At present, paint and other coatings are baked or cured in a radiant oven, wherein the walls and/or floor are heated by combustion burners. In a typical automotive application, the painted vehicle body is conveyed through the radiant oven and the opposed side walls and generally the floor of the oven are heated by combustion burners which direct hot air into rectangular enclosures defining the side and bottom walls of the oven. This method of heating requires flame sensors to avoid a potential explosion in the event that a burner fails and combustible gas is directed into the enclosures which automatically turn off the flow of combustible gas to the burners and thus the enclosures, shutting down the oven. The enclosures must then be purged of combustible gas before restarting the burners and restarting the oven. As a safety feature, if any of the flame sensors fail, the burners are automatically shut down for maintenance.
As will be understood by those skilled in this art, restarting a paint oven after shut down because of a failure of either a burner or a flame sensor requires time and thus considerable expense, but safety precautions must be maintained to avoid a hazardous condition. Radiant tube heaters have previously been used in automotive paint ovens, but only for supplemental heating of the rocker panels. It has now been proposed by General Motors Corporation to utilize radiant tube heaters that are pulse-fired to provide uniform surface temperature on the radiant tubes and the burners may be mounted external to the oven burner enclosures, thus allowing the use of radiant tube heaters throughout the entire length of the oven. This method of heating a paint oven has several important advantages over the prior art. First, the potential for explosion is substantially eliminated because the radiant tube heaters may be formed of a schedule 40 pipe having a diameter of about six inches and a wall thickness of 0.280 inches, which are not subject to explosion even if the burners fail. The timing of the pulse-fire may be controlled by the surface temperature of the radiant tubes and a continuous spark may be utilized to ignite the combustible gas and air mixture, wherein combustible gas and air are mixed with a small portion of excess air and the mixture is at or near stoichiometric conditions. Further, a conventional paint oven has two sections, including a bring-up section and a hold section, wherein the temperature of the oven is brought to the paint curing temperature in the bring-up section and the curing temperature is maintained in the hold section as the painted substrate is moved through the oven. In a conventional paint oven, each section or zone uses a gas-fired heater to heat the zone as described above.
Although the described radiant tube oven provides important advantages over the prior art, further improvements are required to fully implement this invention, including improved control of the temperature of the painted substrate, such as an automotive body, to avoid overheating of areas adjacent the radiant tubes and to provide uniform heating of the substrate and improve efficiency, including conservation of energy. These advantages are provided by the radiant tube heat oven of this invention as described below.
The disclosed embodiment of the radiant tube and convection oven of this invention includes three distinct heat zones, comprising (1) a radiant bring-up zone, (2) a convection bring-up zone; and (3) a hold zone which more efficiently combines the advantages of radiant tube heating and convection heating to uniformly heat a painted or coated substrate without overheating areas and conserving energy. The radiant bring-up zone utilizes radiant tubes or tubular radiators along with a small amount of convection air directed at the underside of the substrate, such as the sill area of a painted vehicle body and is thus referred to as the “sill duct.” The convection bring-up zone directs heated air onto a vehicle body from three groups of nozzles, including one set of large nozzles which direct heated air into the interior of the body through the window openings, one set of smaller nozzles which direct heated air at the sides of the vehicle body and one set of smaller nozzles which direct heated air at the underside of the vehicle. The convection zone may be equipped with tubular radiators for additional heating. The hold zone utilizes tubular radiators along with a small amount of convective air, such as air directed at the sill area at the underside of the body. The three zones are described in more detail hereinbelow.
In one preferred embodiment, the radiant tube or pipe is positioned along one side wall of the oven adjacent to but spaced from the side wall and the radiant tube is then turned or bent 180° at the end of the radiant tube with an additional length of tube or pass running parallel to the direction of the conveyor travel, preferably beneath the substrate, such as a vehicle body. Utilization of this second run of pipe allows greater efficiency and utilization of the heat value of the fuel burned and improved distribution of the heat. The second length of radiant tube is preferably located near the floor of the oven and below the level of the conveyor. This allows for transfer of heat energy to the thicker metal parts of a vehicle body on the underside of the vehicle. The second length of radiant tube may have the same diameter as the first length of tube, but may also have a larger diameter to reduce pressure loss and increase heat transfer. However, a smaller diameter for the second length of tube may be advantageous in fitting under a vehicle body, if space is limited.
The radiant tube and convection oven of this invention also contemplates the use of the products of combustion moving through the radiant tube to improve the overall thermal efficiency of the oven by directing the hot gases from the radiant tube into a secondary heat recovery system which may be utilized, for example, to heat the fresh air prior to circulation through the oven by a secondary heat recovery system that transfers heat from the hot gases exiting the radiant pipes. The three zones of the radiant tube paint oven of this invention will now be described in more detail.
In a preferred embodiment of the radiant tube and convection oven of this invention, the zones of the oven are collinear or axially aligned with the conveyor, such that the painted or coated substrate, such as a painted automotive body, is conveyed through all three sections or zones of the oven and the radiant tube heaters extend through all three zones.
In the radiant bring-up section or zone, radiant tubes extend through the radiant bring-up zone preferably adjacent an intersection between the side wall and the bottom wall of the oven having a generally horizontal metal shield located above the radiant tube heaters to prevent overheating of the light metal parts of the vehicle body located above the radiant tubes. In a more preferred embodiment, the radiant bring-up zone also includes sill ducts located below the vehicle body in the vicinity of the door sills which may include a series or nozzles or holes directing air at the underside of the vehicle. The radiant tube heaters preferably receive pulse-fired gas burners which are heated to a surface temperature of between 400° F. and 1000° F. by the pulse-fired gas burners and the radiant tube heaters preferably have a wall thickness to prevent explosion.
In a preferred embodiment of the radiant tube and convection oven of this invention, the radiant tubes extend through the oven adjacent the outer lower corner of the oven wall and are then turned or bent 180 degrees and directed back through the oven in a second pass preferably located beneath the painted or coated substrate as described above. In the convective bring-up section or zone of the radiant tube and convection oven of this invention, a plurality of groups or sets of nozzles direct heated air into and onto the painted or coated substrate as the substrate is conveyed through the oven. All of the nozzles may be provided with swivel mountings to allow the nozzles to be aimed at specific areas or parts of the substrate and the nozzles may be bolted in place with spare mounting locations to provide further nozzles to be mounted from place to place. In a preferred embodiment, the convective bring-up zone includes outer chambers preferably located on the outer walls adjacent the upper portion of the convective bring-up zone receiving heated air and the nozzles direct the heated air into and onto the painted or coated substrate from the chambers through interior nozzles and side nozzles, preferably including three sets of nozzles. In a disclosed embodiment, the side walls of the interior chambers are angled at an acute angle relative to the side walls of the oven and the nozzles are mounted on the inclined side walls of the chambers. In a preferred embodiment, the air from the oven is circulated by a fan into the side chambers. Alternatively, the heated air may be directed to the enclosed heat chambers from a conventional burner located outside the convective bring-up zone.
The hold zone may be similar to the radiant bring-up zone, except that the volume of heated air delivered to the sill ducts is lower and a substantially constant temperature is maintained in the radiant tube and convection oven of this invention by a proportional integral derivative control system which includes a plurality of spaced temperature probes in direct contact with the exterior of the radiant heat tubes as described further below.
As will be understood, various modifications may be made to the radiant tube and convection oven of this invention within the purview of the appended claims and the following description of the preferred embodiments is for illustrative purposes only.
The radiant tube and convection oven 20 of this invention may be utilized to cure or bake paint or other coatings on various substrates, such as the automotive body 22, which are conveyed through the oven on a conveyor 24 generally through the longitudinal axis of the oven 20. The radiant tube and convection oven of this invention includes three zones, including a radiant bring-up zone, a convection or convective bring-zone and a hold zone. In a preferred embodiment, the three zones are coaxially or linearly aligned, such that the outer wall 26 of the oven 20 encloses all three zones and the conveyor 24 conveys the automotive body 22 through all three zones of the oven 20. As will be understood by those skilled in this art, however, the radiant tube and convection oven of this invention may include more than three zones, but preferably includes at least three zones.
The radiant tubes 28 are preferably heated to a surface temperature of between 400° F. and 1000° F. by pulse-fired gas burners, as described above. The radiant tube heaters 28 are preferably formed of steel and are substantially explosion proof. A suitable radiant tube may be formed of schedule 40 pipe having a diameter of about six inches and a wall thickness of about 0.280 inches.
In a preferred embodiment of the radiant tube and convection oven of this invention, the radiant tubes or radiant tube heaters 28 and radiant shields 34 are used in combination with sill ducts 36 which are preferably located beneath the vehicle body 22 adjacent the sill area of the vehicle under each side of the vehicle body 22. As will be understood by those skilled in this art, sill ducts 36 typically include a series of holes or nozzles 37 directing heated air onto the sill area of the vehicle body and may include one or a plurality of aligned holes or nozzles spaced six to twelve inches apart each having an opening between 0.5 and 1.5 inches, preferably about 0.75 inches, located between six and twelve inches from the sill area of the vehicle body, preferably about nine inches, directing heated air to the sill area of the body as shown by arrows 38. The holes or nozzles in the sill ducts 36 preferably deliver air at a volumetric rate of between 25 and 100 cubic feet per minute or preferably about 50 cfm per foot of oven length. In a preferred embodiment, the radiant tubes 28 and the sill ducts 36 extend the interior length of the oven 20, that is extending through all three zones.
The embodiment of the second zone of the radiant tube and convection oven shown in
Heated air is directed from the chambers 48 and 50 to the substrate 22 by two groups of nozzles 64 and 66. The upper nozzles 64 direct heated air into the interior of the vehicle body 22 through the window areas and the lower nozzles 66 direct heated air against the lower quarter panels of the vehicle body 22. In the disclosed embodiment, the body portion of the nozzles 64 and 66 within the chambers 48 and 50 is tubular having an open end and the nozzles include a generally bell-shaped swivel nozzle portion 68, such that the heated air from the chambers 48 and 50 may be directed as desired for the application. The combined airflow from all the nozzles provide a volumetric airflow of between 250 and 1000 cfm per foot of oven, preferably about 500 cfm per foot of oven and the flow range results in four to six air changes per minute. The temperature of the delivered air is within ±50° F., preferably ±20° F. of the target metal temperature of the substrate, which in the disclosed embodiment is a vehicle body 22. The upper nozzles 64 which direct heated air into the interior of the vehicle body 22 preferably have a larger diameter (not shown) than the lower nozzles 66 to project heated air into the corners of the vehicle body and may have an opening diameter between four and twelve inches, preferably about six inches in diameter. The lower nozzles 66 may have smaller openings, preferably between one and six inches in diameter, preferably between three and four inches in diameter.
In the embodiment of the convective bring-up zone shown in
The final zone of the radiant tube and convection oven 20 of this invention is the hold zone, wherein the final curing or baking of the coating on the substrate 22 occurs. The hold zone may be identical to
As will be understood, it is desirable to maintain a substantially constant temperature in each zone of a paint oven. This may be accomplished with the radiant tube and convection oven of this invention utilizing a control loop, such as a proportional integral derivative (PID) control system. In a preferred embodiment of the radiant tube and convection oven of this invention, the radiant tubes 28 in
Finally, the radiant and convection oven of this invention may include a secondary heat recovery to improve the overall thermal efficiency of the oven. This may be accomplished by directing the hot gas received from the radiant tubes (28 and 40) into a heat recovery system which may be utilized, for example, to heat the fresh air received by the radiant tube oven. For example, the outlet from the oven of the radiant tubes may be include a sheath which coaxially surrounds the radiant tubes and fresh air may be drawn into one end of the sheath and flows through the annular space and heated by convection and radiation from the radiant tubes. The fresh air would then be ducted to the inlet of a conventional fresh air heater where it would be heated additionally by normal means to the required temperature. The secondary recovery system may be of a more conventional design, wherein several radiant tubes are manifolded together and fed into a single heat exchanger. In this case, explosion relief would be incorporated into the manifold and heat exchanger.
As set forth above, the radiant tube and convection oven of this invention preferably includes at least three zones, including a radiant bring-up zone, a convection bring-up zone and a hold zone, wherein a substrate, such as an automotive body 22 is conveyed through the oven on a conveyor 24 and wherein the zones are coaxial or collinear having a common enclosure. However, the radiant tube and convection oven of this invention may be utilized to dry or cure any coating on any substrate and is thus not limited to a paint cure oven as disclosed. Further, various modifications may be made to the disclosed embodiments of the radiant tube and convection oven of this invention within the purview of the appended claims and the disclosed embodiments are for illustrative purposes only. For example, the chambers 48 and 50 may be identical, as described above, and the return pass 44 of the radiant tube 40 is optional, although preferred in applications where heat conservation is desired or preferred. Having described preferred embodiments of the radian tube and convection oven of this invention, the invention is now claimed as follows.
This application claims priority to U.S. Provisional Patent Application Ser. No. 60/513,748 filed Oct. 23, 2003.
Number | Date | Country | |
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60513748 | Oct 2003 | US |