Vehicle Rim Coating Booth Layout for Continuous High-Throughput Spraying

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Solution Overview

Problem

Existing coating booths for rotationally symmetric workpieces, particularly vehicle rims, face limitations in flexibility, productivity, and economy due to conveyor systems that require frequent stops or slow movement, necessitating large installation spaces and limiting throughput.

Innovation Solution

A coating booth with a conveyor device beneath the booth floor and an applicator system comprising multiple gun systems with synchronized and asynchronous axis systems, allowing flexible and automated coating, and a system for recycling overspray material, along with controlled airflow and powder conveyance using pumps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the floor conveyor is continuously moved past the stationary spray guns, then the coating process can proceed without stopping, but the floor conveyor needs to move extremely slowly in order for the vehicle rims to be able to be coated with sufficient coating powder, which limits productivity

Engineering Contradiction:

Improvecoating qualityVSAvoidnumber of vehicle rims coated per unit time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

Instead of moving the conveyor slowly past stationary spray guns, the patent inverts the approach by making the spray guns movable and the conveyor stationary. The spray guns move along the stationary conveyor to coat the vehicle rims, allowing the rims to be coated at optimal speed while maintaining sufficient coating quality.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent applies dynamics by transitioning from a static spray gun system to a dynamic one where the spray guns can move along the conveyor. This allows the coating system to adapt its positioning and movement to optimize both coating quality and productivity, rather than being constrained by fixed spray gun positions.

Inventive Principle:

Principle #15Dynamics

2Productivity

If multiple spraying stations are used to increase productivity, then more vehicle rims can be coated simultaneously, but a relatively large installation space is required for the entire coating system

Engineering Contradiction:

Improvenumber of vehicle rims coated per unit timeVSAvoidinstallation space

Core Design Contradiction:

ProductivityVSArea of stationary object

Solution Approach 1:

The patent transitions from a horizontal arrangement of multiple spraying stations to a vertical arrangement where multiple spray guns are stacked above a single conveyor path. This dimensional change allows multiple coating operations to occur simultaneously over the same footprint, increasing productivity without proportionally increasing installation space.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The movable spray gun system serves multiple functions: it can coat multiple rims simultaneously at different positions along the conveyor, adjust its position to coat different areas of each rim, and adapt to varying production requirements. This multi-functionality replaces the need for multiple dedicated spraying stations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If the floor conveyor is stopped while the rim is being coated, then sufficient coating powder can be applied, but the floor conveyor needs to be stopped every time a vehicle rim is to be coated, which reduces productivity

Engineering Contradiction:

Improvecoating qualityVSAvoidcoating throughput

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent enables continuous operation by allowing the conveyor to move at optimal speed while the spray guns move synchronously to apply coating powder. This eliminates the need to stop the conveyor for coating operations, maintaining continuous productive action while ensuring adequate coating application through coordinated motion of the spray guns.

Inventive Principle:

Principle #20Continuity of useful action

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 high throughput and optimal coating quality by allowing simultaneous coating of multiple workpieces, efficient use of space, and reduced energy consumption while maintaining precise control over coating parameters.

Implementation Method 1

a first gun system (8) for spraying coating material (50) as needed onto a first area (11) of the workpieces (2) to be coated

Methodology Applied

Scientific EffectElectrostatic deposition: Electrostatic Deposition

Data Source

PatentUS12569872B2Coating booth for coating vehicle rims

Publication Date: 2026.03.10 GEMA SWITZERLAND GMBH

AI summary

A coating cabin for coating vehicle wheel rims has a coating chamber and a conveying device for transporting the workpieces for coating through the coating chamber. An applicator system is furthermore provided for spraying coating material as required in the coating chamber, wherein the applicator system has a first pistol system for spraying coating material as required onto a first region of the workpieces for coating, a second pistol system for spraying coating material as required onto a second region of the workpieces for coating, and a third pistol system for spraying coating material as required onto a third region of the workpieces for coating.