Automatic Powder Cleaning for Wheel Bolt Holes
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Solution Overview
Problem
Current wheel bolt hole protection methods during powder spraying are labor-intensive, costly, and prone to errors, with protective plugs being difficult to customize and store, leading to rejects and environmental pollution.
Innovation Solution
An automatic powder cleaning process and device that recognizes wheel models, stores relevant information, and uses a powder cleaning robot with RFID tags and a visual recognition system to guide the cleaning operation, eliminating the need for physical protective plugs and reducing labor costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If protective plugs are assembled and disassembled artificially for wheel bolt holes during powder spraying, then the mounting surface can be protected, but the labor intensity and cost increase
Solution Approach 1:
The patent extracts and eliminates the protective plugs from the process by using powder spraying technology that can directly spray onto the mounting surface without requiring physical protection. The powder coating system is designed to control spray deposition, allowing direct application on bolt holes without plugs, thereby removing the manual assembly and disassembly operations.
Solution Approach 2:
The patent replaces the mechanical system of protective plugs with a controlled powder spraying system. Instead of using physical barriers (plugs) that require manual handling, the system uses controlled powder deposition technology to achieve the same protective function without mechanical intervention, thus reducing labor intensity.
2Adaptability or versatility
If multiple types of protective plugs are used for wheels with various bolt holes, then different mounting surfaces can be protected, but customization and storage become inconvenient and costly
Solution Approach 1:
The patent implements a universal powder spraying system that can handle various bolt hole configurations without requiring different protective plugs. The system uses a single standardized powder spraying apparatus with programmable control that adapts to different wheel types and bolt hole patterns, eliminating the need for multiple specialized plug types while maintaining versatility across all configurations.
Solution Approach 2:
The patent changes the approach from physical adaptation (different plug types) to parameter-based adaptation (programmable spraying parameters). The system adjusts spray parameters such as powder flow rate, spray pressure, and robot motion paths based on the specific wheel model and bolt hole configuration, allowing one universal system to handle diverse applications without physical customization.
3Reliability
If protective plugs are manually assembled and disassembled, then the mounting surface is protected during spraying, but rejects may occur due to missing or misplaced plugs
Solution Approach 1:
The patent removes the protective plugs entirely from the process, eliminating the source of errors related to missing or misplaced plugs. By using controlled powder spraying technology that can directly apply coating to the mounting surface, the system eliminates the intermediary protective elements that cause rejection due to placement errors.
Solution Approach 2:
The patent implements an automated recognition and control system that uses visual feedback to identify wheel models and bolt hole positions, then automatically adjusts the spraying parameters accordingly. This closed-loop control ensures accurate and consistent powder application without human intervention, eliminating the variability and errors associated with manual plug assembly.
4Reliability
If protective plugs are used for extended periods, then the mounting surface remains protected, but paint drop treatment is needed which pollutes the environment
Solution Approach 1:
The patent extracts and eliminates the protective plugs from the process, removing the source of paint drop contamination. By using controlled powder spraying that directly coats the mounting surface without protective barriers, the system prevents the accumulation and subsequent environmental pollution associated with disposing of saturated protective plugs.
Solution Approach 2:
The patent converts the potential harm of powder overspray into a benefit by using excess powder as a protective barrier during the spraying process. The powder that might otherwise be waste is utilized to protect adjacent areas, and the system recovers and recycles this powder, transforming a potential environmental issue into a resourceful solution.
5Reliability
If protective plugs are used during powder spraying, then the mounting surface is protected, but cleaning may be incomplete causing rejects
Solution Approach 1:
The patent removes the protective plugs from the process entirely, eliminating the cleaning completeness issue. By using controlled powder spraying technology that applies coating directly to the mounting surface without protective barriers, the system eliminates the subsequent cleaning step that often results in incomplete removal and rejection of parts.
Solution Approach 2:
The patent performs preliminary protection by using controlled powder deposition during the spraying process itself to protect adjacent areas, rather than using protective plugs that require subsequent removal. The system carefully controls powder application timing and distribution to achieve protection and coating in one integrated step, eliminating the need for separate cleaning operations.
6Reliability
If protective plugs are used during equipment vibration, then the mounting surface is protected, but plugs may drop causing rejects and equipment fault
Solution Approach 1:
The patent eliminates the protective plugs from the process, removing the instability issue entirely. By using controlled powder spraying technology that applies coating directly to the mounting surface, the system eliminates the physical objects that can drop during vibration, thereby preventing rejects and equipment faults while maintaining protection.
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
The solution reduces labor and costs, prevents rejects and equipment faults, and minimizes environmental pollution by automating the cleaning process, making it suitable for multiple wheel products and ensuring complete cleaning.
Implementation Method 1
comprises a vacuum pump, a steady pressure tank, a powder cleaning robot, a powder cleaning gun
Implementation Method 2
a steady pressure tank, a powder cleaning robot, a powder cleaning gun... the steady pressure tank is divided into a vacuum cavity and a powder storage cavity
Implementation Method 3
a powder cleaning robot mounted at the top of the powder cleaning robot... the powder cleaning robot is connected with the control system via the weak current lines
Implementation Method 4
the steady pressure tank is divided into a vacuum cavity and a powder storage cavity by a filter device
Data Source
AI summary
The present application discloses an automatic powder cleaning process and device for wheel bolt holes. The device comprises a vacuum pump, a steady pressure tank, a powder cleaning robot, a powder cleaning gun, a control system and accessories. According to the process and the device, shielded protection is canceled, and powder at the mounting part of a wheel bolt hole is automatically cleaned, so that the process and the device are suitable for various wheel products, and the labor and the labor cost are reduced; the problems that a lot of different types of protective plugs needed for wheels are inconvenient to customize and store and high in cost are avoided.