Rotary Atomizer Coating with Spray Jet Asymmetry Compensation

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Solution Overview

Problem

Modern painting installations for motor vehicle body components face issues with asymmetrical layer thickness distribution due to deformation of the spray jet caused by external forces, leading to irregularities in the coating process.

Innovation Solution

Compensating for the asymmetry of the spray jet by angling its main axis with respect to the component surface and using a guide air stream or an asymmetrical guide air ring to achieve a more uniform layer thickness distribution, with the atomizer's movement direction and angulation adjusted based on deformation forces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the rotary atomizer is guided by multi-axis painting robots with serial kinematics to achieve high application efficiency, then productivity is improved, but the spray jet is deformed by external forces such as gravitational force, electrostatic force, and flow forces, leading to asymmetrical layer thickness distribution

Engineering Contradiction:

Improveapplication efficiencyVSAvoidlayer thickness distribution

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary anti-action by pre-calculating and compensating for the asymmetry of the spray jet before the coating process. The control device determines the asymmetry based on movement parameters and disturbance variables, then adjusts the spray pattern or atomizer orientation in advance to counteract the expected deformation from gravitational force, electrostatic force, and flow forces, thereby achieving symmetrical layer thickness distribution despite high-speed movement

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The patent employs parameter changes by dynamically adjusting movement parameters (such as atomizer speed, rotational speed, and acceleration) and disturbance variables (such as guide air flow rates and electrostatic charging levels) to compensate for spray jet asymmetry. The control device modifies these parameters based on the determined asymmetry to maintain uniform layer thickness distribution while preserving high application efficiency

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If the spray jet is oriented with its main axis parallel to the surface normal of the component surface to achieve symmetrical layer thickness distribution, then manufacturing precision is improved, but external forces such as gravitational force and flow forces cause the spray jet to deflect, leading to asymmetrical layer thickness distribution

Engineering Contradiction:

Improvelayer thickness distributionVSAvoidspray jet deflection

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent implements feedback by continuously monitoring the actual spray jet behavior and comparing it with the desired symmetrical pattern. The control device uses sensor data and movement parameters to determine the asymmetry in real-time, then adjusts the atomizer orientation or spray parameters accordingly to counteract deflection from gravitational force, electrostatic force, and flow forces, maintaining precise layer thickness distribution

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent applies asymmetry by intentionally introducing an asymmetrical compensation angle to the atomizer orientation that counteracts the asymmetrical deflection caused by external forces. Instead of maintaining perfect symmetry, the system deliberately orients the spray jet at a calculated angle to offset the expected distortion from gravitational force, electrostatic force, and flow forces, achieving symmetrical layer thickness distribution on the component surface

Inventive Principle:

Principle #4Asymmetry

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 approach significantly reduces the asymmetry of the spray pattern and layer thickness distribution, resulting in a more uniform coating across the component surface, even when applying multiple overlapping painting paths.

Implementation Method 1

compensating for the asymmetry of the spray jet by angling its main axis with respect to the component surface and using a guide air stream or an asymmetrical guide air ring

Methodology Applied

Scientific EffectFluid spray: Fluid Spray

Implementation Method 2

one generally uses as application devices rotary atomizers, which spin off paint to be applied in the form of droplets from a rapidly rotating bell cup

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Data Source

PatentUS11311903B2Coating method and coating device with compensation for asymmetries of the spray jet

Publication Date: 2022.04.26 DUERR SYST AG

AI summary

The invention relates to a coating method for coating a component surface (4) with a coating agent, in particular for painting a motor vehicle body component with a paint, having the following steps: ⋅ emitting a spray jet (1) of the coating agent onto the component surface (4) of the component to be coated by means of an atomizer (2), said spray jet (1) having a main axis (5) and having an asymmetry with respect to the main axis (5) such that the spray jet (1) generates a spray pattern with a corresponding asymmetry on the component surface (4), and ⋅ at least partially compensating for the asymmetry of the spray jet (1) such that the asymmetry of the resulting spray pattern on the component surface (4) is reduced. The invention further relates to a corresponding coating device.