Extraction Hood for Metallic Coating Lance Overspray
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for metallic coating of engine cylinder bores using a metal plasma jet often result in overspray, leading to defective coatings and layer thickness deviations due to the need to switch the plasma jet on and off, which reduces efficiency and quality.
Innovation Solution
A device with an extraction hood that encloses the coating lance and a ring-shaped holding unit to collect and deposit metal particles, allowing continuous operation of the plasma jet and reducing overspray by using a targeted air flow and anti-adhesion surfaces to prevent particle deposition on the conical surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the metal plasma jet is switched off when moving the coating lance out of the bore, then overspray is reduced, but layer thickness deviations occur and quality deteriorates
Solution Approach 1:
The harmful metal particles (overspray) are extracted from the work area by directing them onto a sacrificial holding unit (sacrificial target) positioned in the path of the plasma jet. This allows continuous operation of the coating lance without switching off the plasma jet, maintaining layer thickness precision while capturing overspray away from the workpiece.
Solution Approach 2:
A replaceable holding unit is introduced as a disposable component that accumulates overspray deposits. When the holding unit becomes heavily coated, it is replaced with a fresh one, preventing contamination of the workpiece while avoiding the need to switch off the plasma jet. This sacrificial component protects the quality of the actual workpiece.
2Productivity
If the coating lance is moved continuously without switching off the plasma jet, then productivity increases, but overspray causes defective coatings
Solution Approach 1:
The holding unit acts as an intermediary element positioned between the coating lance and the workpiece. It intercepts and accumulates overspray metal particles that would otherwise contaminate the workpiece, enabling continuous coating operations without defective coatings.
3Loss of time
If switching on and off the metal plasma jet is avoided, then time loss is reduced, but overspray intensifies and quality deteriorates
Solution Approach 1:
The replaceable holding unit serves as a time-efficient solution by allowing continuous plasma jet operation. Instead of switching off and on the plasma jet (time-consuming), the system continuously operates the jet while the holding unit absorbs overspray, preventing quality issues without time 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
This solution ensures reliable removal of excess metal particles, minimizing defective coatings and layer thickness deviations, thereby improving the efficiency and quality of the metal coating process.
Implementation Method 1
an air or inert gas flow can also be produced through the extraction hood, through which loaded ambient air is guided to a discharge line
Implementation Method 2
a coating lance, with which a metal plasma jet is generated to form the coating of metal particles
Implementation Method 3
The radially inwardly falling conical surface is designed so that impacting metal particles cannot be deposited, or can hardly be deposited, on this conical surface but instead are deflected to the holding unit
Data Source
AI summary
The invention relates to a device and a method for the metallic coating of a work piece with a mobile coating lance (20), by means of which a metal plasma jet can be generated to create the coating consisting of metal particles. According to the invention, an extraction hood (30) is provided, which at least encloses an axial section of the coating lance (20) in a ring-shaped manner, and the extraction hood (30) has a ring-shaped holding unit (50), which is configured to take up the metal particles.