Foil Bearing Support for Rotary Atomizers Under Impact Loads
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Solution Overview
Problem
Aerostatic air bearings used in rotary atomizers for painting motor vehicle components are sensitive to impact forces, require high-purity compressed air, and have limited emergency running properties.
Innovation Solution
The use of a foil bearing system with a cylindrical or free-formed cover foil and a radially inwardly directed spring foil, supported by a bearing shell, which provides a large operating range in speeds and low starting torque, combined with an aerodynamic spiral groove bearing for axial support, reduces sensitivity to impact forces and improves reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aerostatic air bearings are used to support the turbine shaft, then the bearing system provides smooth operation, but the system becomes sensitive to impact forces and requires high-purity compressed air
Solution Approach 1:
The patent employs foil bearings consisting of flexible foil elements that can deform to absorb impact forces. The thin foil structure allows the bearing to accommodate sudden loads without the sensitivity issues of rigid aerostatic air bearings, while still maintaining smooth operation during normal conditions.
Solution Approach 2:
The invention transitions from aerostatic air bearings to foil bearings, changing the fundamental operating parameters from air-cushion-based support to direct foil contact with controlled friction. This parameter change eliminates the sensitivity to impact forces while maintaining operational smoothness through the foil's inherent flexibility.
2Reliability
If aerostatic air bearings are used, then the turbine shaft is supported, but high-purity compressed air with low oil content and small solid particles is required
Solution Approach 1:
The patent replaces the aerostatic air bearing system with a foil bearing system, substituting the air-cushion mechanism with a mechanical foil-based support system. This eliminates the requirement for high-purity compressed air while maintaining reliable turbine shaft support through direct foil contact.
3Reliability
If aerostatic air bearings are used, then the turbine shaft is supported, but the emergency running properties are limited
Solution Approach 1:
The foil bearing's flexible thin film structure allows it to maintain support capabilities during emergency conditions when the turbine shaft may experience abnormal speeds or loads. The foil can deform and adapt to extended operating conditions, providing better emergency running properties than rigid aerostatic air bearings.
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 foil bearing system enhances the rotary atomizer's resistance to impact forces and maintains efficient operation across a wide range of speeds with reduced starting torque, while the spiral groove bearing provides effective axial support and minimizes leakage losses.
Implementation Method 1
a spring foil which is substantially cylindrically shaped and at least partially surrounds the cover foil, wherein the spring foil exerts a radially inwardly directed spring force on the cover foil
Implementation Method 2
an aerodynamic spiral groove bearing for axial support
Data Source
AI summary
The disclosure relates to a bearing system for a drive turbine of a rotary atomizer, having a rotatable turbine shaft for receiving a bell cup which is used for spraying off the paint, and having a radial bearing for rotatably supporting the turbine shaft. The disclosure provides that the radial bearing has at least one foil bearing or a spiral groove bearing.