Patent Grant
8997374
This application is a National Phase entry of International Application PCT/JP2011/061911, filed May 24, 2011, which claims priority to Japanese Patent Application No. 2010-120620, filed May 26, 2010, the disclosure of the prior applications are hereby incorporated in their entirety by reference.
The present invention relates to a drying technique for drying an object by hot air.
As an example of a drying furnace, there is a hot air circulation drying furnace. In this drying furnace, an object is dried by hot air which is circulating. The object is often a combination of a plurality of members and includes thick portions and thin portions. The thick portions have a large heat capacity and thus are regions (hereinafter, referred to as “hard-heating regions”) which are difficult to be warm. On the contrary, the thin portions have a small heat capacity and thus are regions (hereinafter, referred to as “easy-heating regions”) which are easy to be warm. When the object is dried by the hot air circulation drying furnace, a drying operation is continuously carried out until the hard-heating regions are completely dried, despite the fact that the easy-heating regions have been completely dried. Consequently, drying time becomes longer. For this reason, a technology to improve a speed of temperature rising of the hard-heating regions is demanded.
Conventionally, as a technology to improve the speed of temperature rising of the hard-heating regions of the object, drying techniques for locally heating the object have been variously suggested, in addition to a heating by hot air (see Patent Document 1 (
Patent Document 1 is described with reference to
As shown in
A blower is connected to the hot air outlets 116, 117. A heating device is connected to a discharge side of the blower and the hot air inlets 105, 106 are connected to the heating device. In addition, a pair of left and right heaters 118, 119 is disposed near the bottom of the object 101. These heaters 118, 119 are connected to the blower and the heating device.
In the drying furnace 100, the hot air ejected from the hot air ejecting ports 109, 111 is brought into contact with the object 101 and thus the object 101 is dried. The hot air flows out of the furnace body 102 through the hot air suction ports 114, 115 from the interior of the furnace body 102. The hot air is heated and ejected again from the hot air ejecting ports 109, 111 through the hot air inlets 105, 106. That is, the object 101 is dried by the hot air which is circulating.
Further, if a bottom 121 of the object 101 is thick, the bottom 121 has a large heat capacity and thus is the hard-heating region. Ejection nozzles 122 of the heaters 118, 119 eject the hot air toward the bottom 121 of the object 101. As the hot air is ejected in this way, it is possible to improve the temperature rising speed for the bottom 121 of the object 101.
However, since the hot air ejected from the ejection nozzles 122 of the heaters 118, 119 is spread around the bottom 121 of the object 101 in the drying furnace 100, it is difficult to give a target amount of heat to target regions. If a drying time becomes longer as a measure, the temperature of the bottom 121 which is the hard-heating region is increased, but the easy-heating region of the object 101 is subjected to excessive heat, despite the fact that the temperature of the easy-heating region is already increased. This is undesirable from the viewpoint of energy saving.
Embodiments of the present invention provide a drying technique capable of reducing unnecessary amount of heat which was given to easy-heating regions of an object.
According to embodiments of the present invention, a drying furnace 20 for drying an object 11 by hot air may include a heater 36, 38, 43, 45 that applies radiant heat to a hard-heating region 35, 42 having a larger heat capacity than the other region 37, 44 in the object 11 so as to heat the hard-heating region 35, 42 to a temperature approximate to a temperature of the other region 37, 44.
In addition, according to embodiments of the present invention, a drying method for drying an object 11 by hot air using a drying furnace 20 may include: a temperature increasing process of increasing a temperature of the object 11; a temperature measuring process of measuring a temperature of a hard-heating region 35, 42 having a larger heat capacity than the other region 37, 44 in the object 11 by a first temperature measuring part 73, 77 and measuring a temperature of the other region 37, 44 by a second temperature measuring part 75, 79; a local heating process of locally heating the hard-heating region 35, 42 to a temperature approximate to the temperature of the other region 37, 44 by applying radiant heat to the hard-heating region 35, 42 of the object 11; and a temperature maintaining process of constantly maintaining the temperature of the object 11.
Other aspects and advantages will be apparent from the following description and the appended claims.
a) to 1(d) are views for explaining a drying mechanism which dries paint on a surface of an object, according to an exemplary embodiment.
a) and 2(b) are graphs for explaining a local heating start time in a comparative example and an example.
a) and 3(b) are graphs for explaining a temperature rising speed in the comparative example and the example.
a) to 9(c) are views for explaining an operation of a temperature measuring part and a heater.
According to embodiments of the present invention, a drying furnace includes a heater which applies radiant heat to a hard-heating region of an object that has a larger heat capacity than the other regions and thus heats the hard-heating region to a temperature approximate to that of the other regions. Here, the other regions may be easy-heating regions. The drying furnace is configured so that the hard-heating region of the object is locally heated by the heater in a state where the object is entirely heated by the hot air. Since the radiant heat applied by the heater is absorbed by the object in the form of electromagnetic waves, the hard-heating region of the object can be reliably heated. With such a heating, a temperature of the hard-heating region of the object is increased and therefore it is possible to reliably heat the hard-heating region of the object to a temperature approximate to that of the easy-heating regions thereof.
According to a case in which the hard-heating region of the object is locally heated by the hot air ejected from an ejection nozzle in a state where the object is entirely heated by the hot air, the ejected hot air is spread around the hard-heating region. With such a spread of the hot air, it is difficult to allow the hot air to evenly reach the hard-heating region of the object and therefore it is difficult to increase the temperature of the hard-heating region. Heating may be continuously performed in order to increase the temperature of the hard-heating region. However, in this case, the easy-heating regions which have been already heated are subjected to excessive heat.
In contrast, according to the embodiments of the invention, the drying furnace can reliably heat the hard-heating region of the object to a temperature approximate to that of the easy-heating regions thereof by applying the radiant heat to the hard-heating regions. That is, since the temperature of the hard-heating region and the easy-heating regions of the object can be substantially equally increased, there is no case that the easy-heating regions are subjected to the excessive heat. Accordingly, it is possible to provide a drying furnace capable of reducing unnecessary amount of heat which was given to the easy-heating regions of the object.
The heater may be a near-infrared lamp. As an infrared ray, a near-infrared ray and a far-infrared ray whose wavelength is longer than the near-infrared ray are known. Further, it is known that absorption rate (energy absorption rate) is different, depending on the type of target to be irradiated. If the object is a vehicle body, the object is defined by an iron-based material constituting the vehicle body and a coating film which is formed by applying paint such as acrylic water-based paint to the vehicle body. The following Table 1 shows the absorption rate of the iron and the acrylic water-based paint.
When it is intended to mainly heat the coating film, the far-infrared ray having absorption rate of approximately 74% relative to the acrylic water-based paint would be suitable. However, the far-infrared ray does not give an effect to the coating film which is applied to an inner surface of the vehicle body. For this reason, in embodiments of the invention, the near-infrared ray having absorption rate of approximately 35% relative to iron is used to mainly heat the iron, that is, the vehicle body, and the coating film on the inner surface is dried by the heat from the vehicle body. By using the near-infrared ray, even the temperature of the regions of the object which are not directly irradiated by the near-infrared ray can be increased using the heat conduction of the member without time-consumption.
The drying furnace may include a first temperature measuring part for measuring the temperature of the hard-heating region and a second temperature measuring part for measuring the temperature of the other regions, on an upstream side of the heater. Further, the drying furnace may include a control part for controlling a power of the heater based on temperature information from the first temperature measuring part and the second temperature measuring part. When the temperature of the hard-heating region measured by the first temperature measuring part is largely different from the temperature of the other regions measured by the second temperature measuring part, a high-power command is sent to the heater from the control part. On the contrary, when the temperature of the hard-heating region measured by the first temperature measuring part is only slightly different from the temperature of the other regions measured by the second temperature measuring part, a low-power command is sent to the heater from the control part. By comparing the temperature of the hard-heating region of the object with the temperature of the other regions in this way, the control part controls the heater to output a suitable amount of heat in accordance with the temperature difference. Accordingly, the heater can apply the suitable amount of heat to the hard-heating regions of the object.
Further, according to embodiments of the present invention, a drying method is carried out using a drying furnace which dries an object by hot air. The drying method may include a temperature increasing process of increasing a temperature of the object, a temperature measuring process of measuring a temperature of a hard-heating region of the object which have a larger heat capacity than the other regions by a first temperature measuring part and measuring a temperature of the other regions by a second temperature measuring part, a local heating process of locally heating the hard-heating region to a temperature approximate to that of the other regions by applying radiant heat to the hard-heating region of the object and a temperature maintaining process of constantly maintaining the temperature of the object. Here, the other regions may be easy-heating regions.
Since the radiant heat used in the local heating step is absorbed by the object in the form of electromagnetic waves, the hard-heating region of the object can be reliably heated. With such a heating, the temperature of the hard-heating region of the object is increased and therefore it is possible to reliably heat the hard-heating region of the object to a temperature approximate to that of the easy-heating regions thereof.
In a case where the hard-heating region of the object is locally heated by the hot air ejected from the ejection nozzle in a state where the object is entirely heated by the hot air, the ejected hot air is spread around the hard-heating region. With such a spread of the hot air, it is difficult to allow the hot air to evenly reach the hard-heating region of the object and therefore it is difficult to increase the temperature of the hard-heating region. Heating may be continuously performed in order to increase the temperature of the hard-heating region. As a result, the easy-heating regions which have been already heated are subjected to excessive heat.
In contrast, according to embodiments of the invention, the drying method can reliably heat the hard-heating region of the object to a temperature approximate to that of the easy-heating regions thereof by applying the radiant heat to the hard-heating region in the local heating step. That is, since the temperature of the hard-heating region and the easy-heating regions of the object can be substantially equally increased, there is no case that the easy-heating regions are subjected to the excessive heat. Accordingly, it is possible to provide a drying method capable of reducing unnecessary amount of heat which was given to the easy-heating regions of the object.
The object may be subjected to a painting operation before being introduced into the drying furnace. Further, a timing for applying the radiant heat to the hard-heating regions of the object in the local heating step may be the timing when the temperature of the hard-heating region measured by the first temperature measuring part reaches a cross-linking temperature of the paint applied onto the object. Hereinafter, a drying mechanism for drying the paint on a surface of the object is described.
When atomized paint is sprayed onto the object, paint particles are directed to a surface of the object. At this time, a surface temperature of the object is at room temperature.
As the paint particles collide with the surface of the object, the paint adhered to the surface of the object is caused to be swollen. Simultaneously, volatile components of the paint are evaporated and therefore the paint is hardened in a state of being swollen.
Next, as the painted object is put into the drying furnace, the paint which has been hardened on the surface of the object is heated by hot air. The heated paint is fluidized. Further, surface tension and gravity act on the paint in an amplitude direction of the swelling. And then, a smooth coating film is formed.
At timing when the temperature of the object is further increased and thus the surface temperature thereof reaches the cross-linking temperature of the paint, the radiant heat is applied to the surface of the object. Since the cross-linking has been already started at this timing, the paint does not flow and thus the smooth coating film formed as mentioned above can be maintained. Consequently, it is possible to realize the smooth coating film.
In a case the painted object is put into the drying furnace and the radiant heat is applied to the hard-heating region of the object at a start of the hot air drying, the paint applied on the object is fluidized. However, since the object is locally heated by the radiant heat and thus a temperature rising speed of the object becomes larger, the paint in an insufficient flowing state becomes hot and thus the paint is hardened. Accordingly, the coating film is difficult to be smooth and thus the quality of the coating film is degraded.
In contrast, according to embodiments of the invention, the drying method applies the radiant heat to the hard-heating regions of the object at timing when the temperature of the hard-heating regions of the object reaches the cross-linking temperature of the paint applied onto the object. That is, the hard-heating region of the object is subjected to the local heating by the radiant heat when a predetermined time has elapsed from the start of the hot air drying. During the start of the hot air drying to the start of the local heating, the paint applied onto the hard-heating regions is fluidized. At the start of the hot air drying, the temperature rising speed of the object is small. Therefore, after the paint is sufficiently flowing, the paint becomes hot and then is hardened. As a result, the smooth coating film can be achieved and thus the quality of the coating film is improved.
Heat source of the radiant heat may be a near-infrared ray. In this case, as shown in the above-described Table 1, the near-infrared ray having absorption rate of approximately 35% relative to iron is used to mainly heat the iron, that is, the vehicle body and the coating film on the inner surface is dried by the heat from the vehicle body. As a result, by using the near-infrared ray, even the temperature of the region of the object which is not directly irradiated by the near-infrared ray can be increased using the heat conduction of the member without time-consumption.
Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. The drawings are viewed in directions of symbols. In the present embodiment, an object to be dried is a vehicle body. A side sill is represented as an example of the hard-heating region which has a larger heat capacity than the other regions and a door outer panel is represented as an example of the other region. Further, in the present embodiment, the vehicle body put into the drying furnace has been subjected to a painting operation by painting equipment which is provided at an upstream side of the drying furnace.
As shown in
As the paint particles 12 collide with the surface 13 of the vehicle body 11, the paint 14 adhered to the surface 13 of the vehicle body 11 is caused to be swollen, as shown in
Next, as the painted vehicle body 11 is put into a drying furnace (which will be described in detail below), the paint 14 which has been hardened on the surface 13 of the vehicle body 11 is heated by hot air. The heated paint 14 is fluidized. Further, surface tension and gravity act on the paint 14 in an amplitude direction of the swelling. And then, a smooth coating film 15 is formed, as shown in
At a time when the temperature of the vehicle body 11 is further increased and thus the surface temperature of the vehicle body 11 reaches a cross-linking temperature of the paint, radiant heat emitted from a heater (which will be described in detail below) is applied to the surface 13 of the vehicle body 11. Since the cross-linking has been already started at this timing, the paint does not flow and thus the smooth coating film 15 formed in
Next, the timing of the start of local heating will be described.
If the local heating for the side sill of the vehicle body is started at the start of the hot air drying, the paint applied on the side sill is fluidized. However, since the temperature rising speed of the vehicle body is increased by the local heating, the paint in an insufficient flowing state becomes hot and thus the paint is hardened. Accordingly, the coating film is difficult to be smooth and thus the quality of the coating film is degraded.
As shown in
The side sill of the vehicle body is subjected to the local heating when a predetermined time T has elapsed from the start of the hot air drying. During the start of the hot air drying to the start of the local heating, the paint applied onto the side sill is fluidized. At the start of the hot air drying, the temperature rising speed of the vehicle body is small. Therefore, after the paint is sufficiently flowing, the paint becomes hot and then is hardened. As a result, the smooth coating film can be achieved and thus the quality of the coating film is improved.
Next, relationship between the local heating and the drying time is described.
Meanwhile, in a state where the painted vehicle body is dried by the hot air in the drying furnace, the side sill of the vehicle body is subjected to the local heating by the radiant heat emitted from the heater for a certain period of time Ta (=one minute) when twenty minutes have elapses from the start of the hot air drying, as shown in
Since the temperature rising speed of the side sill is increased by the local heating, the temperature rise curve of the side sill is approximated to the temperature rise curve of a door outer panel (which will be described in detail below) of the vehicle body. As a result, it takes a total of thirty-two minutes, for example, until the target surface temperature (160□) of the side sill is maintained for a target time Th (=eleven minutes). As is apparent from comparison between
As shown in
The drying furnace 20 includes a first hot air heating part 23 arranged on an upstream side and a second hot air heating part 24 arranged on a downstream side. The first hot air heating part 23 corresponds to a temperature rising part to increase the temperature of the vehicle body 11. Further, the second hot air heating part 24 corresponds to a temperature maintaining part to maintain the increased temperature of the vehicle body 11.
In addition, a local heating part (25; which will be described in detail below) is provided at a termination of the first hot air heating part 23. Next, a configuration of the local heating part 25 is described.
As shown in
As shown in
The left inner heater 36, the left outer heater 38, the right inner heater 43 and the right outer heater 45 are respectively a near-infrared lamp. The left inner heater 36 is provided with a left inner side reflection plate 47 to surround a left inner side filament 46. Since light generated from the left inner side filament 46 is concentrated on the left inner side reflection plate 47, it is possible to emit directional heat ray to the vehicle body 11. Similarly to the left inner heater 36, the left outer heater 38, the right inner heater 43 and the right outer heater 45 are respectively with a reflection plate to surround a filament.
Further, since specific heat capacity of the near-infrared lamp is smaller compared to a far-infrared lamp, the near-infrared lamp has a faster response speed. If the response speed is faster, a rapid power control for a command from the control part becomes possible. Since a stand-by time to the heating can be shortened, this contributes to the shortening of the drying time.
In addition, the drying furnace 20 is provided with a control part 48. The control part 48 controls the left inner heater 36, the left outer heater 38, the right inner heater 43 and the right outer heater 45. The control part 48 sends a power command to the near-infrared lamp based on the temperature information from the upstream temperature measuring part (reference numeral 27 in
As shown in
The first left upstream temperature measuring part 73, the second left upstream temperature measuring part 75, the first right upstream temperature measuring part 77 and the second right upstream temperature measuring part 79 are respectively a non-contact sensor. These sensors detect thermal radiation which is emitted from the vehicle body 11 heated by the hot air and calculate the temperature of the side sill and the outer door panel of the vehicle body 11.
In addition, the first left upstream temperature measuring part 73, the second left upstream temperature measuring part 75, the first right upstream temperature measuring part 77 and the second right upstream temperature measuring part 79 are connected to the control part 48. The control part 48 sends a power command to the left inner heater (reference numeral 36 in
In the upstream temperature measuring part 27, when the temperature of the left side sill 35 measured by the first left upstream temperature measuring part 73 is largely different from the temperature of the left door outer panel 37 measured by the second left upstream temperature measuring part 75, a high-power command is sent to the left inner heater (reference numeral 36 in
By comparing the temperature of the side sill of the vehicle body with the temperature of the door outer panel in this way, the control part 48 controls the left inner heater and the left outer heater to output a suitable amount of heat in accordance with the temperature difference. Accordingly, the left inner heater and the left outer heater can apply the suitable amount of heat to the side sill.
Further, the control part 48 sends a power command to the right inner heater (reference numeral 43 in
As shown in
The first left downstream temperature measuring part 83, the second left downstream temperature measuring part 84, the first right downstream temperature measuring part 86 and the second right downstream temperature measuring part 87 are respectively a non-contact sensor. These sensors detect thermal radiation which is emitted from the vehicle body 11 heated by the hot air and calculate the temperature of the side sill and the outer door panel of the vehicle body 11.
The first left downstream temperature measuring part 83, the second left downstream temperature measuring part 84, the first right downstream temperature measuring part 86 and the second right downstream temperature measuring part 87 are connected to the control part 48. The control part 48 sends a power command to the left inner heater (reference numeral 36 in
Further, the control part 48 sends a power command to the right inner heater (reference numeral 43 in
Next, an operation of the above-described drying furnace is described.
As shown in
Measurement results are assumed that the temperature of the left side sill 35 is lower than the temperature of the left door outer panel 37 and the temperature of the right side sill 42 is lower than the temperature of the right door outer panel 44.
As shown in
In the drying furnace (reference numeral 20 in
As shown in
In
In this regard, the drying furnace (reference numeral 20 in
In the above-described embodiment, the near-infrared ray is used to locally heat the vehicle body 11. As shown in the above-described Table 1, the far-infrared ray has the absorption rate of approximately 74% relative to the acrylic water-based paint but does not give an effect to the coating film which is applied to an inner surface of the vehicle body. On the contrary, the near-infrared ray has the absorption rate of approximately 35% relative to iron. Since the above-described embodiment uses the near-infrared ray as heat source of the local heating, the iron, that is, the vehicle body is mainly heated and the coating film on the inner surface is dried by the heat from the vehicle body.
Specifically, the near-infrared ray is irradiated on an outer coating film 91 of the left side sill 35, as shown in
Next, the drying method using the drying furnace is described.
As shown in
In ST02, the temperature of the hard-heating region of the object which has a larger heat capacity than the other regions is measured by a first temperature measuring part and the temperature of the other regions is measure by a second temperature measuring part. Specifically, in the upstream temperature measuring part 27, the temperature of the left side sill 35 is measured by the first left upstream temperature measuring part 73, the temperature of the left door outer panel 37 is measured by the second left upstream temperature measuring part 75, the temperature of the right side sill 42 is measured by the first right upstream temperature measuring part 77, and the temperature of the right door outer panel 44 is measured by the second right upstream temperature measuring part 79, as shown in
In ST03, the radiant heat is applied to the hard-heating region of the object and thus the hard-heating region is heated to a temperature approximate to that of the other region. Specifically, the left inner heater 36, the left outer heater 38, the right inner heater 43 and the right outer heater 45 intensively irradiate the left side sill 35 and the right side sill 42 with the near-infrared ray, as shown in
In ST04, the temperature of the object is constantly maintained. Specifically, the increased temperature of the vehicle body 11 is maintained by the second hot air heating part 24, as shown in
The drying method is carried out using the drying furnace 20 which dries the vehicle body 11 by the hot air. Further, the drying method includes a temperature increasing process for increasing the temperature of the vehicle body 11, a temperature measuring process for measuring the temperature of the left side sill 35 by the first left upstream temperature measuring part 73 and measuring the temperature of the left door outer panel 37 by the second left upstream temperature measuring part 75 (see
In
In
In this regard, the drying method of the present invention can reliably heat the left side sill 35 to a temperature approximate to that of the left door outer panel 37 by applying the radiant heat to the left side sill 35 in the local heating process. That is, since the temperature of the side sill and the temperature of the door outer panel can be substantially equally increased, there is no case that the door outer panel is subjected to the excessive heat. Accordingly, it is possible to provide the drying method capable of reducing unnecessary amount of heat which was given to the door outer panel.
In addition, the vehicle body 11 is subjected to a painting operation before being introduced into the drying furnace (reference numeral 20 in
If the painted vehicle body is put into the drying furnace and then the radiant heat is applied to the side sill of the vehicle body at the start of the hot air drying (see
In this regard, the drying method according to the above-described embodiment applies the radiant heat to the side sill at timing when the temperature of the side sill of the vehicle body reaches the cross-linking temperature of the paint applied onto the side sill, as shown in
Further, since the above-described embodiment uses the near-infrared ray as heat source of the radiant heat, the iron, that is, the vehicle body is mainly heated and the coating film on the inner surface can be dried by the heat from the vehicle body.
Meanwhile, although the painted vehicle body has been represented as an example of the object in the above-described embodiment, the present invention may be applied to machines or structures which have been subjected to a painting operation.
Further, although the side sill of the vehicle body has been represented as an example of “the hard-heating region which has a larger heat capacity than the other regions” in the above-described embodiment, “the hard-heating region which has a larger heat capacity than the other regions” may be other thick portion of the vehicle body.
Further, although the door outer panel has been represented as an example of “the other regions” in the above-described embodiment, “the other regions” may be other thin portion of the vehicle body such as a hood outer panel or a lid outer panel.
11 . . . object (vehicle body), 20 . . . drying furnace, 35 . . . hard-heating region (left side sill), 36 . . . heater (left inner heater), 37 . . . the other region (left door outer panel), 38 . . . heater (left outer heater), 42 . . . hard-heating region (right side sill), 43 . . . heater (right inner heater), 44 . . . the other region (right door outer panel), 45 . . . heater (right outer heater), 48 . . . control part, 73 . . . first temperature measuring part (first left upstream temperature measuring part), 75 . . . second temperature measuring part (second left upstream temperature measuring part), 77 . . . first temperature measuring part (first right upstream temperature measuring part), 79 . . . second temperature measuring part (second right upstream temperature measuring part)
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