Patent Application
20190262854
The present application claims the benefit of priority to Chinese patent application No. 201610571824.3, titled “THERMAL SPRAYING DEVICE, THERMAL SPRAYING SYSTEM AND THERMAL SPRAYING TECHNOLOGY THEREOF”, filed with the Chinese State Intellectual Property Office on Jul. 20, 2016, the entire disclosure of which is incorporated herein by reference.
Electric arc spraying is one kind of thermal spraying, and is a technology in which an electric arc between two continually feed-in metal wires is used as a heat source to melt the metal wires, the melted metal is atomized by compressed air, and atomized metal drops is accelerated to be sprayed to a workpiece to form a coating on a surface of the workpiece.
The electric arc spraying in the conventional technology uses a handheld electric arc spraying gun to manually spray a single workpiece, the working efficiency is low, the spraying quality is not steady due to human factors, and the processing cost is high.
In view of this, how to solve the problem of a low efficiency and an unsteady spraying quality of the electric arc spraying becomes an issue urgently to be solved by those skilled in the field.
In view of this, an object of the present application is to provide a thermal spraying device in order to improve the spraying efficiency and stability of the spraying quality.
Another object of the present application is to provide a thermal spraying system having the thermal spraying device in order to improve the spraying efficiency and the stability of the spraying quality.
A third object of the present application is to provide a thermal spraying technology based on the thermal spraying system in order to improve the spraying quality.
For realizing the above objects, the following technical solutions are provided according to the present application.
A thermal spraying device, including:
at least one electric arc spraying device;
a rotatable worktable, the electric arc spraying device being arranged at a periphery of the rotatable worktable;
a plurality of spraying tools arranged on the rotatable worktable in a circumference direction, each of the spraying tools being driven to rotate by a motor;
a plurality of wire placing racks arranged at outside of the rotatable worktable, each of the wire placing racks corresponding to one electric arc spraying device; and
a master controller connected to the rotatable worktable to control the rotatable worktable.
Preferably, the thermal spraying device further includes a lifting device, the electric arc spraying device is arranged on the lifting device and the master controller is connected to the lifting device to control the lifting device.
Preferably, in the thermal spraying device, the electric arc spray device includes:
a bracket;
two wire feeding mechanisms fixed on the bracket;
an insulated fixing bracket fixed on the bracket;
two contact tubes arranged on the insulated fixing bracket, wherein an included angle exists between wire feeding directions of the two contact tubes, wire outlets of the two contact tubes are close to each other, each of the contact tubes corresponds to one wire feeding mechanism, and the wire feeding mechanisms are configured to push and convey metal wires into the corresponding contact tubes;
a compressed air spray pipe fixed on the insulated fixing bracket, wherein a nozzle of the compressed air spray pipe aims at the wire outlets of the two contact tubes; and
an electric arc spray controller connected to the wire feeding mechanisms and the contact tubes to control the wire feeding mechanisms and the contact tubes.
Preferably, in the thermal spraying device, each of the wire feeding mechanisms includes:
a frame;
at least two groups of wire feeding wheel sets rotatably arranged on the frame and distributed in the wire feeding direction, wherein each group of wire feeding wheel sets includes two wire feeding wheels, wheel surfaces of the two wire feeding wheels in each group of wire feeding wheel sets are provided with grooves configured to clamp the metal wires, the two wire feeding wheels in each group of wire feeding wheel sets are engaged via gears, and the two groups of wire feeding wheel sets are both connected to the driving gear by meshing transmission; and
a power component connected to the driving gear by meshing transmission.
Preferably, in the thermal spraying device, the electric arc spraying device further includes wire guide components, each of the wire feeding mechanisms corresponds to one wire guide component, the wire guide components are arranged at an inlet side of the corresponding wire feeding mechanisms, each of the wire guide components includes two wire guide wheel sets, and position-limiting directions to the metal wires, of the two wire guide wheel sets are perpendicular to each other.
Preferably, in the thermal spraying device, the rotatable worktable includes:
a base;
a turntable horizontally arranged and rotatably connected to the base; and
a driving device connected to the turntable to drive the turntable, wherein the master controller is connected to the driving device to control the driving device.
Preferably, the thermal spraying device further includes a plurality of dust removal pipelines, the dust removal pipelines are arranged above the rotatable worktable and each dust removal pipeline corresponds to one electric arc spraying device.
Preferably, the thermal spraying device further includes a protective chamber; the electric arc spraying device, the dust removal pipeline and a part of the rotatable worktable are located inside the protective chamber; and a part of the rotatable worktable is located outside the protective chamber, the wire placing racks are arranged on an outer wall of the protective chamber, and the master controller and the electric arc spraying controller of the electric arc spraying device are located outside the protective chamber.
Preferably, the spraying tools are uniformly distributed on the rotatable worktable in the circumference direction.
Preferably, the driving device is a servo motor.
A thermal spraying system is further provided according to the present application, which includes the above thermal spraying device.
Preferably, the thermal spraying system further includes a sandblasting roughening device including:
a sand box;
a sandblasting gun connected to the sand box by a sand conveying pipe;
a compressed air device arranged between the sandblasting gun and the sand box, and configured to spray compressed air into the sandblasting gun;
a rotary table, wherein the sandblasting gun is arranged at an outside of the rotary table; and
a plurality of sandblasting tool arranged on the rotary table in a circumference direction, wherein each sandblasting tool is driven to rotate by the tool driving device, and the sandblasting gun aims at the sandblasting tools.
Preferably, in the thermal spraying system, the sandblasting roughening device further includes a sand recycling device including:
a helical sand conveying machine located below the sandblasting gun; and
a sand hoister, wherein an outlet of the helical sand conveying machine is in communication with an inlet of the sand hoister and an outlet of the sand hoister is in communication with an inlet of the sand box.
Preferably, in the thermal spraying system, the sandblasting roughening device further includes a sandblasting chamber, and the sandblasting gun, the compressed air device and the rotary table are arranged inside the sandblasting chamber.
Preferably, in the thermal spraying system, the sandblasting roughening device further includes a dust remover which is connected to the sandblasting chamber by dust removal pipelines.
Preferably, in the thermal spraying system, the sandblasting roughening device further includes a filter which is arranged between the dust removal pipelines and the dust remover.
Preferably, in the thermal spraying system, the tool driving device includes:
a tool motor;
a first friction wheel fixedly connected to a shaft of the sandblasting tool;
a friction wheel shaft transmitted and connected to the tool motor; and
a second friction wheel fixedly connected to the friction wheel shaft, wherein a wheel surface of the second friction wheel is in a frictional contact with the an edge of a plane at one side of the first friction wheel.
Preferably, in the thermal spraying system, the sandblasting roughening device further includes a blocking plate assembly fixed above a station where the sandblasting tool, which the sandblasting gun aims at, is located, and configured to block an end opening of a workpiece rotating for spraying.
A thermal spraying technology is further provided according to the present application. The thermal spraying technology is based on the thermal spraying system described above, compressed air with a pressure of 0.6 MPa is adopted and aluminum silicon wire rods with a diameter ranging from 1.6 mm to 3 mm which are melted are sprayed to the workpiece by the electric arc spraying device, the electric arc spraying device sprays the workpiece up and down repeatedly at a speed ranging from 15 mm/s to 45 mm/s, with a repetition times being one to four, and an aluminum silicon coating is formed on the surface of the workpiece.
Preferably, in the thermal spraying technology, the aluminum silicon coating has a roughness, Rz, ranging from 100 μm to 250 μm, and has a thickness ranging from 0.1 mm to 0.8 mm.
Preferably, in the thermal spraying technology, wire feeding speeds of the aluminum silicon wire rods range from 4 m/min to 8 m/min, and a voltage of the electric arc spraying device ranges from 28V to 40V.
Preferably, in the thermal spraying technology, the content of silicon in the aluminum silicon wire rods ranges from 11% to 13%.
Preferably, in the thermal spraying technology, before spraying the workpiece, the surface of the workpiece is roughened by the sandblasting roughening device, compressed air used for sandblasting has a pressure not lower than 0.6 Mpa, and a roughening time ranges from 5 seconds to 15 seconds.
Preferably, in the thermal spraying technology, a roughened portion of the workpiece which is roughened has a roughness, Rz, ranging from 30 μm to 90 μm, and has a cleanliness level of Sa 3.
Compared with the conventional technology, the present application has the following technical effects. In the thermal spraying device according to the present application, the electric arc spraying device is arranged at the periphery of a rotatable worktable, spraying tools which are driven to rotate by the motor are located on the rotatable worktable in a circumference direction and the rotatable worktable is controlled to rotate by the master controller; when a certain spraying tool rotates together with the rotatable worktable to the station where the electric arc spraying device is located, the electric arc spraying device performs a thermal spraying operation to the workpiece on the spraying tool; after that, the rotatable worktable continues to rotate and the electric arc spraying device sprays the workpiece on a next spraying tool, thereby realizing the assembly line spray. Compared with holding the electric arc spraying gun in hands in the conventional technology, the spraying efficiency is improved, manual spray is needless, and the stability of the spraying quality is improved.
For more clearly illustrating embodiments of the present application or the technical solution in the conventional technology, drawings used in the embodiments or the descriptions about the conventional technology are briefly introduced below. Apparently, the drawings described below are merely the embodiments of the present application, and those skilled in the art may achieve other drawings, based on these drawings, without any creative efforts.
A thermal spraying device is provided according to the present application, which can perform an assembly line spray operation, thus may improve the spraying efficiency and the stability of spraying quality.
A thermal spraying system including the thermal spraying device is further provided according to the present application, which can perform the assembly line spray operation, thus may improve the spraying efficiency and the stability of spraying quality.
A thermal spraying technology based on the thermal spraying system is further provided according to the present application, which may improve the spraying quality.
The technical solutions in the embodiments of the present application will be described clearly and completely hereinafter in conjunction with the drawings in the embodiments of the present application. Apparently, the described embodiments are only a part of the embodiments of the present application, rather than all embodiments. Based on the embodiments in the present application, all of other embodiments, made by the person skilled in the art without any creative efforts, fall into the scope of the present application.
Referring to
The working process of the above thermal spraying device is as follows. The electric arc spraying device 06 is arranged on the periphery station of the rotatable worktable 01, and the master controller 08 controls the rotatable worktable 01 to rotate. When the spraying tool 02 reaches the station where the electric arc spraying device 06 is located, the master controller 08 controls the rotatable worktable 01 to stop rotating, the electric arc spraying device 06 aims at the workpiece on the spraying tool 02, and at the same time the spraying tool 02 is driven to rotate by the motor 021, an electric arc spraying controller 8 controls a wire feeding mechanism 3 to feed the metal wires and controls a voltage of a contact tube 6 to melt the metal wires by electrifying, and a compressed air spray pipe 7 sprays atomized metal fine drops to a surface of the rotating workpiece. After the spraying is completed, the master controller 08 controls the rotatable worktable 01 to continue to rotate so that a next spraying tool 02 reaches the station where the electric arc spraying device 06 is located, and the spraying of a workpiece on the next spraying tool 02 is performed, and the above process cycles in turn. Therefore, the assembly line spray operation is achieved. Compared with manually performing the spraying by a handheld electric arc spraying gun in the conventional technology, the spraying efficiency is improved, the problem of unstable spraying quality due to human factor is avoided, and the stability of the spraying quality is improved.
Preferably, the number of the electric arc spraying device 06 is two, thus can spray different positions of each workpiece, which allows the spraying to be uniform.
Furthermore, in this embodiment, the thermal spraying device further includes a lifting device 05, the electric arc spraying device 06 is arranged on the lifting device 05, and the master controller 08 is connected to the lifting device 05. The lifting device 05 can rise and fall through an electric lifting cylinder, a hydraulic cylinder or a pneumatic linear actuator. The lifting device 05 is common in the market and can be directly bought to use. The purpose of setting the lifting device 05 is to control the lifting device 05 to move upward and downward by the master controller 08 when the spray operation is performed, thus the electric arc spraying device 06 is driven to move upward and downward so that the workpiece can be thoroughly and uniformly sprayed. Of course, the lifting device 05 may not provided, just the spraying is not as uniform as the spraying when the lifting device 05 is provided.
As shown in
The working principle of the contact tubes 06 are as follows. Two metal wires are respectively conveyed into the two contact tubes 6 via two wire feeding mechanisms 3, and the two metal wires are in contact after respectively extending from the wire outlets of the contact tube 6. After the two contact tubes 6 are electrified, the two metal wires are electrically connected and are melted under the action of electricity. Compressed air is introduced into the compressed air spray pipe 7 and is sprayed to melted portions of the two metal wires via the nozzle of the compressed air spray pipe 7 to atomize the metal wires and spray atomized metal at a high speed, and the atomized metal fine drops are sprayed on the workpiece and form a metal coating, thus the electric arc spraying is completed. Since the supporting base 2, the contact tubes 6, the compressed air spray pipe 7, the wire feeding mechanisms 3 and the insulated fixing bracket 5 of the electric arc spraying device in the present application are fixed together, which as a whole can be arranged on an assembly line station and realize the assembly line spray operation. Compared with manually performing the spraying in the conventional technology by the handheld electric arc spraying gun, the spraying efficiency is improved, the problem of unstable spraying quality caused by human factor is avoided, and the stability of the spraying quality is improved.
As shown in
Of course, the wire feeding mechanism 3 also may include one or more wire feeding wheel sets 302, as long as the pushing and conveying directions of the wire feeding wheel sets 302 are identical.
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A thermal spraying system is further provided according to the present application, which includes the thermal spraying device described in the above embodiments, through which the assembly line spray operation is realized. Compared with manually performing spray by handheld electric arc spraying gun in the conventional technology, the spraying efficiency is improved, the problem of spraying quality being unstable caused by human factors is avoided, and the stability of the spraying quality is improved.
As shown in
The working principle of the above sandblasting roughening device is as follows. The workpiece to be sandblasted is fixed on the sandblasting tool 14, the rotary table 110 rotates, and the sandblasting tool 14 performs a circular motion together with the rotary table 110. When a certain sandblasting tool 14 reaches the station where the sandblasting gun 111 is located, the rotary table 110 stops rotating, the sandblasting gun 111 aims at the workpiece on the sandblasting tool 14, and at the same time the sandblasting tool 14 is driven to rotate by the tool driving device 15, the compressed air device 12 sprays high-speed air flow into the sandblasting gun 111, the sand in the sand box 11 is absorbed into the sandblasting gun 111 and is sprayed to the surface of the workpiece via the nozzle of the sandblasting gun 111, and the surface of the workpiece is roughened. After the sandblasting roughening is finished, the rotary table 110 continues to rotate to allow a next sandblasting tool 14 to reach the station where the sandblasting gun 111 is located, so that the sandblasting roughening of the workpiece on the next sandblasting tool 14 is performed, and the above process sequentially and circularly proceeds. The roughened workpiece is conveyed to the thermal spraying device to perform the spraying operation, the workpiece having a roughened surface can better adhere the paint, thus the spraying quality is further improved.
As shown in
As shown in
Of course, the sand recycling device may have other structural styles as long as the sand can be recycled and conveyed to the sand box 11, and the structure styles are not limited to the styles listed in the embodiment. Of course, the sand recycling device may not be provided, and the sand in the sandblasting roughening device is cleaned regularly instead.
For further improving the operating environment of the sandblasting roughening device, in this embodiment, the sandblasting roughening device further includes a sandblasting chamber, which is a half closed chamber. The sandblasting gun 111, the sandblasting tool 14 and the rotary table 110 are arranged inside the sandblasting chamber, one side of the sandblasting chamber is provided with a window for installing and disassembling the workpiece, and other portions of the sandblasting chamber are all closed. Thus, the scattering to the surrounding environment of the sand sprayed by the sandblasting gun 111 is reduced and the operating environment is improved.
In this embodiment, the sandblasting roughening device further includes a dust remover 17 connected to the sandblasting chamber by the dust removal pipelines. During the working process of the sandblasting roughening device, the sand inevitably scatters in the sandblasting chamber, and the working environment is adversely affected. The dust in the sandblasting chamber is drawn into the dust remover 17 by a draught fan and the like, so that the dust is removed and after the dust is removed, the air is discharged to the outer environment, thus the operating environment is improved and protected.
Further, the sandblasting roughening device further includes a filter 16 which is arranged between the dust removal pipelines and the dust remover 17. Before the dust in the sandblasting chamber entering the dust remover 17, the dust first enters the filter 16 to be filtered, thus the dust removal effect is enhanced and the dust remover 17 is protected. A discharged air filter 18 is arranged at an outlet of the dust remover 17, thus the air discharged to the outer environment is further purified.
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A thermal spraying technology is further provided according to the present application. The thermal spraying technology is based on the thermal spraying system described above, the specific operation is that: compressed air with a pressure of 0.6 MPa is adopted and aluminum silicon wire rods with a diameter ranging from 1.6 mm to 3 mm which are melted are sprayed to the workpiece by the electric arc spraying device, the electric arc spraying device sprays the workpiece up and down repeatedly at a speed ranging from 15 mm/s to 45 mm/s, with a repetition times being one to four, and an aluminum silicon coating is formed on the surface of the workpiece.
Further, in this embodiment, the aluminum silicon coating has a roughness, Rz, ranging from 100 μm to 250 μm, and has a thickness ranging from 0.1 mm to 0.8 mm.
In this embodiment, wire feeding speeds of the aluminum silicon wire rods range from 4 m/min to 8 m/min, and a voltage of the electric arc spraying device ranges from 28V to 40V.
Further, in this embodiment, the content of silicon in the aluminum silicon wire rods ranges from 11% to 13%.
Further, in this embodiment, before spraying the workpiece, the surface of the workpiece is roughened by the sandblasting roughening device, compressed air used for sandblasting has a pressure not lower than 0.6 Mpa, and a roughening time ranges from 5 seconds to 15 seconds.
Further, in this embodiment, a roughened portion of the workpiece which is roughened has a roughness, Rz, ranging from 30 μm to 90 μm, and has a cleanliness level of Sa3.
The above embodiments are described in a progressive manner. Each of the embodiments is mainly focused on describing its differences from other embodiments, and references may be made among these embodiments with respect to the same or similar portions among these embodiments.
Based on the above description of the above described embodiments, the person skilled in the art is capable of carrying out or using the present application. It is obvious for the person skilled in the art to make many modifications to these embodiments. The general principle defined herein may be applied to other embodiments without departing from the spirit or scope of the present application. Therefore, the present application is not limited to the embodiments illustrated herein, but should be defined by the broadest scope consistent with the principle and novel features disclosed herein.
| Number | Date | Country | Kind |
|---|---|---|---|
| 201610571824.3 | Jul 2016 | CN | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/CN2017/079468 | 4/5/2017 | WO | 00 |
