Automated Wheel Mold Spraying Apparatus for Uniform Coating
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Solution Overview
Problem
Manual spraying of aluminum alloy wheel molds in the die casting process results in non-uniform coating and poses health risks due to environmental hazards, making it difficult to achieve consistent and safe application.
Innovation Solution
An automatic wheel mold spraying device comprising a frame, servo electric cylinder, guide posts, servo motor, belt wheels, and a spray gun mechanism that allows for precise positioning and automated spraying of wheel side molds, enabling uniform coating and adjustment of spraying parameters based on wheel type.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual spraying with handheld spray gun is used, then operation flexibility is maintained, but spraying uniformity and consistency deteriorate
Solution Approach 1:
The patent replaces the manual mechanical spraying operation with an automated robotic spraying system. The robot arm equipped with spray gun executes pre-programmed trajectories and spraying parameters, eliminating human variability while maintaining operational flexibility through programmable control. This substitution resolves the contradiction by achieving both uniformity (through automated precision) and flexibility (through programmable adaptability).
Solution Approach 2:
The patent implements automated control of spraying parameters including spray pressure, gun-to-workpiece distance, moving speed, and spray angle. These parameters are precisely controlled and adjusted according to different wheel types through programming, ensuring consistent spraying quality while maintaining adaptability to various workpiece geometries.
2Device complexity
If manual spraying is used, then equipment complexity is low, but operator health safety deteriorates due to environmental hazards
Solution Approach 1:
The patent replaces manual spraying operations with an automated robotic system, removing operators from the hazardous spraying environment. The robot performs all spraying tasks within the enclosed or controlled area, eliminating direct human exposure to paint aerosols and harmful chemicals while the overall system complexity increases but is justified by safety benefits.
3Manufacturing precision
If automated spraying device is implemented, then spraying uniformity is improved, but device complexity increases
Solution Approach 1:
The patent designs a multi-functional automated spraying system that can handle different wheel types and geometries through programmable control. The robot arm, spray gun, and control system work together as an integrated universal platform that achieves consistent spraying quality across various workpieces without requiring separate specialized equipment for each wheel type.
Solution Approach 2:
The patent introduces a computer control system as an intermediary between the operator and the spraying mechanism. This intermediary handles the complexity of parameter control, trajectory planning, and process optimization, allowing the physical spraying system to achieve high uniformity while the operational complexity is managed through software rather than mechanical complexity.
4Device complexity
If manual spraying is used, then device complexity is low, but productivity and labor intensity worsen
Solution Approach 1:
The patent replaces manual spraying labor with an automated robotic system that operates continuously at consistent speed and precision. The robot can spray multiple wheel molds in sequence without fatigue, breaks, or repositioning delays, significantly increasing productivity compared to manual operations while the added automation complexity is offset by the labor savings and efficiency gains.
Data Source
AI summary
The present invention discloses a wheel mold spraying device, which is composed of a frame, a servo motor, a servo electric cylinder, a hollow shaft, a nozzle and the like. Four side molds of a wheel are respectively placed on four slide plates; hand wheels are rotated to adjust the slide plates to proper positions through lead screws and guide rails; the servo motor drives the rotation of the hollow shaft and the nozzle through belt wheels and a synchronous belt, and the nozzle is automatically opened; and through guide posts, the servo electric cylinder lifts the nozzle to the top end while rotating, in which case the process of spraying for the four side molds can be completed.