Cylinder Bore Coating Thickness Uniformity
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Solution Overview
Problem
The existing spraying techniques for forming a sprayed film on the inner surface of aluminum cylinder bores result in uneven film thickness, particularly at the axial ends, leading to increased spraying and finishing times, and excessive material usage due to higher airflow rates affecting the material flow.
Innovation Solution
The method involves adjusting the spraying gun's movement and material supply at the axial ends by increasing the spraying material amount, reducing movement and rotational speeds, and incorporating reciprocating motions to ensure uniform film thickness across the bore surface, using a specialized apparatus with a spraying gun, material supply device, and control system to manage these adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If air flow is provided inside the cylinder bore to prevent foreign matter, then foreign matter is removed, but the sprayed film thickness becomes non-uniform at the axial end
Solution Approach 1:
The patent applies different spraying conditions to different regions of the cylinder bore. Specifically, the spraying gun moves at different speeds for the axial end region compared to other portions, and the material supply amount is adjusted locally to compensate for the air flow effect, achieving uniform film thickness while maintaining foreign matter prevention
2Manufacturing precision
If the sprayed film thickness is increased to compensate for thin axial end, then film thickness uniformity is improved, but spraying time and material usage increase
Solution Approach 1:
The patent applies different spraying conditions to different regions of the cylinder bore. Specifically, the spraying gun moves at different speeds for the axial end region compared to other portions, and the material supply amount is adjusted locally to compensate for the air flow effect, achieving uniform film thickness while maintaining foreign matter prevention
3Manufacturing precision
If the sprayed film thickness is increased to compensate for thin axial end, then film thickness uniformity is improved, but material usage increases
Solution Approach 1:
The patent applies different spraying conditions to different regions of the cylinder bore. Specifically, the spraying gun moves at different speeds for the axial end region compared to other portions, and the material supply amount is adjusted locally to compensate for the air flow effect, achieving uniform film thickness while maintaining foreign matter prevention
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 approach achieves uniform film thickness, reduces spraying and finishing times, and minimizes material usage by optimizing the spraying process at the axial ends, ensuring consistent film quality and efficiency.
Implementation Method 1
moving and rotating a spraying gun inside of a bore, forming a sprayed film by spraying a melted spraying material at the inner surface of the bore using the spraying gun
Implementation Method 2
forming a sprayed film by spraying a melted spraying material at the inner surface of the bore
Data Source
Figure 1
Figure 2
Figure 3(a)~3(c)
AI summary
A sprayed film forming method and apparatus in which the thickness of the sprayed film in a predetermined region is increased so as to unify the entire thickness. A sprayed film is formed at a cylinder bore (3) inner surface while a spraying gun (5) is moved in an axial direction during rotation inside the bore. Air inside the bore is sucked out (49) to prevent foreign material from being caught in the sprayed film. The flow rate inside the bore tends to become higher at an axial end on a suction side, resulting in a thinned region. The supply speed of a wire (11) serving as a spraying material to the spraying gun (5) or the number of sprays in this region is higher than those at other portions. The thickness at the axial end of the bore is made equal while suppressing an increase in working time and spraying material used.