Print Head Color Change via Segmented Control Valve
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Solution Overview
Problem
Conventional printheads for coating vehicle body components face challenges in color change during operation due to paint residue accumulation, which impairs functionality and prevents efficient rinsing, leading to high rinsing agent consumption and prolonged downtime.
Innovation Solution
The printhead design incorporates separate coating and rinsing agent supplies, with a rinsing agent flow through the coil tube and control valve components to facilitate efficient rinsing and color change, allowing for simultaneous coating and rinsing operations, and features like a flexible diaphragm and axial rinsing channels to minimize paint residue and reduce rinsing agent usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the control valve interior is exposed to paint for coating operation, then coating application is enabled, but paint residues accumulate and impair functionality
Solution Approach 1:
The control valve interior is divided into a paint-exposed region (coil tube) and a protected region (valve body with electronics), separated by a diaphragm that allows paint passage while preventing residue accumulation in the protected region
Solution Approach 2:
The vulnerable electronic components and sealing elements are extracted from the paint-exposed coil tube interior and relocated to the protected valve body region, eliminating their exposure to paint residues
2Reliability
If the printhead is rinsed with high amount of rinsing agent, then paint residues are removed, but rinsing agent consumption and time increase
Solution Approach 1:
The rinsing function is extracted and concentrated to specific rinsing channels that directly target paint residue accumulation points, eliminating the need for bulk rinsing of the entire control valve interior
Solution Approach 2:
Rinsing is applied locally and selectively to specific regions where paint residues accumulate (coil tube and nozzle areas) rather than uniformly rinsing the entire control valve, reducing rinsing agent consumption
3Reliability
If the control valve is disassembled for cleaning, then paint residues are removed, but downtime increases
Solution Approach 1:
The control valve performs self-cleaning through integrated rinsing channels that automatically flush paint residues during operation or between color changes, eliminating the need for manual disassembly and cleaning operations
Solution Approach 2:
The rinsing function operates continuously or periodically during printhead operation to prevent paint residue accumulation, rather than requiring periodic shutdowns for cleaning maintenance
4Reliability
If the coil tube interior is sealed against paint, then paint residues are prevented, but coating agent supply is blocked
Solution Approach 1:
A flexible diaphragm separates the paint-exposed coil tube interior from the protected valve body, allowing paint and coating agent to pass through while preventing residue accumulation in the protected region
Solution Approach 2:
The diaphragm acts as an intermediary barrier that selectively permits coating agent flow while blocking paint residue migration into the protected control valve regions
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
Enables fast color changes within minutes, minimizes paint and rinsing agent losses, and reduces rinsing agent consumption, allowing for efficient and practical color changes during operation without disassembly or replacement.
Implementation Method 1
A coil tube 5 is arranged on the upper side of the base plate 3 and is wound with a coil 6 on the outside. In the coil tube 5 there is a magnetic coil core 7... In addition, there is a magnetic armature 9 in the coil tube 5, which can also be called a valve needle and can be moved in the direction of the double arrow depending on the current supplied to the coil 6
Data Source
AI summary
The disclosure concerns a printhead for the application of a coating agent to a component, in particular for painting a vehicle body component with a paint. The disclosure provides that the printhead is designed in such a way that it enables a color change during coating operation and can be rinsed with a rinsing agent during a color change in order to rinse out coating agent residues from the printhead.