The present invention relates to finishing systems and processes for manufactured parts, and more particularly to carriers for transporting manufactured parts through a finishing process and methods relating to the same. For example, a finishing process can include an electrodeposition coating or “e-coat” process whereby manufactured parts are immersed in coating material and the process is charged with electrical current to deposit latent coating material onto immersed manufactured parts. The shape of elongated parts (e.g., pipes, fluid lines, etc.) are taken into consideration during the e-coat process to ensure full coating or covering of inner and outer surfaces.
Typically, large and complex machines will be utilized to ensure complete coating and transportation of such parts. Such machines typically include extensive processes carried out in different containers and/or housings that are separated from one another in order to provide parts with a desirable surface finish.
In one aspect, the invention provides a product coating system including a first end, a second end, and a frame extending between the first end and the second end, a pre-coating treatment station disposed between the first end and the second end, a first e-coat station disposed between the pre-coating treatment station and the second end, a second e-coat station disposed between the pre-coating treatment station and the second end, a curing station including an oven having an entrance and an exit, a process track supported on a portion of the frame and selectively moveable between a lowered position and a raised position, the process track extending above the pre-coating treatment station, the first e-coat station, and the second e-coat station, an oven track extending through the oven, a rack configured to carry one or more products, the rack selectively moveable along the process track and the oven track and moveable with the process track to the lowered position, in which the rack is positioned within one of the pre-coating treatment station, the first e-coat station, and the second e-coat station, a first hold up inhibiting the rack from being lowered into the second e-coat station, a second hold up inhibiting the rack from being lowered into the first e-coat station, a first rack path including the pre-coating treatment station, the first e-coat station, the first hold up, and the curing station, and a second rack path including the pre-coating treatment station, the second hold up, the second e-coat station, and the curing station. The rack is sequentially moveable through the first rack path and the second rack path.
In another aspect, the invention provides a method for coating a product including providing a frame having a first end and a second end, supporting a process track on a portion of the frame, and extending the process track above a product pre-coating treatment station, a first product e-coat station, and a second product e-coat station. The product pre-coating treatment station is disposed between the first end and the second end, the first product e-coat station is disposed between the product pre-coating treatment station and the second end, and the second product e-coat station is disposed between the product pre-coating treatment station and the second end. The method further includes selectively moving the process track between a lowered position and a raised position, supporting an oven track on a portion of the frame, extending the oven track through a e-coat cure oven defining a curing station, the cure oven including an entrance and an exit, removably supporting a rack for carrying one or more products on the process track and the oven track, selectively moving the rack along the process track and along the oven track through a first rack path and a second rack path, and sequentially moving the rack through the first rack path and the second rack path. When the process track is in the lowered position, the rack supported on the process track is lowered into one of the product pre-coating treatment station, first product e-coat station, and the second product e-coat station. The first rack path includes the product pre-coating treatment station, the first product e-coat station, a first series of hold ups supported on the frame above the second product e-coat station configured to prevent the rack from being lowered with the process track, and the curing station. The second rack path includes the product pre-coating treatment station, a second series of hold ups supported on the frame above the first product e-coat station configured to prevent the rack from being lowered with the process track, the second product e-coat station, and the curing station.
In another aspect, the invention provides an e-coat line including a frame supporting a process track configured to extend along a process direction, a workpiece rack moveably supported on the frame, the rack including support members configured to hold a plurality of hollow workpieces in a predetermined arrangement, the workpiece rack moveable relative to the frame between a raised position and a lowered position, and a plurality of electrodes supported on an electrode rack in a predetermined arrangement complementary to the predetermined arrangement of the plurality of hollow workpieces on the support members. The electrode rack is moveable relative to the workpiece rack in a direction crossing the process direction between a first position, in which the plurality of electrodes are extended along and overlapping with the support members to fit within the plurality of hollow workpieces, and a second position, in which the plurality of electrodes are retracted away from the support members to be removed from the plurality of hollow workpieces.
Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
Before embodiments are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the accompanying drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limited. The use of “including,” “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.
It should be noted that while the below description is made with respect to pipes, the system 10 and method can be used to coat any product 14 having an internal cavity that may be difficult or impossible to effectively and economically coat using conventional methods. Likewise, while the below description is made with respect to coating the interior surface 18 of the product 14 with an electrodeposition or e-coat method, other types of coating applications may be used for the interior surfaces 18. For example, the interior surface 18 of the product 14 may be coated using powder coating, auto deposition, and other product coating systems and methods. Furthermore, while computer automated processes are well known, it should be noted that the below description is made with respect to a hybrid process including automated and human-conducted tasks, but could be fully automated or fully human-conducted based on design preferences and/or monetary considerations.
With reference to
The frame 26 further supports a plurality of yokes 74 along the frame 26 to assist in driving the product rack 46 along the process track 38. Once the product racks 46 have been loaded onto the process track 38, the product racks 46 may be advanced along the process track 38 under influence from the yoke 74 in combination with the force of the load conveyer 62 loading a new product rack 46 onto the process track 38. In another embodiment by way of example, advancement of the product racks 46 along the tracks 38, 42 may be continuously driven by a motor 78 in communication with a programmable logic controller (PLC) 82 or other suitable controlling device. In still another embodiment by way of example, advancement of the product racks 46 along the tracks 38, 42 may be driven solely by a pushing force on a single or select number of product racks 46 in a series of product racks 46 on the tracks 38, 42. Once the product racks 46 are loaded on the tracks 38, 42, the product racks 46 are then advanced selectively through the tanks 66, and into the oven 34 at the second end 70 of the finishing line 30. In the illustrated embodiment, rack actuators 86 are supported on the frame 26 at the first end 50 and the second end 70 for carrying the product racks 46 from the process and stationary tracks 38, 42 to an oven track 90, or vice versa. The oven track 90 is supported on the frame 26 within the curing oven 34. The rack actuators 86 are supported, respectively, at an oven entrance 94 located at the second end 70 and at an oven exit 98 located near the loading zone 54 at the first end 50.
With reference to
Referring now to
The product support members 134 arranged on the rack 46 include conducting teeth 136 (
The pipes 14 may be loaded onto the support members 134 prior to loading the product racks 46 onto the load conveyor 62, or at another time before the product rack 46 proceeds to the first immersion rinse phase 110a along the process track 38. Once the pipes 14 have been loaded onto the product support members 134, the product rack 46 loaded with pipes 14 may proceed to the first immersion rinse phase 110a, in which the process track 38 may be lowered to immerse the product rack 46 in an unheated rinsing solution that may be pump-agitated within the first immersion rinse station 110a. Once the product rack 46 undergoes the first immersion rinse phase 110a, the entire process track 38 may be elevated to remove the product rack 46 from the first immersion rinse phase 110a. Next, another product rack 46 may be loaded on to the process track 38 at the loading zone 54, which pushes all of the product racks 46 on the process track 38 ahead a phase. The product rack 46 may then proceed to the first immersion conditioner phase 110b in a similar manner, in which the process track 38 is lowered to immerse the product rack 46 in an unheated conditioner solution that may be pump agitated within the first immersion conditioner station 110b. Next, as another product rack 46 is added onto the process track 38, each product rack 46 on the process track 38 advances along the process direction PD. The product rack 46 then proceeds to the first immersion zinc phosphorus phase 110c, in which the process track 38 is lowered to immerse the product rack 46 in a zinc phosphate solution heated at approximately 130 degrees Fahrenheit and pump agitated within the first immersion zinc phosphorus station 110c at a maximum agitation. Once the product rack 46 completes the first immersion zinc phosphorus phase 110c, the product rack 46 advances on the process track 38 through the second and third immersion rinse phases 110d, 110e that are each generally the same as the first immersion rinse phase 110a but provided in their respective stations.
Upon completion of the second and third immersion rinse phases 110d, 110e, the pipes 14 on the product racks 46 are suited to proceed to either of the cathodic e-coat and anodic e-coat phases 114, 118, depending on whether the pipes 14 require a first e-coat (e.g., cathodic e-coat) or a second e-coat (e.g., anodic e-coat). In the cathodic e-coat phase 114, the process track 38 may be lowered to immerse the product rack 46 in a first electrocoating liquid chilled at approximately 90 degrees Fahrenheit in the cathodic e-coat station 114. The first electrocoating liquid within the cathodic e-coat station 114 is then charged with electric current for a prescribed duration (e.g., about 120 seconds) to drive the deposition of coating material on to the pipes 14. In theoretical terms, the pipe 14 acts as a cathode in an electrolysis equation, hence the term “cathodic e-coat.” As electric current flows, charged ions in the first electrocoating liquid gain electrons at the inner surface 18 and the outer or surface 22 of the pipe 14 and transform into a coating on the pipe 14. In the cathodic e-coat phase 114, the first electrocoating liquid may be a positively charged acidic liquid that is flushable from the cathodic e-coat phase 114 periodically throughout the coating process. As described in greater detail below, electrodes 142 supported on an electrode rack 146 may be inserted within the interior surface 18 of the pipe 14 during the cathodic e-coat phase 114. This increases the current flow and current flow density within the pipe 14 and therefore increases an amount and/or quality of coating on the interior surface 18 of the pipe 14.
Following the cathodic e-coat phase 114, the process track 38 may be selectively lowered to accommodate moving the product racks 46 along the process direction PD through the first, second, and third immersion post rinse phases 122. The first and second immersion post rinse phases 122 include mixer agitation of respective post rinse solutions. The first, second, and third immersion post rinse phases 122a, 122b, 122c include pump agitation of a respective post rinse solution. After the first, second, and third immersion post rinse phases 122a, 122b, 122c, the product racks 46 proceed to the first drip phase 126a, where the product racks 46 are allowed to drip in the first drip station 126a for any suitable pre-determined interval of time.
With specific reference to
Referring now to
Still referring to
The second rack path will now be described in greater detail with reference to
The anodic e-coat or “anodized layer” improves the hardness, wear resistance, electrical insulation, etc. of the pipe 14. The porous surface of the anodized layer may be sealed during the fourth, fifth, and sixth immersion post rinse phases 122d, 122e, 122f, which sequentially follow the anodic e-coat phase 118 along the process direction PD. The fourth and fifth immersion post rinse phases 122d, 122e include mixer agitation of respective post rinse solutions. The fourth, fifth, and sixth immersion post rinse phases 122d, 122e, 122f include pump agitation of a respective post rinse solution. After the sixth immersion post rinse phase 122f, the product racks 46 may proceed to the second drip phase 126b, where the product racks 46 can drip in the second drip station 126b for any suitable pre-determined interval of time.
In both of the first and second rack paths, following the respective drip stations 126, the product racks 46 may proceed through the oven 34, along the oven track 90, while being heated at approximately 450 degrees Fahrenheit. Once the curing process 130 is complete, the product racks 46 may be transported by the rack actuators 86 either to be unloaded from the finishing line 30 (upon completion of the second rack path) or back to the process track 38 (upon completion of the first rack path). Alternatively, as stated above by way of example, the rack actuators 86 may be omitted such that the product racks 46 may be continuously transported on the alternate process track 38 through the first and second rack paths.
With reference to
Referring now to
As will be described further below,
In another embodiment by way of example, the electrode rack 146 can be offset to any direction to accommodate the length L of each pipe. For example, the pipes 14 may be supported on the product rack 46 with one end of the pipe 14 farther forward in the process direction PD than another end of the pipe 14. In such example embodiment, the electrode rack 146 may be aligned in a corresponding orientation. Stated another way, the electrode rack 146 and product rack 46 are formed to nest or physically mesh with one another such that each of the electrodes 142 may be fully inserted into one of the pipes 14 during the cathodic and anodic e-coat phases 114, 118. In yet another embodiment by way of example, the electrode rack 146 may be mounted on the process track 38 and moveable with the process track 38 between the raised and lowered positions by the track actuators 102. In such example, the electrode rack 146 is moveable between the lowered and raised positions and is operable to insert the electrodes 142 into the pipes 14 prior to being lowered into the corresponding e-coat phase 114, 118. Disassociating the electrode racks 146 from the structure of the tank 66 and retracting the electrodes 142 while above the tank 66 may allow for the width W1 of the cathodic and anodic e-coat phases 114, 118 to be reduced.
The electrode rack 146 is attached to chain drive mechanisms 148, which are driven by a motor 149, to move the electrodes 142 and the electrode rack 146 in the direction DD. In some embodiments, the motor 149 is driven by compressed air in order to minimize additional electrical components, but other types of motors and driving mechanisms (e.g., hydraulic motors, electric motors, etc.) are contemplated and could be suitable. For example, the compressed air motor 149 could be supplemented or replaced by an electric motor as long as electrical charge produced by the electric motor is isolated from other electrical components (i.e., electrodes 142, cathodic and anodic e-coat stations 114, 118) in the coating process within the coating system 10. The chain drive mechanism 148 may be further operated to completely remove the electrode racks 146 from either of the e-coat stations 114, 118 to facilitate easier maintenance and/or cleaning of the e-coat stations 114, 118 and electrode racks 146.
As further illustrated in
Each electrode 142 may include or be partially surrounded/encased by insulating material 151 to further prevent direct contact between the electrode 142 and the pipe 14. The insulation material 151 also prevents the electrodes 142 from receiving undesired coating and protects the electrodes 142 against scratching and/or wear. In the illustrated embodiment, the insulating material 151 is a high heat resistant material (i.e., Teflon) but other insulating materials are contemplated (e.g., high heat resistant polymers and plastics, ceramics, etc.). The insulating material 151 is additionally electrically insulating so as to prevent electrical conduction between uninsulated portions of the electrodes 142 and pipes 14.
As best illustrated in
Additionally, the walls 153 of the funnel 152 may include electrically insulating material such that, during insertion of the electrodes 142 through the funnel 152 and into the pipe 14, the insulating material 151 of the electrodes 142 may contact the electrically insulated walls 153 without conducting electricity/charge between the electrodes 142 and the product rack 46. Stated another way, the walls 152 and insulating material 151 provide an electrically non-conductive barrier between the funnel 152/product rack 46 and at least an uninsulated portion of the electrodes 142. As such, the pipe 14 does not physically contact uninsulated portions the electrode 142. Rather, the pipe 14 is in fluid communication with the electrode 142 through the electrocoating liquid. The electric current provided in the e-coating phases 114, 118 flows through the contactless fluid engagement between the electrodes 142 and the pipes 14 and therefore at least partially drives the deposition of the coating on the pipes 14.
The insulating material 151 also prevents the electrodes 142 in the anodic e-coat station 118 from contacting any structure portion of the frame 26 (i.e., finishing line 30, curing oven 34, etc.). The electrode racks 146 in the anodic e-coat station 118 are also isolated from other structure portions of the frame 26. The electrodes 142 and electrode racks 146 in the anodic e-coat station 118 are oppositely charged from the rest of the conductive components, particularly the pipe 14 and product racks 46. Contact and/or close contact arcing between a charged electrode 142 in the anodic e-coat station 118 and a portion of the frame 26 could cause a short circuit or “dead short” and fault/damage the system 10.
Shorts and/or close contact arcing are detected by the PLC 82, which monitors an output amperage for several seconds at the beginning of each of the e-coat stations 114, 118 and determines if a short/arc occurred. The PLC 82 may interpret the output amperage data and alter the coating process if a large enough short is detected. It should be understood that any oppositely charged components in the system 10 that could cause a potential dead short are isolated from one another by isolation/insulation material and/or physical distance. For example, components present in the anodic e-coat station 118 are isolated from components not present in the anodic e-coat station 118. Such oppositely charged components could include mating surfaces, fasteners, mounting parts, etc.
With continued reference to
Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the invention as described. For example, although the invention has been described as including a single process track 38, stationary track 42, and oven track 90, it should be understood that any number of tracks 38, 42, 90 are contemplated. Such example applies to any supporting mechanisms discussed herein that may be dependent on the number of tracks 38, 42, 90 provided (e.g., number of tanks 66 provided, number of curing ovens 34 provided, etc.).
This application claims priority to U.S. Provisional Patent Application No. 63/225,096, filed Jul. 23, 2021, the entire contents of which are incorporated herein by reference.
Number | Date | Country | |
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63225096 | Jul 2021 | US |