Removable Nozzle Insert for Thermal Spray Gun Adaptability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current thermal spray guns require extensive modifications and disassembly to adjust for different coatings or specimens, leading to inconvenient reprogramming and delays, especially when changing power levels or plasma plumes, which affects the robotic arm's configuration and coolant system.
Innovation Solution
A nozzle insert system that allows for adjustable thermal spray gun operation without disassembling the gun, enabling the modification of plasma discharge properties such as velocity, temperature, and plume shape by inserting or removing nozzle inserts within the existing nozzle, allowing for different coatings to be applied without altering the gun's configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a thermal spray gun is disassembled to install a replacement nozzle for different coatings, then the ability to spray different types of coating is improved, but the downtime and operational complexity increase due to draining and refilling coolant reservoirs
Solution Approach 1:
The nozzle is divided into a fixed nozzle body and a removable nozzle insert. The insert contains the coating-specific geometry and can be quickly exchanged without disassembling the entire nozzle or cooling system, thus enabling different coating types while minimizing downtime.
Solution Approach 2:
The removable nozzle insert is nested within the fixed nozzle body. The insert fits into the nozzle's internal passage, allowing it to be inserted or removed through the nozzle's opening without disturbing the external cooling reservoirs or mounting structure.
2Adaptability or versatility
If the thermal spray gun is disassembled to change nozzles, then different plasma discharges can be achieved, but the complexity of the procedure increases due to coolant system management
Solution Approach 1:
The nozzle functionality is segmented into a permanent cooling structure and a replaceable insert. This allows the complex plasma discharge characteristics to be changed by simply swapping inserts, while the cooling system remains untouched and manageable.
Solution Approach 2:
The coating-specific functional elements are extracted into a separate removable insert that can be taken out and replaced independently from the main nozzle assembly, simplifying the changeover procedure while maintaining plasma discharge versatility.
3Adaptability or versatility
If a single thermal spray gun is used for multiple coatings, then the need for multiple guns is reduced, but the frequency of nozzle changes increases requiring extensive modifications
Solution Approach 1:
The nozzle system is made dynamically configurable through quick-change inserts. This allows a single gun to adapt to different coating requirements by simply changing inserts, reducing the need for multiple dedicated guns while minimizing the time and effort required for each change.
Solution Approach 2:
The fixed nozzle body is designed as a universal platform that can accommodate multiple different inserts for various coating types. This multi-functionality allows one gun to perform multiple coating applications without requiring extensive modifications, improving productivity.
4Adaptability or versatility
If the nozzle is modified to change plasma plume properties, then different coating applications are enabled, but the coolant system requires opening and refilling
Solution Approach 1:
The nozzle is segmented into a cooling structure that remains closed and a functional insert that can be changed. This allows plasma plume properties to be modified by inserting different inserts without requiring the coolant system to be opened or refilled, maintaining ease of operation.
Solution Approach 2:
The removable insert is nested within the sealed nozzle body, allowing it to be exchanged without breaking the coolant system's sealed environment. This maintains proper coolant levels and temperatures throughout the process, simplifying operation.
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
Enables efficient adaptation to various spray needs without disassembling the thermal spray gun, reducing downtime and costs by allowing multiple coatings to be applied with a single gun using interchangeable nozzle inserts, maintaining consistent power output and reducing the need for coolant system modifications.
Implementation Method 1
a plasma jet to heat or melt the feedstock before propelling it toward a desired surface
Implementation Method 2
Current thermal spray guns operate efficiently (e.g., over 60% efficiency) at one power mode (e.g., 75 kW) and deliver one coat in one position
Implementation Method 3
uses a plasma jet to heat or melt the feedstock before propelling it toward a desired surface
Implementation Method 4
The hot gas stream entrains the feedstock, transferring heat and momentum thereto
Implementation Method 5
The hot gas stream entrains the feedstock, transferring heat and momentum thereto. The heated feedstock becomes a discharge that is further impacted onto a surface, where it adheres and solidifies
Implementation Method 6
The assembly and reassembly process typically require a reservoir of cooling water to be opened, drained, and then refilled
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Various aspects of the present disclosure relate to a nozzle insert which may be used with a thermal spray gun apparatus 10. A nozzle insert 212 according to the disclosure may include a body having an outer surface 216, the outer surface of the body being configured to circumferentially contact and transfer heat to an inner face of a thermal spray gun nozzle 12 of a thermal spray gun. The body of the nozzle insert may be removed from the thermal spray gun nozzle 12 without disassembling the thermal spray gun, and includes an axial passage 218 configured to communicate a plasma discharge from the nozzle insert. A thermal spray gun apparatus 10 and a thermal spray gun system 5 including the nozzle insert are also disclosed.