The present exemplary embodiment relates to an apparatus for coating fiber based products. It also finds particular application in conjunction with a coating process including a system for indexing parts to be coated, and will be described with particular reference thereto. However, it is to be appreciated that the present exemplary embodiment is also amenable to other like coating and/or manufacturing applications.
A number of disadvantages exist with prior coating machines and part conveyors. For one, prior art part conveyors typically use a spring detent mechanism to maintain the orientation of the part or product to be coated throughout the entire path that the part travels throughout the machine. If for any reason this detent fails or if the part is bumped out of position, the part may be spoiled and/or severe damage could occur to the machine. In addition, other prior art systems use electric components such as sensors, motors, servos, etc. to locate and reorient parts. These systems are not only highly expensive but also prone to reliability issues due to the harsh and unforgiving environment of the coating and heat curing processes.
Still another disadvantage, current chain-on-edge machines use a gear or sprocket attached to the part spindle which engages with a stationary gear/sprocket on the machine to reorient the spindle. The rotational speed of the spindle is thus controlled only by the ratio of the pitch diameters of these driving components and the speed at which the part spindle is moving through the machine. Since only a limited number of combinations of gears/sprockets exist (due to the upper and lower diameter limitations of these driving components), there are only a limited range of speeds at which the part spindle could be rotated. In addition, since a sprocket's diameter will remain constant, it will turn at the same speed in relation to the speed of the chain conveyor, regardless of where it is placed along the chain conveyor path in the machine.
Moreover, the prior art chain-on-edge sprocket systems do not provide for any method to selectively lock or fix the orientation of one or more part spindles in relation to the conveyor chain and/or the direction of travel. Also, such prior art sprocket systems cannot force a rotational stop which could allow inertia to cause the spindle to rotate too far. As such, the part spindles and the parts or products supported thereon, may become randomly oriented which further leads to quality control issues in the manufacturing process.
In accordance with one aspect, a coating apparatus for coating an associated product comprises a conveyor mechanism for advancing the associated product, and an indexing system configured to index the associated product as it is advanced by the conveyor mechanism. The indexing system includes a product support member coupled to the conveyor mechanism for advancement therewith, the product support member adapted to support the associated product during movement through the coating apparatus, the product support member including a rotatable spindle shaft and a first indexing member rotationally interlocked with the rotatable spindle shaft, the indexing member configured to engage a guide surface of an adjacent first guide member as the product support member is advanced by the conveyor mechanism past the guide member to change an orientation of the rotatable spindle shaft from a first angular position to a second angular position thereby rotating the associated product.
The coating apparatus can further comprise a second guide member for engaging a second indexing member rotationally interlocked with the rotatable spindle shaft, the second indexing member configured to engage a guide surface of the second guide member as the product support member is advanced by the conveyor mechanism past the second guide member to change an angular position of the rotatable spindle shaft and the associated product to a position different than at least one of the first angular position and the second angular position. The conveyor mechanism can include a chain supported for movement in a track of a frame, and wherein the product support member is received by the track for movement therealong.
The apparatus can also include a plurality of indexing members rotationally interlocked with the rotatable spindle shaft and a corresponding plurality of guide members, each indexing member configured to engage a guide surface of a corresponding guide member as the product support member is advanced by the conveyor mechanism along the track past the corresponding guide member to change an orientation of the rotatable spindle shaft. The plurality of guide members can be spaced along a length of the track such that, as the product support member is advanced along the length of the track, the rotatable spindle shaft is rotated to different orientations. At least two of the plurality of guide members can include guide surfaces spaced at different distances from the track for engaging with first and second indexing members spaced apart along an axial dimension of the rotatable spindle shaft.
The apparatus can further comprise a plurality of product support members having at least one indexing member and/or a plurality of guide members spaced along the track, two or more of said guide members having guide surfaces with different profiles for rotating respective rotatable spindle shafts at different rates at different locations along the track.
The apparatus can further include a spindle lock assembly for locking the rotatable spindle shaft against rotation. The spindle lock assembly can include a locking bushing fixed to the rotatable spindle shaft for rotation therewith, and a locking arm movable between a locked position whereat a portion of the locking arm is engaged with a portion of the locking bushing thereby restricting rotation of the locking bushing, and an unlocked position whereat rotation of the locking bushing is not restricted by the locking arm. The locking bushing can include a concave surface thereof, and the locking arm can include a corresponding convex surface thereof adapted to be received along the concave surface of the locking bushing when the locking arm is in the locked position. A biasing member can be provided for biasing the locking arm towards the locked or unlocked position. At least one toggle member can be provided for urging the locking arm to the locked or unlocked position.
The indexing member and/or or guide member(s) can have a variable slope surface whereby a variable rate of rotation of the spindle shaft is produced as the indexing member engages the guide member. The indexing system can include a smooth lobed cam and a smooth guide surface upon which the cam impinges.
In accordance with another aspect, a method of indexing a product in a coating apparatus comprises supporting the product on a rotating spindle shaft of an indexing system, advancing the rotating spindle through the coating apparatus with a conveyor mechanism, and rotating the product to a prescribed orientation with the indexing system as the conveyor mechanism advances the product through the coating apparatus. The rotating the product includes providing an indexing member fixed to the spindle for rotation therewith, the indexing member configured to engage a guide surface of an adjacent first guide member as the spindle shaft is advanced by the conveyor mechanism past the guide member to change an orientation of the spindle shaft from a first angular position to a second angular position thereby rotating the associated product.
With reference to
Permitting the product or part to be manipulated in such a manner provides a particular advantage in the coating process as it allows the part to be uniformly coated in a very compact space while utilizing a generally unidirectional flow of air and spray coating material through the spray booth. Once the part to be coated PRT is coated, it may then be advanced through a curing oven OVN through which the conveyor 14 and track assembly 15 may make several passes in a serpentine-like course. Once the coated parts PRT have dwelled for an adequate period of time within the oven OVN, the parts may advance through a cooling chamber CC to be cooled to an appropriate handling temperature. Finally, the parts PRT may advance to an unloading area UDA where they may be unloaded, packaged or presented to another machine for further processing. Naturally, one or more aspect of the coating apparatus 10 may be fully automated (e.g., as in the automated loading and unloading of parts, heating and cooling control, part detection, etc.)
Now with reference to
Now with reference to
As the spindle 12 passes the first guide 22A, the spindle 12 may encounter a second or subsequent guide 22B. The second guide 22B may be disposed at a lower elevation with respect to the first guide 22A, such that a second or lower indexing member 26 may slidably engage a lead in profile or edge 23B. As the second indexing member 26 engages the edge 23b, the spindle shaft 25 will be urged to rotate by approximately another 90°, thus presenting the next side of the mounted part PRT to be coated. Next, the indexing process is repeated (as described with regard to the first guide 22A) by the third guide 22C since the third guide 22C is at the same or similar elevation of the first guide 22A. Here again, the upper or first indexing member 24 will engage the profile or edge of the guide 23C, thus causing the spindle to rotate yet another 90° and present a different surface of the part to be coated. Finally, the fourth guide 22D is disposed at the same level as the second guide 23B which again engages the second or lower indexing member 26 to bring the part PRT back to its original orientation.
It should be noted that any number of indexing members and guides could be combined at various heights and contours, respectively, to achieve any number of spindle/part orientations and angular rates of turn. Furthermore, the spindle assemblies may be modified to include multiple degrees of freedom so that a part can be manipulated in different planes/axes. By way of example, a mounted part could be manipulated in more than one plane/axis by using a combination of nested part spindles, angled drive systems, multiple guide/indexing members, and/or spindle locks, etc.
The process of indexing or rotation of the spindle 12 is further illustrated in
Now with reference to
Now with reference to
Now with reference to
As disclosed above, the spindle assemblies and chain can be contained and guided by a track with a specific profile. The profile of the track could be made by extruding aluminum or plastic or it could be machined. Other parts, channels, or surface features can be added to the track (or formed therein as part of the extrusion) for additional stability or functionality. Other guides can be attached to capture the chain or more complicated guides could be added to capture the chain and add stability. Here, the track design may accomplish multiple objectives. It may support the chain as well as provide a surface for the spindle housing to ride upon. By capturing the chain and spindle housing, it provides stability to the whole assembly. As illustrated, various chain guide designs could be employed to capture more or less of the chain, depending on the level of chain stability that is required. Furthermore, externally accessible channels could be incorporated as part of the design of the track profile to allow for the ease of securing the track to the frame and for the mounting of other components (e.g., part spindle index guides, spindle interlock trigger/toggle, electrical/mechanical sensors, and/or machine guards, etc.).
As discussed previously, prior art chain-on-edge machines use a gear or sprocket attached to the part spindle which engages with a stationary gear/sprocket on the machine to index or reorient the spindle. This offers only a limited range of speeds at which the part spindle can be rotated and whichever speed is selected is the only speed that can be used throughout the pathway of the driving chain conveyor. By contrast, and in accordance with the indexing system of the present disclosure, the indexing guides could be shaped differently in different areas of the machine so that various rates of rotation could be accomplished regardless of chain conveyor speed, etc. The indexing guides could even be contoured to achieve non-linear rates of rotation if needed.
Also, as previously mentioned, the prior art chain-on-edge sprocket systems do not provide for any method to selectively lock or fix the orientation of one or more part spindles in relation to the conveyor chain and/or the direction of travel. As such, the part spindles and the parts or products supported thereon, may become randomly oriented which further leads to quality control issues in the manufacturing process. The interlock system of the present disclosure addresses this problem by allowing the machine to force an absolute spindle orientation. As described previously, toggles placed in the track can engage or disengage the interlock or locking assembly of the spindle assemblies at any desired point. Due to its design, the interlock can only be engaged when the spindle is in its proper orientation. This design allows for the simple addition of electronic sensors for the control system to verify proper spindle orientation in various areas of the machine. If improper spindle orientation is detected via the position of the locking arm, the machine can be programmed to automatically stop. In areas of the machine where the spindle needs to be reoriented, the spindle locking assembly would be disengaged and the previously disclosed indexing system could be used.
The exemplary embodiment has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the exemplary embodiment be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.
This application claims the benefit of U.S. provisional application Ser. No. 61/523,519 filed Aug. 15, 2011, all of which is incorporated herein by reference
Number | Name | Date | Kind |
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3730637 | Cellini | May 1973 | A |
6436189 | Reuscher | Aug 2002 | B1 |
6911085 | Knop | Jun 2005 | B2 |
Number | Date | Country |
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100 45 515 | Apr 2002 | DE |
Number | Date | Country | |
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20130042806 A1 | Feb 2013 | US |
Number | Date | Country | |
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61523519 | Aug 2011 | US |