Rotary Atomiser Bell Cup Additive Manufacturing
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Solution Overview
Problem
Rotary atomisers face issues with gyroscopic effects due to high-speed rotation, affecting the accuracy and lifetime of the spindle and robotic arm, particularly in paint spraying applications where high precision is required.
Innovation Solution
A rotary atomiser bell cup is manufactured using a machined metal hub and an additive manufacturing process for the bell portion, allowing for accurate and efficient production while minimizing gyroscopic effects, with optional machining for finished dimensions and bonding, and incorporating features like internal voids and apertures for fluid communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the bell cup is manufactured using traditional machining for the entire structure, then manufacturing precision and structural integrity are maintained, but the weight is high which increases gyroscopic effects
Solution Approach 1:
The bell cup is divided into two distinct portions: the hub portion manufactured by traditional machining and the bell portion manufactured by additive manufacturing. This segmentation allows each portion to be optimized by the most suitable manufacturing process, reducing overall weight while maintaining precision where needed.
Solution Approach 2:
Different manufacturing methods are applied to different portions of the bell cup based on local requirements. The hub portion requiring high precision and structural integrity is machined, while the bell portion where weight reduction is prioritized is additively manufactured. This local differentiation resolves the contradiction between weight and precision.
2Ease of manufacture
If the bell portion is manufactured using additive manufacturing, then weight is reduced and complex shapes are enabled, but manufacturing precision may be compromised
Solution Approach 1:
The bell cup is segmented into hub and bell portions, allowing the bell portion with complex shapes to be manufactured additively while the hub portion is precisely machined. This resolves the contradiction by enabling complex geometry where needed without compromising overall precision.
Solution Approach 2:
Two different manufacturing processes (additive manufacturing and traditional machining) are merged in the production of a single component. The additive manufacturing provides ease of manufacture for complex shapes, while traditional machining ensures precision for critical portions, combining the advantages of both methods.
3Reliability
If the bell cup weight is reduced to minimize gyroscopic effects, then accuracy and lifetime improve, but structural integrity may be compromised
Solution Approach 1:
The hub portion requiring high structural integrity for reliability is manufactured by precise machining, while the bell portion is additively manufactured with optimized geometry. This local differentiation maintains strength where needed while reducing overall weight to minimize gyroscopic effects and improve system reliability.
Solution Approach 2:
The bell cup effectively becomes a composite structure combining materials and manufacturing methods optimized for different functions. The machined hub provides structural integrity, while the additive-manufactured bell provides weight reduction, creating a composite solution that balances strength and weight for improved reliability.
Data Source
AI summary
A rotary atomiser bell cup comprising a bell portion for spraying media in use and a hub portion via which the bell portion is rotatingly drivable in use, wherein the hub portion is a machined metal portion and the bell portion has been built up on the hub using an additive manufacturing process.