Thermal Spray Gun Coupling Device for Rapid Tool Change

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Solution Overview

Problem

The complexity and inflexibility of existing thermal spraying apparatuses make it time-consuming and difficult to change between different spray guns and supply devices, particularly due to the need for individual connection and disconnection of multiple supply lines with different connectors and sealing devices, limiting the ability to use various spray methods on the same workpiece.

Innovation Solution

A thermal spraying apparatus featuring a releasable coupling device with an adapter part that connects to the spray gun's feed line and a base part connected to the supply unit's supply line, allowing for quick and tool-free exchange of spray guns without losing operating media or causing electrical short circuits, using a fast-release adapter with an eccentric catch, bayonet connector, or screw connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple individual supply lines with different connectors and sealing devices are used to connect spray guns, then reliable supply of operating media (electrical energy, cooling water, gases) is achieved, but the complexity and time required for changing spray guns increases significantly

Engineering Contradiction:

Improvereliable supply of operating mediaVSAvoidcomplexity of supply line connections

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple separate supply lines (electrical energy, cooling water, operating gases) into a single integrated coupling device. This coupling device has a housing with multiple connection elements that simultaneously connect all supply lines when the spray gun is attached, eliminating the need for separate connectors and sealing devices for each line.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The coupling device is designed as a universal interface that can connect different types of spray guns to the same supply unit. The standardized housing and connection elements allow multiple spray guns with different functions (plasma, flame, HVOF) to use the same coupling mechanism, making the system multi-functional and adaptable.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If multiple individual supply lines with different connectors and sealing devices are used to connect spray guns, then reliable supply of operating media (electrical energy, cooling water, gases) is achieved, but the time required for changing spray guns increases significantly

Engineering Contradiction:

Improvereliable supply of operating mediaVSAvoidtime for changing spray guns

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The coupling device is pre-assembled with all necessary connection elements and sealing components integrated into the housing. This preliminary preparation allows the operator to simply attach the spray gun to the housing without needing to individually connect multiple lines or install separate sealing devices, significantly reducing changeover time.

Inventive Principle:

Principle #10Preliminary action

3Loss of time

If a standardized coupling device with integrated supply lines is used, then the time and complexity for changing spray guns is reduced, but the risk of losing operating media or causing electrical short circuits increases

Engineering Contradiction:

Improvetime for changing spray gunsVSAvoidrisk of losing operating media or electrical short circuits

Core Design Contradiction:

Loss of timeVSReliability

Solution Approach 1:

The coupling device housing acts as an intermediary between the supply unit and the spray gun. It provides a controlled interface where all connections are made through standardized elements with integrated sealing, preventing direct exposure to operating media and reducing the risk of leaks or short circuits.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The housing is designed with pre-positioned sealing elements and connection geometries that automatically engage when the spray gun is attached. This beforehand preparation ensures that sealing and electrical isolation are established before any operating media flow or electrical connection is activated, preventing leaks and short circuits.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Reliability

If specialized connectors and sealing devices are used for each supply line, then reliable and leak-free connections are achieved, but the adaptability to use different spray guns and spray methods is limited

Engineering Contradiction:

Improveleak-free connectionsVSAvoidadaptability to different spray guns

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS7578451B2Apparatus for thermal spraying

Publication Date: 2009.08.25 SULZER METCO AG

AI summary

The invention relates to an apparatus for thermal spraying (1) including a spray gun (2) with a burner (3), wherein an operating media (5) can be supplied to the spray gun (2) via a feed line (4), and a base part (6) which is in communication with a supply unit (8) for the operating medium (5) via a supply line (7). A releasable coupling device (9) is provided, with the feed line (4) including an adapter part (10) such that the adapter part (10) can be connected to the base part (6) by means of the releasable coupling device (9).