Double Bell Cup Centrifugal Paint Atomization
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Solution Overview
Problem
Conventional bell cups in painting robots fail to uniformly eject pigment, leading to non-uniform paint films, increased costs, and pollution due to the need for multiple spray applications and high overspray ratios.
Innovation Solution
A double bell cup design with a tapered structure and specific internal and external components that allow for simultaneous centrifugal injection of pigment into both the central and outer regions, optimizing the injection angles and paths to enhance uniformity and reduce pigment usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional bell cup with a single tapered structure is used, then the device complexity is low, but the manufacturing precision of the paint film is insufficient due to non-uniform pigment ejection
Solution Approach 1:
The bell cup is divided into two separate bell cups: an outer bell cup and an inner bell cup. Each bell cup has its own ejection holes positioned at different locations and angles, allowing independent control of pigment ejection patterns. This segmentation enables the outer bell cup to cover outer regions while the inner bell cup targets central regions, achieving uniform paint film composition without requiring a single complex structure
Solution Approach 2:
The inner bell cup is positioned inside the outer bell cup, with the inner bell cup's ejection holes directed toward the central region and the outer bell cup's ejection holes directed toward outer regions. This nested configuration allows both bell cups to operate simultaneously with coordinated pigment ejection, achieving uniform paint film formation while maintaining a compact integrated structure
2Productivity
If a conventional bell cup is used, then the device complexity is low, but the productivity is reduced due to the need for multiple spray applications
Solution Approach 1:
The bell cup system is segmented into outer and inner bell cups with dedicated ejection holes for different regions. The outer bell cup ejection holes are positioned to target outer regions, while the inner bell cup ejection holes target central regions. This segmentation allows simultaneous coverage of all areas in a single spray operation, eliminating the need for multiple applications and improving productivity
Solution Approach 2:
The outer bell cup and inner bell cup are merged into a single integrated painting device, with both bell cups operating simultaneously during one spray cycle. The controller coordinates pigment ejection from both bell cups to achieve uniform paint film formation across the entire surface in a single operation, combining the functions of multiple spray applications into one efficient process
3Loss of substance
If a conventional bell cup is used, then the device complexity is low, but the loss of substance increases due to high overspray ratio and redundant pigment usage
Solution Approach 1:
The bell cup is segmented into outer and inner bell cups with precisely positioned ejection holes. The outer bell cup ejection holes are oriented to deliver pigment specifically to outer regions, while the inner bell cup ejection holes are oriented to deliver pigment to central regions. This segmentation ensures pigment is ejected only where needed, minimizing overspray and reducing pigment waste
Solution Approach 2:
Different regions of the bell cup system are designed with locally optimized ejection characteristics. The outer bell cup has ejection holes positioned and angled for optimal outer region coverage, while the inner bell cup has ejection holes positioned and angled for optimal central region coverage. This local quality optimization ensures efficient pigment utilization in each region, reducing overall substance loss
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 double bell cup achieves improved color and texture uniformity on paint targets, reduces the need for multiple spray applications, and decreases pigment and thinner usage, thereby lowering costs and environmental impact.
Implementation Method 1
a bell cup (3) installed at a driving shaft of the driving motor (2) and configured to centrifugally inject the pigment moved from an ejection pipe to a paint target
Data Source
AI summary
The present invention relates to a double bell cup installed on an end portion of a painting robot to centrifugally spray paint to an object to be painted, the double bell cup comprising: an outer body having a tapered structure that becomes gradually wider from the top to the bottom, wherein the outer body has an inlet passage formed on the top side thereof, a stagnation passage formed therein to communicate with the inlet passage, and a spray passage formed on the bottom side thereof to communicate with the stagnation passage, and paint is introduced through the inlet passage and retained in the stagnation passage; and an inner body having a tapered structure that becomes gradually wider from the top to the bottom.