Robot Printhead Coating for Low-Overspray Color Changes
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Solution Overview
Problem
Existing coating technologies, such as rotary atomizers and conventional printheads, suffer from inefficiencies in application, overspray, and limitations in color change capabilities, leading to increased waste and downtime due to printhead drying during breaks.
Innovation Solution
A coating device with replaceable printheads or multiple printheads on a robot, utilizing a wet deposit device for printhead storage and circulation to prevent drying, and an A/B operation for uninterrupted color changes, minimizing overspray and downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional printheads are used for coating, then application efficiency is improved with minimal overspray, but the printhead coating can become dry during coating breaks leading to loss of function
Solution Approach 1:
The patent implements a circulation mode that actively moves coating through the printhead channels before and during breaks, preventing the coating from becoming dry and clogging the nozzles. This preliminary and continuous action maintains the coating in a fluid state, ensuring the printhead remains functional and ready for immediate use when needed.
2Loss of substance
If conventional printheads are used for coating, then application efficiency is improved with minimal overspray, but color change capability is limited causing increased downtime
Solution Approach 1:
The circulation mode is activated before color changes to flush out the previous coating color from the printhead channels. This preliminary flushing action prepares the printhead for the new color, significantly reducing the time required for color changes and minimizing downtime in the coating process.
Solution Approach 2:
The system discards the remaining coating of the previous color through the circulation and flushing process, allowing the printhead to be quickly recovered and reused for the new color without requiring complete disassembly or extensive cleaning procedures.
3Area of stationary object
If rotary atomizers are used for painting, then coating coverage is achieved, but application efficiency is limited with significant paint disposal as overspray
Solution Approach 1:
The patent extracts the coating delivery mechanism from the conventional rotary atomizer spray approach and replaces it with a direct printhead jet injection system. This extraction of the coating delivery method eliminates the aerosolization process that causes overspray, delivering paint directly to the target surface with minimal waste.
Solution Approach 2:
The patent replaces the mechanical rotary atomizer system with a printhead-based jet injection system. This substitution eliminates the need for high-speed rotation and aerosol generation, achieving coating coverage through direct, controlled paint delivery that significantly reduces overspray and paint waste.
Data Source
AI summary
The disclosure concerns a coating device and a corresponding coating process for coating components, in particular motor vehicle body components, with a coating agent (e.g. paint), with a coating robot with a first printhead which is mounted on the coating robot. The disclosure provides that the first printhead is exchangeably mounted on the coating robot and can be exchanged for a second printhead during a color change. Another variant of the disclosure, on the other hand, provides for a second printhead to be mounted on the coating robot in addition to the first printhead, the two printheads each applying a specific coating agent in order to enable a color change without changing the printhead.