Arc wire spraying method, equipment and product

Abstract

An arc wire spraying method includes conveying at least two wires out of respective lance nozzles of a wire conveying device by means of the wire conveying device, applying current to the two wires to form an arc for melting the ends of the two wires, and applying airflow to the arc in the direction transverse to the longitudinal direction of the wire conveying device by means of an airflow applying device so as to spray the melted wire material toward a surface to be sprayed. The airflow applying device rotationally applies the airflow around the longitudinal direction of the wire conveying device. Parameters for spraying are variably adjusted along the rotating direction of the airflow applying device. The airflow is rotationally applied at a varying rotating speed.

Claims

1. An arc wire spraying method, comprising the following steps: conveying at least two wires out of respective lance nozzles of a wire conveying device by means of the wire conveying device, applying current to the at least two wires to form an arc for melting the ends of the at least two wires, and applying airflow to the arc in the direction transverse to the longitudinal direction of the wire conveying device by means of an airflow applying device so as to spray the melted wire material toward a surface to be sprayed, wherein the airflow applying device rotationally applies the airflow around the longitudinal direction of the wire conveying device, wherein parameters for spraying are variably adjusted along the rotating direction of the airflow applying device, wherein the airflow is rotationally applied at a varying rotating speed, wherein the lance nozzles are arranged in a straight line, wherein the rotating speed of the airflow applying device at the positions where its rotating trajectory is crossed with the straight line is higher than that at the positions where the tangents of the rotating trajectory are parallel to the straight line.

2. The arc wire spraying method of claim 1, wherein the rotating speed is increased when the positions are approached where the rotating trajectory is crossed with the straight line, but decreased when the positions are approached where the tangents of the rotating trajectory are parallel to the straight line.

3. The arc wire spraying method of claim 2, wherein the rotating speed is continuously varied.

4. The arc wire spraying method of claim 1, wherein the rotating speed is selected according to the angle between the airflow and the plane of the rotating trajectory.

5. The arc wire spraying method of claim 1, wherein the airflow is applied at a varying air flow rate.

6. The arc wire spraying method of claim 5, wherein the air flow rate of the airflow applying device at the positions where its rotating trajectory is crossed with the straight line is lower than that at the positions where the tangents of the rotating trajectory are parallel to the straight line.

7. The arc wire spraying method of claim 1, wherein the wires are applied with varying current.

8. The arc wire spraying method of claim 7, wherein the current applied by a current charger when the airflow applying device passes through the positions where the rotating trajectory is crossed with the straight line is lower than the current applied when the airflow applying device passes through the positions where the tangents of the rotating trajectory are parallel to the straight line.

9. The arc wire spraying method of claim 1, wherein additional airflow is applied in the longitudinal direction of the wire conveying device.

10. The arc wire spraying method of claim 1, wherein the arc wire spraying method is used for spraying the inner surface of a cylindrical cavity.

11. The arc wire spraying method of claim 10, wherein the inner surface of the cylindrical cavity is a cylinder working face of a crankcase.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows a schematic side view of arc wire spraying equipment of the present disclosure;

(2) FIG. 2 shows a bottom view of the arc wire spraying equipment of the present disclosure;

(3) FIG. 3 shows a detail view of the arc wire spraying equipment of the present disclosure;

(4) FIG. 4a shows a polar coordinate diagram of coating thickness distribution generated without adjusting parameters for spraying;

(5) FIG. 4b shows a curve diagram of coating thickness distribution generated without adjusting parameters for spraying;

(6) FIG. 5a shows a polar coordinate diagram of coating thickness distribution generated under the condition that airflow is rotationally applied at a varying rotating speed;

(7) FIG. 5b shows a curve diagram of coating thickness generated under the condition that airflow is rotationally applied at a varying rotating speed.

DETAILED DESCRIPTION OF THE EMBODIMENTS

(8) Different embodiments are now described in detail with reference to the accompanying drawings, wherein some embodiments are shown in the drawings. For the sake of clearness, the widths of lines and/or areas can be exaggeratedly shown in the drawings.

(9) In the accompanying drawings, same or mutually corresponding elements are respectively indicated by the same drawing signs. The elements described by the same drawing signs can be implemented equally or differently if necessary on single, multiple or all features (e.g., their dimensions). The disclosure contents included in the whole description can be diverted to the same parts having the same drawing signs or the same component signs according to the meanings. The positions selected in the description, e.g., upper, lower, left, right, side and the like, refer to the directly described and shown drawings and are diverted to new positions according to the meanings when the positions are changed. Besides, a single feature or a feature combination in different embodiments shown and described can also constitute a creative solution per se.

(10) Although each embodiment can be modified in multiple modes, the embodiment in each drawing is shown as an example and described in detail therein. However, it shall be clear that each embodiment is unintentionally limited to the corresponding disclosed form, and more exactly speaking, each embodiment shall cover all functional and/or structural modified solutions, equivalent solutions and alternative solutions in the scope of the present disclosure.

(11) FIG. 1 shows a schematic side view of arc wire spraying equipment of the present disclosure. The arc wire spraying equipment 1 herein includes a wire conveying device 2 and an airflow applying device 3. The wire conveying device 2 includes a current charger not shown and at least two lance nozzles 4. The wire conveying device 2 conveys at least two wires out of the respective lance nozzles 4. Current is applied to the at least two wires by the current charger not shown to form an arc in the region of the lance nozzles, so that the ends of the at least two wires are melted. Airflow is applied to the arc in the direction approximately transverse to the longitudinal direction z of the wire conveying device 2 by the airflow applying device 3 so as to spray the melted wire material toward a surface 5 to be sprayed. According to the present disclosure, the airflow applying device 3 can rotationally apply the airflow around the longitudinal direction z of the wire conveying device 2, wherein parameters for spraying are variably adjusted along the rotating direction of the airflow applying device 3. Particularly, the wire conveying device 2 does not rotate herein, only the airflow applying device 3 rotates around it, and relative rotation is thus produced between them.

(12) FIG. 1 schematically shows the wire conveying device 2. The wire conveying device is schematically a cylinder. As shown in the figure, the axis of the cylinder is defined as the longitudinal direction z of the wire conveying device 2. A pipeline not shown is integrated inside the wire conveying device 2 to convey wires. A device enabling wires to move is arranged upstream of the wire conveying device 2, or inside the wire, conveying device to continuously convey the wires in the spraying process. According to this embodiment, two lance nozzles 4 are arranged at the bottom of the wire conveying device 2, and the lance nozzles 4 are connected with the pipeline. The two lance nozzles 4 form hollow cones for conveying spraying wires therein.

(13) The sharp ends of the cones approach each other, so that the wires conveyed out of the lance nozzles 4 approach each other. It should be noted that only two lance nozzles are shown in the drawings, but the present disclosure is not limited to the two lance nozzles, and the number of the lance nozzles may be two, three, four or more.

(14) The wire conveying device includes a current charger not shown, and the current charger applies current to the at least two wires respectively. The current charger is connected with a current source not shown as well to provide energy for forming an arc between the wires. The at least two wires produce arc discharge in the region of the lance nozzles, so that the wires produce high temperature based on continual strong current and the ends of the wires are instantaneously melted.

(15) FIG. 1 also schematically shows the airflow applying device 3. The airflow applying device 3 is shown as a cuboid schematically, and its longitudinal extending direction is parallel to the axis of the wire conveying device 2 or the longitudinal direction z. A pipeline for air flowing is integrated in the airflow applying device 3, and a nozzle is arranged on the side of the lower end as shown in the figure. The nozzle points to the region of the lance nozzles.

(16) The airflow applying device 3 can rotate around the longitudinal direction z of the wire conveying device 2 in the direction shown by the arrow p in FIG. 1, so that the airflow applying device 3 can rotationally apply airflow to the arc, the melted wire material are atomized and the atomized wire particles are sprayed toward the surface to be sprayed. However, the present disclosure is not limited to the rotation direction showing in the Figures and the airflow applying device 3 can rotate in a clockwise direction or in a counterclockwise direction.

(17) However, the airflow applying device of the present disclosure is not limited to such embodiment. A sleeve-type airflow applying device may also be considered. The sleeve-type airflow applying device also rotates around the longitudinal direction z of the wire conveying device 2, and thus rotationally applies airflow to the arc. The sleeve may be provided with a double-layer wall for air flowing, even the double-layer wall is saved, so that the outer wall of the wire conveying device is utilized to define the air flowing space. It should be noted that the nozzle 6 as shown in FIG. 1 is merely schematic. The nozzle 6 may be in a single-hole or multi-hole form. Various arrangement modes of holes can be considered in the multi-hole form to meet different spraying requirements. Particularly, different airflow directions can be realized via the nozzle, and reference may be made to the detailed description on FIG. 3 below.

(18) An arc wire spraying method will be described by means of the accompanying drawings, too. The arc wire spraying method of the present disclosure includes the steps of conveying at least two wires out of respective lance nozzles 4 of the wire conveying device 2 by means of the wire conveying device 2, applying current to the at least two wires to form an arc for melting the ends of the at least two wires, and applying airflow to the arc in the direction approximately transverse to the longitudinal direction z of the wire conveying device 2 by means of the airflow applying device 3 so as to spray the melted wire material toward a surface to be sprayed, wherein the airflow applying device 3 rotationally applies the airflow around the longitudinal direction z of the wire conveying device 2, wherein parameters for spraying are variably adjusted along the rotating direction of the airflow applying device 3.

(19) According to a preferred application of the present disclosure, the arc wire spraying method and equipment are used for spraying the inner surface of a cylindrical cavity. FIG. 1 schematically shows a section view of the cylindrical cavity 7, and the inner surface of the cylindrical cavity 7 is a surface 5 to be sprayed in the present disclosure. Particularly preferably, the inner surface of the cylindrical cavity is a cylinder working face of a crankcase.

(20) When arc wires are sprayed to the inner surface of the cylindrical cavity, in order to spray different depth positions of the inner surface, the wire conveying device 2 and the airflow applying device 3 can jointly move downwards in the longitudinal direction z to plunge into the lower part of the cylindrical cavity. In the spraying process, the airflow applying device 3 continually rotates around the wire conveying device 2, and the wire conveying device 2 and the airflow applying device 3 simultaneously rise up to spray the whole inner surface of the cylindrical cavity from bottom to top. Needless to say, spraying from top to bottom may also be considered. Similarly, it could consider that the airflow applying device only rotates around the wire conveying device 2 without changing the height positions of the wire conveying device 2 and the airflow applying device 3. In this case, the height position of the cylindrical cavity can be changed, so that the cylindrical cavity moves from bottom to top or from top to bottom relative to the wire conveying device 2 and the airflow applying device 3.

(21) In order to achieve the effect that the coating is relative uniform when the inner surface of the cylindrical cavity is sprayed, it is defined according to the present disclosure that parameters for spraying are variably adjusted along the rotating direction of the airflow applying device 3. Specifically, airflow can be rotationally applied at a varying rotating speed. Correspondingly, the airflow applying device 3 can rotate at the varying rotating speed. Besides, the airflow can be applied at a varying air flow rate. Correspondingly, the airflow applying device 3 can apply the airflow at the varying air flow rate. In addition, the wires can be applied with varying current. Correspondingly, the current charger can apply the wires with the varying current.

(22) How to variably adjust the parameters for spraying will be described in more detail below by means of the position relationship shown in FIG. 2.

(23) FIG. 2 shows a bottom view of the arc wire spraying equipment 1 in FIG. 1. FIG. 2 shows the situation of the bottom view of the arc wire spraying equipment. According to the coordinate system shown in FIG. 1, an x axis and a y axis are added in FIG. 2 and angles are marked on the axes, in order to express the position relationship of all parts more clearly.

(24) Two lance nozzles 4 are arranged at the bottom of the wire conveying device 2. In FIG. 2, the two lance nozzles 4 are arranged along a straight line or arranged horizontally along the x axis. At the bottoms of the two lance nozzles 4, two wires for spraying are respectively conveyed out of a hole 8 of the lance nozzle 4 and approach each other.

(25) The airflow applying device 3 is arranged beside the wire conveying device 2. The airflow applying device 3 rotates around the origin O in the direction of arrow p shown in the figure. The z axis shown in FIG. 1 passes through the origin O.

(26) FIG. 2 also shows one position of the airflow applying device 3 represented by a solid box, and this position is called a 0 position below. FIG. 2 shows one position of the airflow applying device 3 represented by a dashed box, and this position is called a 90 position below.

(27) The airflow applying device 3 can rotate 90 from the position of the dashed box to the position of the solid box along the direction shown by the arrow p, can continuously rotate, passes through 180 and 270 positions, and finally returns to the 0 position. A rotating trajectory is formed when the airflow applying device 3 rotates, the rotating trajectory is a circle around the origin O, and the circle is also concentric with the wire conveying device 2.

(28) It can be seen from FIG. 2 that the rotating trajectory of the airflow applying device 3 is crossed with the straight line of the lance nozzles or the x axis at the 90 and 270 positions. At 0 and 180 positions, the tangents of the rotating trajectory of the airflow applying device 3 are parallel to the straight line of the lance nozzles or the x axis.

(29) As mentioned above, the phenomenon that the coating is not uniform when the inner surface of the cylindrical cavity is sprayed is related to the positions of the lance nozzles. The thicker positions of the coating correspond to the positions where the rotating trajectory of the airflow applying device is crossed with the straight line of the lance nozzles, i.e., 900 and 270 positions in FIG. 2. At the positions where the tangents of the rotating trajectory of the airflow applying device are parallel to the straight line of the lance nozzles, i.e., 0 and 180 positions shown in FIG. 2, a thin coating is produced. Upon such research conclusions, the present disclosure puts forward variably adjusting parameters for spraying along the rotating direction of the airflow applying device, so that more wire material is sprayed at the original thin (0 and 180) positions of the coating, less wire material is sprayed at the original thick (90 and 270) positions of the coating, and a coating having uniform thickness on the whole circumference is produced. Specifically, a straight line (represented as x axis in FIG. 2) can be prescribed through the lance nozzles 4, and the rotating speed of the airflow applying device 3 at the positions (90 and 270 positions) where its rotating trajectory is crossed with the straight line may be higher than that at the positions (0 and 180 positions) where the tangents of the rotating trajectory are parallel to the straight line. Besides, the air flow rate of the airflow applying device 3 at the positions (90 and 270 positions) where its rotating trajectory is crossed with the straight line may be lower than that at the positions (0 and 180 positions) where the tangents of the rotating trajectory are parallel to the straight line. In addition, the current applied by the current charger when the airflow applying device 3 passes through the positions (90 and 270 positions) where the rotating trajectory is crossed with the straight line can be lower than the current applied when the airflow applying device 3 passes through the positions (0 and 180 positions) where the tangents of the rotating trajectory are parallel to the straight line. Through the above three modes, more wires can sprayed at the original thin positions of the coating, less wire material is sprayed at the original thick positions of the coating, and a coating having uniform thickness on the whole circumference is thus produced.

(30) In order to realize more uniform thickness, it may also be considered that the rotating speed is increased when the positions are approached where the rotating trajectory is crossed with the straight line, but decreased when the positions are approached where the tangents of the rotating trajectory are parallel to the straight line. Referring to FIG. 2, the rotating speed of the airflow applying device 3 is decreased when the 0 and 180 positions are approached, but increased when the 90 and 270 positions are approached in the rotating process. In other words, in the coordinate system shown in FIG. 2, when the airflow applying device rotates anticlockwise, the rotating speed of the airflow applying device 3 is decreased in the first quadrant and the third quadrant, but increased in the second quadrant and the fourth quadrant. Particularly preferably, the rotating speed is continuously varied.

(31) FIG. 3 shows a detail view of the arc wire spraying equipment of the present disclosure. Particularly shown herein is airflow 9 jet from the nozzle 6 of the airflow applying device 3. A fluid director of the nozzle 6 is also schematically shown herein, and the jet direction of the airflow 9 can be defined under the action of the fluid director. FIG. 3 additionally shows a rotating plane of the airflow applying device 3 with a dotted line, i.e., a plane defined by the airflow applying device 3. The airflow 9 forms an angle relative to the rotating plane. According to the present disclosure, the rotating speed of the airflow applying device 3, particularly the varying rotating speed, can be selected according to the angle between the airflow 9 and the plane of the rotating trajectory. Thus, the maximum, minimum, intermediate value and the like of the rotating speed can be set according to the angle between the airflow 9 and the plane of the rotating trajectory. The varying curve, varying function, value list or the like of the rotating speed can also be set according to the angle. Thus, a coating having uniform thickness can be realized particularly well.

(32) FIG. 4a and FIG. 4b show a polar coordinate diagram and a curve diagram of coating thickness distribution generated without adjusting parameters for spraying in the prior art, respectively, wherein three different lines represent a schematic diagram of coating thickness measured on the inner surface of the top, middle and bottom part of the sprayed cylindrical cavity. In the diagrams, the dotted line represents the thickness result of the top part of the cylindrical cavity, the dashed line represents the thickness result of the middle part of the cylindrical cavity, and the solid line represents the thickness result of the bottom part of the cylindrical cavity. FIG. 4a shows a polar coordinate diagram of thickness distribution, and FIG. 4b shows a curve diagram of thickness in each angle direction. It can be clearly seen that the thickness fluctuates drastically within the angle range of the circumference under the condition that the parameters for spraying are constant.

(33) Two thin positions and two thick positions are produced on the whole circumference. The polar coordinate diagram in FIG. 4a clearly shows that the thickness distribution on the whole circumference is elliptic, thick positions appear at 90 and 270, and thin positions appear at 0 and 180. The angles shown in FIG. 4a to FIG. 5b also correspond to the angles shown in FIG. 2. In other words, when the inner surface of the cylindrical cavity is sprayed by the arc wire spraying equipment 1 in FIG. 2, the thickness corresponding to FIG. 4a to FIG. 5b will appear in each angle direction shown in FIG. 2.

(34) FIG. 5a and FIG. 5b show a polar coordinate diagram and a curve diagram of coating thickness distribution generated under the condition that airflow is rotationally applied at a varying rotating speed according to the present disclosure, respectively. FIG. 5a and FIG. 5b adopt the same signs as FIG. 4a and FIG. 4b. FIG. 5a and FIG. 5b particularly show a result of thickness generated by applying the following embodiment, i.e., the rotating speed of the airflow applying device 3 at the positions (90 and 270 positions) where its rotating trajectory is crossed with the straight line may be higher than that at the positions (0 and 180 positions) where the tangents of the rotating trajectory are parallel to the straight line.

(35) It can be obviously seen from the curve diagram in FIG. 5b that the coating thickness no longer fluctuates drastically on the whole circumference, but falls into a certain tolerance range of about 400 m. Such thickness shows that a rough circle can be seen from the polar coordinate diagram in FIG. 5a. Accordingly, uniform coating thickness can be realized via the present disclosure, and the problems caused by non-uniform thickness as mentioned above can be solved.