Automated Tube Coating Apparatus with Rotation Feedback
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Solution Overview
Problem
Manual blasting and coating processes on large tube bodies, such as those in wind power generators, are inefficient, pose harmful working environments, and result in non-uniform paint application, especially on conical shapes.
Innovation Solution
A coating-forming apparatus featuring a support member for rotating the tube body, a robot that moves along its length to apply paint or abrasive materials, a rotation-detecting device to measure and adjust the rotation angle, and a controller to synchronize the robot's position with the tube's rotation, ensuring uniform coverage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual blasting and coating processes are used on tube bodies, then workers can perform the processes flexibly, but the processes are inefficient and result in non-uniform paint application
Solution Approach 1:
The patent replaces manual mechanical operations with an automated robot system that applies coating material to the tube body. The robot arm moves precisely along the tube surface while a rotation-detecting device monitors and compensates for tube rotation, ensuring uniform coating application without manual intervention.
Solution Approach 2:
The patent employs a rotation-detecting device that provides real-time feedback on tube body rotation to the control system. This feedback mechanism allows the robot to dynamically adjust its positioning and coating application rate, maintaining uniform coating density even when the tube rotates during the coating process.
2Object-affected harmful factors
If manual coating processes are used, then equipment complexity is low, but working environments are harmful and coating quality is non-uniform
Solution Approach 1:
The patent introduces a robot as an intermediary between the operator and the hazardous coating environment. The robot performs all operations involving blasting and coating materials, keeping workers away from harmful dust and chemicals while the control system manages the complex coordination between robot movement and tube rotation.
3Area of stationary object
If the tube body rotates during coating, then the entire surface can be accessed, but paint density becomes non-uniform on conical shapes
Solution Approach 1:
The patent makes the coating system dynamic by allowing the tube body to rotate during coating while the robot arm dynamically adjusts its position and movement speed in response to real-time rotation data. This dynamic coordination ensures that the coating application rate matches the surface speed at each location, maintaining uniform paint density across the entire conical surface.
Solution Approach 2:
The patent changes operational parameters based on tube rotation state. The control system adjusts robot arm position, coating material flow rate, and robot movement speed according to the real-time rotation angle and surface velocity, ensuring consistent coating density across different sections of the conical tube body.
Data Source
AI summary
Provided is a coating-forming apparatus. The coating-forming apparatus according to one embodiment of the present invention includes a support member rotatably supporting a tube body about the central axis thereof; a robot moving in the longitudinal direction of the tube body and spraying paint or an abrasive material on the outer circumferential surface of the tube body, a rotation-detecting device attached to the tube body and measuring the angle of rotation of the tube body, and a controller for controlling the supporting member or the robot.