Laser Decoating Wheel Screw Channels Without Masking
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Solution Overview
Problem
Existing methods for stripping coated wheels with screw channels and central openings face challenges in achieving high accuracy, efficiency, and cost-effectiveness due to the need for masking, which leads to quality issues and increased costs, and the limitations of existing laser decoating systems in terms of cycle time and mechanical defects.
Innovation Solution
A decoating method that eliminates the need for masking, utilizing a direct suction device and a scanner-controlled CO2 laser beam to precisely remove coatings from the functional surfaces without a jet tube, allowing for flexible processing spots and improved accuracy, and sharing a single laser source among multiple decoating stations to reduce costs and cycle times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If masking is used to protect functional surfaces before coating, then paint-free functional surfaces are achieved, but masking requires additional work steps and increases costs
Solution Approach 1:
The patent replaces the mechanical masking system with a laser-based selective removal system. Instead of physically masking functional surfaces before coating, the system applies coating to the entire wheel surface and then uses a laser to selectively remove coating only from functional surfaces, eliminating masking complexity while maintaining paint-free quality
Solution Approach 2:
The patent inverts the traditional process sequence: instead of protecting surfaces before coating (masking), it coats all surfaces and then selectively removes coating from functional areas. This inversion eliminates the need for masking while achieving the same paint-free functional surface result
2Manufacturing precision
If a blast tube is used for laser stripping, then coating removal is achieved, but the blast tube must be placed on each individual area and replaced when changing wheels, impacting cycle time
Solution Approach 1:
The patent replaces the individual blast tube approach with a single universal scanner device that can direct the laser beam to any area of the wheel. This scanner-based system eliminates the need to physically reposition or replace blast tubes when changing wheels or processing different areas, maintaining coating removal accuracy while significantly improving cycle time
Solution Approach 2:
The patent transitions from a static blast tube system to a dynamic scanner-based system. The scanner can rapidly redirect the laser beam to different areas of the wheel without physical repositioning, enabling flexible processing of any area while maintaining precision and reducing cycle time through rapid beam steering
3Manufacturing precision
If a blast tube is used to expel fumes and particles, then coating removal is effective, but the seal is inherently prone to failure and mechanical defects occur along the contact line
Solution Approach 1:
The patent extracts the fume and particle removal function from the blast tube contact system. Instead of using a sealed blast tube that contacts the wheel surface, the system uses a scanner-based laser with a remote extraction system that removes fumes and particles without requiring a sealed contact interface, eliminating seal failure risks and mechanical defects along contact lines
Solution Approach 2:
The patent introduces an intermediary extraction system that handles fume and particle removal separately from the laser stripping process. This remote extraction system mediates the removal of byproducts without requiring direct contact or sealing with the wheel surface, maintaining coating removal effectiveness while eliminating seal reliability issues
4Manufacturing precision
If masking is used to achieve paint-free functional surfaces, then coating removal is achieved, but the contact line of the blast tube causes mechanical defects in the existing paint
Solution Approach 1:
The patent replaces the mechanical blast tube contact system with a non-contact laser scanner system. The laser beam is directed onto the coating to be removed without requiring physical contact or masking, eliminating the mechanical defects that occur along the contact line of traditional blast tubes while achieving the same paint-free functional surface result
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 method enables rapid, accurate, and cost-effective decoating of coated surfaces on wheels, eliminating the need for masking and reducing mechanical defects, while achieving high machining precision and increased production capacity.
Implementation Method 1
The stripping process uses a pulsed CO2 laser beam with a pulse duration of approximately 2 μs and a pulse power exceeding 6 J
Implementation Method 2
During the stripping process, fumes and particles are removed by pressurizing the beam tube, causing the fumes and removed material to be expelled through the corresponding screw channel
Data Source
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AI summary
The invention relates to a method for stripping a coating (8) from a surface of a wheel (1) provided with screw channels (6) and a centrally arranged hub opening within one or more areas (7) to be stripped, which extend in an annular, in particular circular, shape around one of the screw channels (6) and/or around the hub opening (8), wherein the method is carried out using a laser beam generated by a laser source (12), characterized in that the laser beam is moved over the area(s) (7) of the surface to be stripped without limiting the area(s) (7) to be stripped by additional means. The invention further relates to a stripping station (10) for carrying out the method.