without interrupting the process for manual checks and adjustments.
Solution Approach 2:
The spray angle control system is self-regulating, automatically detecting deviations from the target angle and correcting them without operator intervention. The control unit autonomously adjusts the spray device based on camera feedback, eliminating the need for frequent manual monitoring and adjustment that would reduce productivity.
3Adaptability or versatility
If a single jet system is used, then the device is simpler, but the spray angle cannot be adjusted during operation
Solution Approach 1:
The coating jet is divided into multiple partial jets, each controllable independently. By adjusting the volume flow of individual partial jets, the overall spray angle can be modified during operation. This segmentation allows flexible angle adjustment while maintaining a relatively simple device structure compared to completely redesigning the spray system.
Solution Approach 2:
The system transitions from a static single-jet configuration to a dynamic multi-partial jet system where the volume flow of each partial jet can be independently adjusted. This dynamic control enables real-time spray angle modification during operation, providing adaptability without requiring complete structural redesign of the spray device.
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 a consistently uniform coating quality, extends the service life of the spray device, and allows for timely recognition and compensation of wear-related issues, preventing defective outcomes.
Implementation Method 1
a control jet is formed from a second partial jet which is used to deflect the first partial jet and thereby modify the spray angle
Data Source
AI summary
A method for coating a surface with a coating jet containing coating particles includes forming the coating jet from at least two partial jets. The method also includes forming one of the exit channels as a spray channel for a first gas stream containing the coating particles. The method also includes forming the other of the exit channels as a control channel. In case of a deviation of the ascertained spray angle (α) from the predetermined target spray angle, the method also includes increasing the volume flow of a first partial jet of the at least two partial jets, and decreasing the volume flow of a second partial jet of the at least two partial jets.