Modular Workpiece Coating with Shared Measurement Stations
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing coating systems are inefficient for small workpieces, as they require expensive and large machinery, and lack flexibility in processing multiple pieces with high quality and reliability.
Innovation Solution
A modular coating system with multiple identical coating modules, a common input measuring station, and a common output measuring station, along with a conveying apparatus and control system, allowing for efficient processing and replacement of modules, enabling consistent measurement and coating of multiple workpieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single large coating device is used for workpieces, then coating quality can be maintained, but efficiency and productivity are low for small workpieces
Solution Approach 1:
The system is divided into multiple independent coating modules (first coating module, second coating module, etc.) that can process workpieces in parallel. Each module is a self-contained unit with its own coating device, allowing simultaneous processing of multiple workpieces while maintaining consistent coating quality through standardized module design.
Solution Approach 2:
The coating modules are designed as universal, interchangeable units that can be configured in different numbers and arrangements based on production requirements. The common input measuring station and output measuring station serve all modules, creating a flexible system that can adapt to different workpiece volumes and types while maintaining quality standards.
2Productivity
If multiple coating devices are provided to increase efficiency, then productivity improves, but system complexity and costs increase
Solution Approach 1:
The system uses identical, standardized coating modules that are segmented into discrete, replaceable units. This standardization reduces complexity by using the same design repeatedly rather than designing unique systems, while still providing multiple processing channels for high productivity.
Solution Approach 2:
Multiple coating modules share common infrastructure including the input measuring station, output measuring station, and control system. This merging of common functions reduces overall system complexity and cost while maintaining the productivity benefits of multiple parallel processing units.
3Reliability
If coating modules are made replaceable for maintenance, then availability improves, but device complexity increases
Solution Approach 1:
Each coating module is designed as an independent, self-contained unit that can be removed and replaced without affecting other modules. This segmentation allows quick replacement of malfunctioning modules to maintain system availability, while the standardized interface design keeps the replacement process simple and manageable.
4Device complexity
If a common measuring station is shared among multiple modules, then costs are reduced, but measurement precision may be compromised
Solution Approach 1:
The common input measuring station and output measuring station are designed as universal measurement systems that can accurately measure all workpieces regardless of which coating module processes them. This universal design ensures measurement consistency across the entire system while reducing costs by eliminating the need for duplicate measuring stations at each module.
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 system increases efficiency and availability, allowing for high-quality coating of small workpieces like brake discs or drums with reduced costs, enabling flexible capacity adjustments and early defect detection.
Implementation Method 1
a metal coating being applied to the cylindrical bore surfaces by means of plasma spraying
Implementation Method 2
by means of which station a surface of the face of the workpiece to be coated can be detected
Data Source
AI summary
The invention relates to a system and to a method for coating workpieces using a coating device, which is designed to apply a metal coating to a surface of the workpiece. According to the invention, it is provided that a plurality of coating devices, which are designed as identical coating modules, are provided and are arranged in a module group, that an input measuring station is assigned to the module group, by means of which station a surface of the face of the workpiece to be coated can be detected, that a conveying apparatus is provided, by means of which a workpiece can be supplied to one of the coating modules from the input measuring station, and that an output measuring station is assigned to the module group, by means of which station a surface of the coated face of the workpiece can be detected.