Powder Coating Plant With Dual Spray Applicators

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Solution Overview

Problem

Existing powder coating plants face inefficiencies in coating multiple workpieces per unit time due to large installation space requirements and high energy consumption, with limited throughput and lengthy color change processes.

Innovation Solution

A powder coating plant design featuring a booth with upward and downward spray applicator arrangements, a manipulator for moving these applicators, and a cyclone separator for efficient powder extraction, along with optional horizontal spray applicators and an electrostatic charging device, optimized for compact construction and reduced energy use.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the floor conveyor is continuously moved past stationary spray guns, then the coating process can proceed without stopping, but the floor conveyor has to move extraordinarily slowly to ensure sufficient coating powder application

Engineering Contradiction:

Improvethroughput of workpieces coated per time unitVSAvoidspeed of floor conveyor

Core Design Contradiction:

ProductivityVSSpeed

Solution Approach 1:

The spray applicator arrangement is made movable relative to the workpiece instead of keeping the workpiece stationary or moving it slowly. The manipulator enables the spray applicators to dynamically adjust their position and follow the workpiece at optimal coating distances, allowing the floor conveyor to move at higher speeds while maintaining coating quality

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

Multiple spray applicators (upper and lower) are combined in a single movable arrangement that can simultaneously coat both the front and rear sides of the workpiece. This integrated approach increases throughput without requiring multiple separate stationary coating stations

Inventive Principle:

Principle #5Merging (Combining)

2Productivity

If multiple spray stations are used to increase the number of rims coated per time unit, then the coating capacity increases, but the installation space for the entire coating plant becomes relatively large

Engineering Contradiction:

Improvenumber of workpieces coated per time unitVSAvoidinstallation space of powder coating plant

Core Design Contradiction:

ProductivityVSArea of stationary object

Solution Approach 1:

The coating process transitions from a horizontal arrangement with multiple spray stations along the conveyor to a vertical arrangement with upper and lower spray applicators operating simultaneously on opposite sides of the workpiece. This dimensional change doubles the coating capacity within the same installation footprint

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The single manipulator with multiple spray applicators serves multiple functions: it positions upper and lower spray applicators to coat both front and rear sides of the workpiece, and can adjust its position along the workpiece length. This multi-functional design replaces what would traditionally require multiple dedicated spray stations

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If the booth is cleaned efficiently with cross flow, then powder does not adhere to booth walls, but the system requires effective powder extraction and air flow management

Engineering Contradiction:

Improveease of maintaining clean booth environmentVSAvoidenergy consumption for powder extraction

Core Design Contradiction:

Ease of manufactureVSUse of energy by stationary object

Solution Approach 1:

The cleaning system replaces complex mechanical cleaning mechanisms (such as brushes or scrapers) with an aerodynamic cross-flow system. Pressurized air flows through the booth to continuously remove powder deposits, converting a mechanical maintenance problem into a fluid dynamics solution that operates continuously during coating

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 design minimizes surface area, increases workpiece throughput, reduces energy consumption, and enables quick color changes by maintaining a clean booth environment and optimizing coating processes, allowing for consistent and efficient coating of various workpiece shapes and sizes.

Implementation Method 1

a cyclone separator for efficient powder extraction

Methodology Applied

Scientific EffectCyclone separation: Cyclone Separation

Implementation Method 2

an electrostatic charging device

Methodology Applied

Scientific EffectElectrostatic charging: Electrostatic Induction

Data Source

PatentUS11577266B2Powder coating plant for coating a workpiece with coating powder

Publication Date: 2023.02.14 J WAGNER GMBH

AI summary

A powder coating plant for coating a workpiece with coating powder includes a booth, which receives the workpiece delivered via a floor conveyor. In addition, the powder coating plant has an upper spray applicator arrangement for spraying coating powder downward, and a lower spray applicator arrangement for spraying coating powder upward. The upper and the lower spray applicator arrangement are thereby oriented toward the same workpiece. In addition, a manipulator is provided, to which the upper and the lower spray applicator arrangement is fastened. The manipulator is formed such that the spray applicator arrangements can be moved at least in the transport direction of the workpiece by the manipulator.