Coating System Integrating Low and High-Pressure Conveyors
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Solution Overview
Problem
The existing coating systems require separate low-pressure and high-pressure applications, which are costly and inefficient, especially when dealing with varying workpiece sizes and surface quality requirements, as they generate more overspray and take longer for low-pressure applications, while high-pressure systems are more robust and expensive.
Innovation Solution
A coating system that integrates both low-pressure and high-pressure material conveyors and applicators, with a distributor and mixer to manage pressure and material components, allowing for flexible operation between 0.5 bar and 500 bar, and includes features like double diaphragm pumps, gear pumps, and non-return valves for safety and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a low-pressure conveyor is used to deliver coating material, then coating quality is higher and thin layers can be achieved, but more overspray is generated and the coating process takes longer
Solution Approach 1:
The system dynamically switches between low-pressure and high-pressure conveyors based on the coating requirements. The control unit activates the appropriate conveyor type (low-pressure for quality-critical thin layers, high-pressure for faster coating of larger areas) to optimize both coating quality and productivity for different operational scenarios
2Productivity
If a high-pressure conveyor is used to deliver coating material, then the coating process is faster and more robust, but the system is heavier, uses more materials and produces more expensively
Solution Approach 1:
The coating system is segmented into two independent conveyor units (low-pressure and high-pressure) that can operate independently. This segmentation allows the system to use only the necessary high-pressure infrastructure when high speed is required, rather than maintaining always-on high-pressure components, thereby reducing overall system complexity and cost while preserving productivity when needed
Solution Approach 2:
The system is designed with multi-functionality by incorporating both low-pressure and high-pressure conveyors that share common control and distribution infrastructure. This universal design allows a single system to handle both quality-critical low-speed coating and high-speed robust coating operations, eliminating the need for separate dedicated systems
3Adaptability or versatility
If both low-pressure and high-pressure application systems are purchased to handle varying workpiece requirements, then versatility is improved, but the purchase cost increases
Solution Approach 1:
The patent merges low-pressure and high-pressure conveyor systems into a single integrated coating installation with a common control unit and distributed material delivery network. This consolidation allows the system to handle varying workpiece requirements (thin layers, large areas, different viscosities) with one unified platform, eliminating the need to purchase and maintain two separate coating systems
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
Enables efficient and safe coating of workpieces with both high-quality thin layers and high-pressure capabilities, reducing overspray and operational costs by using a single system for varying applications, ensuring safety and reliability.
Implementation Method 1
a diaphragm pump (1) in order to convey the coating material (31) from a storage container (21)
Implementation Method 2
a high-pressure conveyor (12) for conveying the coating material (31) at high pressure to the high-pressure material applicator (13)
Implementation Method 3
a non-return valve (16) arranged at the downstream end of a supply line (81) which connects the high-pressure conveyor (12) to the distributor (11)
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The coating system according to the invention for coating workpieces with coating material comprises a low-pressure material feeder (1) for conveying the coating material (31) at low pressure from a storage container (21). The system also includes a high-pressure material applicator (13) and a high-pressure material feeder (12) for conveying the coating material (31) at high pressure to the high-pressure material applicator (13). Furthermore, a distributor (11) is provided, which has a distributor inlet (11.1) and a first and a second distributor outlet (11.2; 11.3), wherein the distributor inlet (11.1) is connectable to the first distributor outlet (11.2) and the second distributor outlet (11.3). The distributor inlet (11.1) can be supplied with the coating material (31) originating from the low-pressure material feeder (1). The high-pressure material conveyor (12) can be supplied with coating material via the first distributor outlet (11.2).The system also includes a low-pressure material applicator (14) which can be supplied with coating material via the second distributor outlet (11.3).