Rotating Spindle Finishing Line for 3D Objects
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Solution Overview
Problem
Existing methods for metallizing small three-dimensional objects are inefficient due to the need for simultaneous processing of multiple objects to reduce vacuum creation time, leading to high energy consumption and inability to operate continuously, requiring significant storage and operator intervention.
Innovation Solution
A finishing line and method that uses a transfer line with rotating spindles and airless painting devices, allowing for independent painting and metallization processes, with a pre-chamber for efficient vacuum management and continuous operation, enabling flexible production and reduced maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If multiple objects are processed simultaneously in a vacuum chamber for metallization, then the vacuum creation time is reduced, but energy consumption increases significantly
Solution Approach 1:
The system divides the batch processing into individual object processing. Each object is metallized separately through the vacuum chamber, eliminating the need to maintain vacuum for large batches. This segmentation reduces the total time objects wait in vacuum while proportionally reducing energy consumption compared to simultaneous batch processing.
Solution Approach 2:
Objects are pre-positioned on rotating spindles and organized in trays before entering the vacuum chamber. This preliminary arrangement allows continuous loading and unloading, minimizing the time the vacuum chamber needs to maintain vacuum conditions, thereby reducing overall energy consumption while maintaining efficient processing.
2Productivity
If batch processing is used to reduce vacuum creation time, then productivity increases, but the ability to operate continuously decreases
Solution Approach 1:
The system implements continuous operation through automated transfer lines that continuously move objects between painting, drying, and metallization stations. Rotating spindles and automated loading/unloading mechanisms ensure uninterrupted processing, eliminating batch interruptions while maintaining high productivity through continuous material flow.
Solution Approach 2:
Manual batch loading and unloading operations are replaced with automated mechanical transfer systems. Robots and automated conveyors handle object movement between stations, enabling continuous operation without human intervention and eliminating the stop-start nature of manual batch processing.
3Productivity
If batch processing is implemented, then processing efficiency improves, but storage requirements and operator intervention increase
Solution Approach 1:
The system uses self-contained rotating spindles that automatically rotate and position objects during metallization. The spindles are designed to hold multiple objects and rotate them independently within the vacuum chamber, eliminating the need for complex external positioning mechanisms and reducing storage space requirements for support equipment.
Solution Approach 2:
The rotating spindles serve multiple functions: they hold objects during transfer, position objects for painting, and rotate objects during metallization. This multi-functionality eliminates the need for separate positioning devices and reduces overall system complexity while maintaining high processing efficiency.
4Manufacturing precision
If spray painting is used for primer application, then coverage is achieved, but solvent abatement and drying time are required
Solution Approach 1:
The system uses airless hydraulic painting devices that deliver paint through high-pressure hydraulic systems without aerosolization. This eliminates solvent evaporation requirements, allows immediate drying, and provides precise surface coverage without the need for separate drying or solvent abatement steps.
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 enables continuous, flexible, and efficient processing of small three-dimensional objects by minimizing energy consumption and eliminating the need for batch processing, allowing for high-speed rotation and reduced maintenance, while maintaining object integrity and preventing contamination.
Implementation Method 1
the paint is atomised by forcing it to pass at a very high pressure (around 35 bar) through a small nozzle
Implementation Method 2
the paint is pressurised by a pump which sucks in the paint, brings it up to pressure, then sends it to the nozzle
Implementation Method 3
the paint used does not contain solvents (or in any case the solvent contained is a minimal fraction) and may be a paint containing a photoinitiator which, when subjected to electromagnetic radiation causes a chain reaction of paint cross-linking (curing)
Implementation Method 4
Said technique is implemented by the ejection of atoms, ions or molecular fragments from a solid material, called the target, which is bombarded with a beam of energetic particles, usually an ion plasma
Implementation Method 5
The ion plasma strikes the target which, due to the collision, releases atoms and particles which recondense on the surfaces of the object to be coated
Implementation Method 6
a vacuum is created in the chamber to allow their metallization
Data Source
AI summary
A machine (12, 13) for painting small three-dimensional objects (2) comprises a plurality of spindles (9) equipped with holders (10) for objects (2) to be painted. A unit (15) able to rotate about an axis (16) is equipped with a plurality of seats (17) which are distributed in a circle around said axis (16) and which can move, following the rotation of the rotary unit (15), in a predetermined direction of travel (F') of a circular path around said axis (16). Each seat (17) is structured to receive a spindle (9) allowing, relative to the rotary unit (15), rotation at least of the holder (10) for the object (2) to be painted about a painting axis (18). The spindle (9) is removably associable with said seat (17). An airless painting device (25) is operatively positioned at a painting station (26) designed to receive said seats (17) in sequence. First actuator means (27) structured in such a way as to drive the rotation about said painting axis (18) at least of the holder (10) for the object (2) to be painted of each spindle (9) associated with a respective seat (17) when said seat is positioned at the painting station (26). Means (29) for transferring the objects (2), structured in such a way as to grip a spindle (9) positioned along a transfer line (3) and place it in one of the seats (17) and/or vice versa.