Wire Arc Spray Swivel Head for Robotic Coating
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Solution Overview
Problem
Existing wire arc spray torches face challenges in applying consistent coatings, especially when spraying hard-to-reach areas, leading to inefficient and labor-intensive manual spraying, which results in inconsistent coatings and increased downtime due to wire jamming.
Innovation Solution
A wire arc spray head with arc-making contact points and a carrier gas outlet that can swivel in a pivoting motion, allowing for radial arc movement of up to 180 degrees, enabling consistent coating application without stressing the torch cable and facilitating robotic operation for efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual spraying is used to spray hard-to-reach areas, then the torch can access complex surfaces, but coating consistency deteriorates and labor time increases
Solution Approach 1:
The spray head is made dynamically adjustable with a swivel mechanism that allows the spray tip to pivot through a radial arc (e.g., 180 degrees) while maintaining proper orientation. This dynamic positioning capability enables consistent coating application on complex surfaces while preserving torch cable integrity, eliminating the need for manual repositioning that causes inconsistent coatings
2Adaptability or versatility
If the spray head is redirected over a 180-degree range to spray I-beams, then hard-to-reach areas become accessible, but torch cable stress increases
Solution Approach 1:
The spray head incorporates a swivel mechanism that allows the spray tip to pivot through a radial arc while the torch body remains relatively stationary. This dynamic adjustment enables wide spray angle coverage (e.g., 180 degrees) without subjecting the torch cable to excessive stress from repeated repositioning of the entire torch assembly
Solution Approach 2:
The torch is segmented into a stationary body and a movable spray tip section. The spray tip can be independently positioned through a radial arc range while the main torch body remains fixed, separating the functions of cable support and spray direction control to minimize cable stress
3Adaptability or versatility
If manual spraying is used for long-length structures, then the torch can be repositioned manually, but production efficiency decreases
Solution Approach 1:
The swivel mechanism enables quick and easy adjustment of the spray tip angle without requiring manual repositioning of the entire torch assembly. This dynamic positioning capability significantly reduces the time and effort needed to spray long-length structures, thereby improving production efficiency while maintaining the ability to access various surfaces
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 swiveling head allows for even, high-quality coatings on complex or hard-to-reach surfaces, reducing downtime and labor costs, and enabling efficient robotic spraying of long-length structures like bridge girders, while maintaining coating quality across a wide range of angles.
Implementation Method 1
providing electric power to the solid wire feed stock such that the solid wire feed stock is changed into a state suitable for spraying
Implementation Method 2
providing a carrier gas under pressure to the device; carrying the spray by the carrier gas to the work piece
Data Source
AI summary
Device for spray coating embraces a wire arc spray head that includes arc-making contact points and a carrier gas outlet, which is configured to swivel with feed wire in a pivoting motion. The device can be operated to spray coat a work piece.