Electromagnetic Wire Spray Coating With Integrated Metal Dust Capture
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Solution Overview
Problem
Arc spraying technologies generate high temperatures leading to metal evaporation, resulting in occupational hazards such as pneumoconiosis and metal fever due to metal dust inhalation, as workers are exposed to long-lasting metal particles in the air.
Innovation Solution
A wire-feeding electromagnetic spray additive manufacturing device and method that uses an AC power source, heating coils, and a stirring needle with spinnerets to melt metal wires, which are then sprayed onto a substrate, incorporating a smoke collection system with a negative ion generator to purify the air and a rotating mechanism for forming a dense coating, reducing metal dust exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If arc spraying technology is used to heat spraying materials to molten state, then spraying efficiency and coating formation are improved, but metal evaporation occurs causing occupational health hazards
Solution Approach 1:
The patent extracts and removes the harmful arc heating process from the spraying system, replacing it with electromagnetic induction heating. This separation eliminates the high-temperature arc that causes metal evaporation while maintaining the core spraying function, thus resolving the contradiction between spraying efficiency and occupational health safety.
Solution Approach 2:
The patent replaces the mechanical/thermal arc heating system with an electromagnetic induction heating system. This substitution uses electromagnetic fields to heat the wire feedstock without direct contact or high-temperature arcs, eliminating metal evaporation while maintaining heating efficiency for coating formation.
2Speed
If high-speed airflow is used to atomize and spray materials, then coating deposition speed is improved, but metal particles remain suspended in air longer increasing inhalation risk
Solution Approach 1:
The patent converts the harmful effect of airborne metal particles into a beneficial dust collection system. The electromagnetic spray process generates fewer particles, and the system incorporates dust collection devices that capture and remove particles from the air, transforming the potential hazard into an active air quality management feature.
3Object-affected harmful factors
If electromagnetic induction heating is used instead of arc heating, then metal evaporation is reduced, but heating mechanism complexity increases
Solution Approach 1:
The patent introduces an electromagnetic field as an intermediary between the power source and the wire feedstock. The induction heating coil generates an electromagnetic field that penetrates the wire and induces eddy currents, heating the material internally without direct contact or arcs. This intermediary approach simplifies the overall system by eliminating complex arc control mechanisms while reducing metal evaporation.
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 device effectively reduces air pollution by capturing metal dust and forming a dense coating on the substrate, minimizing occupational hazards and improving working conditions by eliminating the inhalation of metal particles.
Implementation Method 1
a heating coil is arranged between the fixed seat and the stirring needle, and an input end of the heating coil is connected with the AC power box through a wire
Implementation Method 2
an electromagnetic pulse coil is sleeved on each of the metal rods
Implementation Method 3
a DC negative high voltage is formed after a current passes through the negative ion generator, and then a large number of free electrons are emitted from an emitting head to absorb large suspended substances in the smoke
Data Source
AI summary
A wire-feeding electromagnetic spray additive manufacturing device and method are provided. The device includes a housing, an alternating current power box is fixedly installed on the housing, and a stirring needle is also arranged in the housing. The device further includes a fixed seat fixedly installed in the housing, and a heating coil is arranged between the fixed seat and the stirring needle; a lower end of the stirring needle is provided with spinnerets and heating channels adapted with corresponding the spinnerets respectively; upper ends of the heating channels penetrate through the stirring needle and are fixedly connected with the housing, and an extrusion assembly is fixedly installed on each of the heating channels; and a smoke pipe is fixedly installed on the extrusion assembly, and an upper end of the smoke pipe penetrates through the housing and is connected with a negative pressure fan.