Patent Application
20150158145
The present disclosure relates to a system and method of cleaning at least one component of a painting installation, e.g., cleaning a component of a painting robot or of a handling robot. The phrase “cleaning system” in this disclosure means a system that in addition to cleaning components may also comprise the components to be cleaned and optionally motional devices therefor and also possibly necessary program controls, motion controls and other, e.g., automatic control means.
When motor-vehicle bodies and their attachment parts are painted, soiling of the components used in the painting installation, such as atomisers, door or bonnet openers (“opener tools”), gratings, robot parts, painting booth walls, etc., due to emitted paint mist, drops of paint, paint overspray, etc. inevitably occurs. Various cleaning systems and cleaning methods are known for the cleaning which is therefore necessary at regular intervals, but these involve some disadvantages.
A conventional cleaning method is a spray-cleaning method using flushing agents and compressed air for drying the components to be cleaned. A further conventional cleaning method is a mechanical cleaning method with a brush, which is mostly used in combination with the spray-cleaning method.
Disadvantages of these conventional cleaning methods are the long time which is necessary for drying, the consumption of flushing agent and the overall size of the cleaning equipment necessary. In the case of the mechanical cleaning method with a brush there is furthermore the disadvantage that the brush is prone to wear and can itself be soiled by paint. Furthermore, detached bristles may be left behind on the components to be cleaned and later, during the painting process, fall e.g. onto motor-vehicle bodies or their attachment parts which are to be coated, and damage them.
There is therefore a need to provide an alternative and/or improved cleaning system, suitable for a painting installation, for cleaning components of a painting installation.
Disclosed herein is a cleaning system, suitable for a painting installation, for cleaning at least one component of the painting installation, e.g., at least one component of a painting robot or of a handling robot, wherein at least one dry-ice nozzle for producing a dry-ice jet that cleans the component, and typically for applying dry ice to the component to be cleaned, is provided. In the context of this disclosure, “dry ice” covers at least one of the following: snow (preferably carbon dioxide snow), dry snow, carbon dioxide (CO2) and/or a two-phase carbon dioxide mixture which comprises carbon dioxide gas and carbon dioxide particles. In the context of this disclosure, “dry ice” alternatively or additionally covers any grain sizes in a solid aggregate state and/or in the form of individual particles. Furthermore, in the context of this disclosure the dry ice or generally the carbon dioxide may be admixed and/or admetered to an expediently pressurised carrier gas.
This disclosure for the first time provides a cleaning system with at least one dry-ice nozzle for spraying dry ice onto a component to be cleaned, wherein both the cleaning system per se and the dry ice which is to be applied and/or sprayed are configured for use in a painting installation. Not only the cleaning system per se, but also the dry ice produced, has to be configured for use in a painting installation (e.g. explosion-protected, paint-resistant and solvent-resistant, etc.). Thus, conventional dry-ice configurations which are applied for cleaning purposes are unsuitable for use in painting installations, e.g., because the carbon dioxide particles are too small or too large, with the consequence that paint which is to be removed cannot be removed appropriately and/or that the sensitive components which are to be cleaned are damaged.
The cleaning of objects by spraying with dry ice is known. However, from the above explanation it arises that known dry-ice cleaning methods and dry-ice cleaning systems are unsuitable for automated use in painting installations, e.g., because of a lack of paint resistance, lack of flushing-agent/solvent resistance, lack of freedom from substances that impair paint-wetting; lack of explosion protection, which is imperative in painting installations, unsuitable dry-ice configuration, etc.
In an embodiment, a robot is provided that guides the component to be cleaned and that may be configured such that it positions the component to be cleaned in front of the dry-ice nozzle and/or moves (e.g., rotates, moves transversely and/or rectilinearly translationally) it relative to the dry-ice nozzle during the cleaning operation, as a result of which the component to be cleaned can be cleaned, e.g., over its entire outer periphery.
The distance between the dry-ice nozzle and the component to be cleaned, i.e., between the nozzle mouth and the surface of the component which is to be cleaned, may be between 1 mm and 30 mm during jet exposure. In this case, the jet exposure angle of the nozzle relative to the component surface can be expediently selected according to requirements.
The nozzle may also be oriented relative to the component such that the surface to be cleaned is influenced and/or exposed merely indirectly by the dry-ice jet, since even “spraying-past” of the dry ice past the object to be cleaned can have a cleaning effect. In such case, the cooling of the soiling, e.g. by carbon-dioxide carrier gas flowing past, makes the soiling brittle and then detaches it.
In particular with such, but also with other, embodiments, the dry-ice nozzle may be arranged in stationary manner.
Further, the surface to be cleaned (for example of an atomiser) may be divided into a plurality of cleaning sections, which are then approached and cleaned sequentially and in a freely parametrisable sequence. These cycles can be set in freely parametrisable manner and corresponding to the soiling. Fixedly set cycles are also possible.
Between the individual cleaning operations and sections, the component to be cleaned can again and again perform its actual function in the painting booth. Merely all the sections together then yield a completely clean component.
The cycles and/or times when the individual sections are cleaned can be freely programmed and set.
It is likewise possible to place the various sections in various dependencies with one another, so that one part, for example the lower part of a painting means, is always cleaned before the other sections. This can be achieved with special software and a cycle counter accounting for the dependencies.
It is possible for the dry-ice nozzle to be carried by a robot and to be movably guidable by the robot. The robot may be configured such that it positions the dry-ice nozzle in front of the component to be cleaned and/or moves (e.g., rotates, moves transversely and/or rectilinearly translationally) it relative to the component to be cleaned during the cleaning operation, as a result of which the component to be cleaned can be cleaned, e.g., over its entire outer periphery.
In one special embodiment of this disclosure, the robots are configured such that both the dry-ice nozzle and the component to be cleaned are moved during the cleaning process. The movement of the dry-ice nozzle and of the component to be cleaned can take place in opposite directions and/or in succession or simultaneously.
The dry-ice nozzle may, e.g., be mounted fixedly on a robot. It is, however, also possible for the dry-ice nozzle to be mounted exchangeably on a robot and, e.g., before a cleaning process to be automatically picked up/exchanged by a robot and/or after a cleaning process to be automatically put down/exchanged by a robot.
In one embodiment, a robot carries both an atomiser or a handling tool (e.g. a gripping tool of a handling robot) and also the dry-ice nozzle. The dry-ice nozzle in such case is expediently attached to the robot such that the function of the atomiser or of the handling tool is not impaired by the dry-ice nozzle. Expediently, the dry-ice nozzle may be shielded from the atomiser or the handling tool e.g. by means of a covering.
The dry-ice nozzle may be designed to be adjustable in its nozzle contour and/or in its orientation, e.g., to permit adaptation to different outer contours of the component to be cleaned, to be able to be directed at the component to be cleaned in different orientations (e.g., different cleaning angles), and/or to be able to emit the dry ice from the dry-ice nozzle with different jet configurations (e.g., different jet divergence angles, different jet widths, etc.). For this purpose, the cleaning system may comprise corresponding setting mechanisms which are operatively connected with the dry-ice nozzle.
In an embodiment, a plurality of dry-ice nozzles is provided.
It is possible that dry-ice nozzles are positioned or can be positioned at the same height, e.g., to be able to clean different regions of the outer periphery of the component which is to be cleaned simultaneously. Alternatively or additionally, it is possible that dry-ice nozzles are positioned or can be positioned at different heights, e.g., in order to be able to clean regions of the component to be cleaned which differ in height (e.g., a bell cup, an electrode-holder portion, e.g., electrode ring or electrode fingers, and/or a hand axis of a robot) simultaneously.
The dry-ice nozzles are arranged or can be arranged such that they cover the preferably entire outer periphery of the component to be cleaned during the cleaning operation.
It is possible for the dry-ice nozzle to be directed downwards during a cleaning operation, so that detached dirt particles are carried away downwards. This can be achieved, e.g., by the dry-ice nozzle adjustment function mentioned and/or by the robot carrying the dry-ice nozzle.
Alternatively or additionally, it is possible that a protective element is provided (e.g., a protective sheet or a housing or a collecting funnel with or without suction removal means) in order to prevent dirt particles detached during cleaning or dry ice from striking a component which is to be painted.
The cleaning system may be constructed such that internal flushing processes, e.g., of an atomiser, can take place in parallel with the cleaning by the dry ice, namely expediently independently of the atomiser orientation (e.g., bell-plate axis obliquely in space; pipe, sheets for collecting, deflecting the media which are atomised by means of the bell cup, etc.).
The component to be cleaned may be at least one of the following: an atomiser which is guided by a painting robot; a grip (e.g., an opener or opener tool of a handling robot, e.g., for opening doors, bonnets or flaps); a hand axis of a robot; a proximal robotic arm of a robot; a distal robotic arm of a robot; a booth wall of a painting booth, e.g., a windowpane in the booth wall; a floor of a painting booth, e.g., a grating in the floor of the painting booth; a guide rail for a robot (e.g., for displacing the robot); a conveyor for transporting components to be painted through the painting installation; an electrode holding ring of an atomiser; light arrays; silhouettes; silhouette doors; components to be painted; and/or a frame for hanging components to be painted. In brief, all the components of a painting installation which may be contaminated by paint particles, e.g., overspray, can be cleaned by the cleaning system.
The cleaning system may be equipped, e.g., with a supply device for supplying the dry-ice nozzle with the dry ice or carbon dioxide for producing dry ice. Further, a ring line for connecting the supply device to a plurality of dry-ice nozzles via respectively one stub line which branches off from the ring line to the respective dry-ice nozzle may be provided.
It is possible that a sensor, e.g., a camera sensor, is provided which determines the cleaning result. In the context of this disclosure, this also covers monitoring of the cleaning operation. Furthermore, e.g., a temperature sensor may be provided which determines the temperature of the component to be cleaned. By this the cleaning performance (e.g., the cleaning result) can be expediently monitored, e.g., quasi online. The atomiser might partially evaluate the cleaning result itself, e.g., by measuring the current and/or the voltage during stoppage/idle running. The success of the cleaning or generally the cleaning result can be determined therefrom.
The dry ice may be at least partially a carbon dioxide mixture which comprises carbon dioxide gas and carbon dioxide particles. The dry ice emitted by the dry-ice nozzle is thus preferably two-phase or multiphase (comprising carbon dioxide gas and carbon dioxide particles, optionally with conveying air or another carrier gas).
The cleaning system, e.g., the dry-ice nozzle, is configured such that the carbon dioxide, e.g., the carbon dioxide mixture, is miscible with a pressurised carrier gas before it emerges from the dry-ice nozzle, e.g., can be admixed to a pressurised carrier gas. For this purpose, the cleaning system may comprise a carrier-gas supply means and/or a mixing device (e.g. a mixing chamber or the agglomeration chamber mentioned below) for mixing carbon dioxide, e.g., the carbon dioxide mixture, with the pressurised carrier gas. The pressurised carrier gas may be compressed air. The carbon dioxide in the context of the invention can be admixed to the carrier gas and/or vice versa. The cleaning system is consequently expediently configured to mix carbon dioxide, e.g., the two-phase carbon dioxide mixture, with a pressurised carrier gas.
It is possible for the cleaning system to comprise a heating mechanism for heating the pressurised carrier gas.
Further, it may be expedient, following the cleaning, for the surface to be cleaned to be heated with hot air using a subsequent blower, in order to prevent conditions from dropping below the dew point at the surface of the object to be cleaned. The heating may also take place with other heating methods, such as for example with infrared radiation and other methods known from the prior art.
Furthermore, it is possible to supply the object to be cleaned with hot air through internal channels in order to heat it. Further, an electric heating device such as a heating coil or a heating wire may also be incorporated in the object in order to prevent excessive cooling of the surface.
The cleaning system may comprise an agglomeration chamber, to which fluid carbon dioxide can be supplied and in which a carbon dioxide mixture which comprises carbon dioxide gas and carbon dioxide particles and thus expediently is designed to be two-phase can be formed by agglomeration of carbon dioxide snow crystals. The carbon dioxide, e.g., the carbon dioxide mixture, can be mixed with a pressurised carrier gas (e.g. compressed air) in the agglomeration chamber and/or the mixing chamber mentioned, e.g., can be admetered thereto via a metering means.
The mixing chamber and the agglomeration chamber may be connected together, e.g., via a metering opening. It is, however, also possible for the agglomeration chamber and the mixing chamber to overlap at least partially, or for the agglomeration chamber and the mixing chamber to be one and the same chamber. The mixing and/or agglomeration chamber may be arranged close in front of the dry-ice nozzle or in said nozzle.
The liquid carbon dioxide supplied to the agglomeration chamber may be relaxed in the agglomeration chamber and/or converted at least partially into carbon dioxide crystals, which are compressed and/or agglomerated.
The cleaning system may comprise at least one setting mechanism (e.g., a control and/or regulating mechanism) to set the quantity, pressure and/or temperature of the carrier gas for the carbon dioxide and/or of the carbon dioxide for producing the dry ice, as a result of which expediently the cleaning action can be influenced, e.g., before and/or during the cleaning operation. The setting can be controlled in a closed control loop.
For temperature control purpose, for example, a throughflow cooler may be inserted between the agglomeration chamber and the carbon dioxide supply to permit temperature control of the carbon dioxide. The temperature control of the cooler may be freely parametrisable, also via the robot control.
Furthermore, it is possible that a device which prevents gas bubbles of the liquid CO2 supply which may occur in the feed line, e.g., with a buffer bottle, is contained in the CO2 supply to thus obtain a stable cleaning result.
The cleaning system may furthermore comprise at least one checking unit for checking (e.g., monitoring, detecting, etc.) at least one parameter which allows a conclusion to be drawn about at least one of the following, e.g., which indirectly or directly describes one of the following: pressure, quantity and/or temperature of the carbon dioxide for producing the dry ice; pressure, quantity and/or temperature of the dry ice itself; pressure, quantity and/or temperature of the carrier gas; room temperature; cleaning distance between dry-ice nozzle and component to be cleaned; position of the component to be cleaned; orientation of the component to be cleaned; position of the dry-ice nozzle; orientation (e.g., cleaning angle) of the dry-ice nozzle; and/or temperature of the component to be cleaned. The checking unit may comprise, e.g., measurement and/or sensor means.
It is likewise possible to use an apparatus for increasing the carbon-dioxide pressure to then parameterise and vary it freely, corresponding to the cleaning process, via a checking unit.
It is possible that dependent on at least one of the above-mentioned monitored parameters by at least one setting mechanism (e.g. a control and/or regulating mechanism) at least one output variable of the cleaning system can be set and that the output variable is selected from at least one of the following: orientation (e.g., cleaning angle) of the dry-ice nozzle relative to the component to be cleaned; quantity, pressure and/or temperature of the carbon dioxide for producing the dry ice; quantity, pressure and/or temperature of the dry ice itself; quantity, pressure and/or temperature of the carrier gas; cleaning distance between dry-ice nozzle and component to be cleaned; cleaning duration; cleaning interval; positioning and/or movement parameters of the robot carrying the dry-ice nozzle; and/or positioning and/or movement parameters of the robot carrying the component to be cleaned.
The cleaning system is expediently designed to be explosion-protected, e.g., by means of earthed elements, explosion-protection compliant electrical elements, electrically conductive materials, etc. For this purpose, the legal bases for explosion protection of the countries, such as ATEX directive 94/9/EG for Europe, have to be complied with. Alternatively or additionally, the cleaning system may comprise a valve which for safety reasons preferably automatically closes or at least reduces an emission of carbon dioxide if a potential, e.g., imminent, excessive escape of carbon dioxide or one which has already taken place is ascertained by a detection mechanism (e.g., a sensor).
The cleaning system and e.g., the dry-ice nozzle may be configured such that it can clean the component to be cleaned by the dry ice in a substantially exposed manner, so that, e.g., cleaning receptacles which are conventional in the prior art and into which the atomisers to be cleaned have to be introduced are not necessary. However, embodiments with a cleaning receptacle into which the components to be cleaned can be guided to be cleaned by the dry ice in the cleaning receptacle are also covered by this disclosure. In the exposed cleaning variant, the cleaning system can comprise an air-stream generation means which generates a downwards air stream in order to guide cleaned-off dirt or emitted dry ice downwards, e.g., via a painting booth floor (e.g., a grating) out of a painting booth.
The setting of pressure and/or temperature of the carrier gas and/or of the carbon dioxide can take place preferably by a pressure regulator and/or a proportional valve, e.g., to influence the amounts consumed and/or the cleaning action. These may be arranged centrally or in decentralised manner, wherein carbon dioxide control valves are arranged in the vicinity of the dry-ice nozzles. The actuation may, however, take place centrally.
Further, the carrier gas may be pressurised (e.g. compressed air). The carrier gas serves, e.g., to accelerate the dry ice (e.g., in the form of the two-phase carbon dioxide mixture) preferably to supersonic speed.
The acceleration of the mixture of conveying air or another carrier gas and carbon dioxide to supersonic speed can take place for example by a nozzle formed in accordance with the Laval principle. Such Laval nozzle geometries are widely known in the prior art.
Furthermore, it should be mentioned that the carbon dioxide supplied to the agglomeration chamber is expediently in fluid form, e.g., liquid.
Further, the dry ice can be emitted from the dry-ice nozzle as a dry-ice jet.
The painting installation may be a painting installation for painting motor-vehicle bodies and/or their attachment parts (e.g. bumpers, buffer strips etc.).
The robots mentioned may be painting or handling robots. The robots, however, in the context of this disclosure comprise any, possibly multi-axis, movement automatons.
This disclosure furthermore covers a painting installation with a cleaning system as described here.
Furthermore, this disclosure covers a cleaning method, to be used in a painting installation, for cleaning at least one component of the painting installation, e.g., at least one component of a painting robot or a handling robot, wherein for cleaning dry ice is applied to the component to be cleaned. Further method steps according to this disclosure will become apparent from the above description of the cleaning system and the description of the figures which follows below.
The above features and embodiments according to this disclosure can be combined with each other. Other advantageous developments of this disclosure are disclosed in the sub claims or will become apparent from the description below of preferred examples of embodiment of this disclosure in conjunction with the appended figures. The figures are summarized as follows:
The embodiments shown in the figures partially correspond, with similar or identical parts being provided with the same reference signs, and for their explanation reference also being made to the description of one or more other embodiments, in order to avoid repetition.
The component B to be cleaned is borne and guided by a robot RB which is configured such that the robot RB positions the component B to be cleaned in front of the dry-ice nozzle 2 and during the cleaning operation moves, e.g., rotationally, transversely, or translationally moves, the component B relative to the dry-ice nozzle 2. The dry-ice nozzle 2 is arranged in the painting booth 100 in stationary manner. In the example illustrated, the robots RB may typically be painting robots and/or handling robots, and the component B may be the atomiser or handling tool thereof.
The cleaning system 1 comprises a supply device V for supplying the dry-ice nozzle 2 with the dry ice or generally carbon dioxide for producing the dry ice.
For example, the cleaning system 1 comprises a main supply line RL for connecting the supply device V to a plurality of dry-ice nozzles 2 via respectively one stub line SL which branches off from the ring line RL to the respective dry-ice nozzle 2.
The cleaning system 1 furthermore comprises a checking unit KE (e.g. camera sensor, temperature sensor, etc.), which is shown only diagrammatically in
The checking unit KE is shown separated from the dry-ice nozzle 2 and the robot RB in
It is advantageous that, dependent on the at least one parameter by means of at least one setting means ER (see
The cleaning system 1 is designed to be explosion-protected. The cleaning system 1 furthermore comprises a valve SV which for safety automatically closes or at least reduces an emission of carbon dioxide if a potential, e.g., imminent, excessive escape of carbon dioxide or one which has already taken place is ascertained by a detection mechanism (e.g. a sensor). By way of example, in
The robots RT are configured such that they position the dry-ice nozzles 2 in front of the component B to be cleaned, which here is depicted as a rotary atomiser, and during the cleaning operation move them relative to the component to be cleaned. The robot RT can rotate the dry-ice nozzles 2, e.g., at least partially about the component B to be cleaned, so that the entire outer periphery of the component B to be cleaned can be cleaned by only one dry-ice nozzle 2.
In
The dry-ice nozzles 2 may be mounted fixedly or exchangeably on the robots RT. In the latter variant, it is possible for the dry-ice nozzles 2 to be put down automatically after a cleaning operation and to be picked up before a cleaning operation. The robots RT carrying the dry-ice nozzles 2 can be configured accordingly for this purpose.
The dry-ice nozzles 2 comprise a protective element S shown schematically in
The cleaning system 1 shown in
Although the cleaning angle of the upper dry-ice nozzle 2 which is shown in
It should be mentioned that in the context of this disclosure it is also possible for both a dry-ice nozzle 2 to be carried and guided by a robot RT and for the component B to be cleaned to be carried and guided by a robot RB, and for them to be moved relative to each other during the cleaning process. The movements in such case can be selected at will. For example, the component B to be cleaned can be, e.g., rotated and moved translationally relative to the dry-ice nozzle 2. Likewise, it is possible for the dry-ice nozzle 2, e.g., at least in portions, to be rotated about the component B to be cleaned, and simultaneously or in succession for the dry-ice nozzle 2 to be moved along the component to be cleaned (e.g., from the bell cup to the electrode ring). The movements of the dry-ice nozzle 2 and of the component B to be cleaned may take place simultaneously or in succession.
It should furthermore be mentioned that the dry-ice nozzles 2 shown in
The dry-ice nozzle 2 comprises an agglomeration chamber AK to which fluid carbon dioxide (CO2) can be supplied and in which a two-phase carbon dioxide mixture which comprises carbon dioxide gas and carbon dioxide particles can be formed by agglomeration of carbon dioxide snow crystals. The liquid carbon dioxide supplied to the agglomeration chamber AK is relaxed in the agglomeration chamber AK, and carbon dioxide crystals are produced which are compressed and agglomerated.
The carbon dioxide mixture is mixed with a pressurised carrier gas TG (e.g., compressed air) in the agglomeration chamber AK, preferably in order to accelerate it. In one embodiment of the invention, not shown, it is possible for the agglomeration chamber AK to be connected, e.g., via a metering opening, to a mixing device in the form of a mixing chamber, and for the carbon dioxide mixture to be mixed with the pressurised carrier gas TG in the mixing chamber. In the embodiment shown in
It can be seen from
The dry-ice nozzle 2 is adjustable in its nozzle contour (e.g., the jet divergence angle can be changed, which is indicated by the arrow P3). Alternatively or additionally, the dry-ice nozzle 2 may comprise an adjustment function to be able to change its orientation, e.g., the cleaning angle. These features make possible adaptation to different outer contours of the component B to be cleaned or generally make the cleaning operation able to be set according to requirements.
The cleaning system 1 may furthermore have a carrier-gas heater TE indicated schematically in
The cleaning system 1 in the context of this disclosure may comprise a plurality of dry-ice nozzles 2, which are fixedly arranged or can be arranged such that they can preferably cover the entire outer periphery of the component B to be cleaned and/or that they can correspond to the outer contour of the component B to be cleaned.
In an embodiment, not shown, one robot carries both an atomiser and a dry-ice nozzle, which is attached to and arranged on the robot such that the function of the atomiser is not impaired by the dry-ice nozzle. For this purpose, the dry-ice nozzle may be shielded from the atomiser, e.g., by a covering.
The invention is not limited to the preferred embodiments described above. Rather, a large number of variants and modifications, which likewise make use of the inventive concept and therefore fall within the scope of protection, is possible. Protection is claimed for the subject-matter and the features of the individual dependent claims independently of the subject-matter and the features of the claims referred to.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2012 006 567.1 | Mar 2012 | DE | national |
This application claims priority to PCT International Application No. PCT/EP2013/000955, filed Mar. 28, 2013, which is in turn based upon and claims benefit of priority from German Patent Application No. DE 10 2012 006 567.1, filed Mar. 30, 2012, the entire contents of which prior applications are incorporated herein by reference.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2013/000955 | 3/28/2013 | WO | 00 |
