DEVICE AND SYSTEM FOR TRANSPORTING A PLURALITY OF PARTS TO BE TREATED THROUGH AN APPARATUS FOR WET-CHEMICAL TREATMENT

Abstract

A device for transporting parts through an apparatus for wet-chemical treatment includes a transporter including at least one runner for supporting the transporter for movement along a track in a first direction (x). At least part of the transporter is located next to the runners, seen in a second direction (y) transverse to the first direction (x). This part extends from a level below the runners to a level above the runners in a third direction (z) transverse to the first and second directions (x,y). The device further includes a container for accommodating the parts and a frame at least indirectly connecting the container to the transporter to allow the transporter to carry the container below the runners. The container is liquid-pervious between the axial ends to allow liquid to flood the interior when the container is immersed in the liquid.

Claims

1. Device for transporting a plurality of parts to be treated through an apparatus for wet-chemical treatment, the device comprising: a transporter (16), comprising at least one runner (39a,b,40a,b) for supporting the transporter (16) for movement along at least one track (5a,b) in a first direction (x), wherein at least part of the transporter (16) is located next to the runners (39a,b,40a,b), seen in a second direction (y) transverse to the first direction (x), and wherein this part extends from a level below the runners (39a,b,40a,b) to a level above the runners (39a,b,40a,b) in a third direction (z) transverse to the first and second directions (x,y); a container (14) having an interior for accommodating the plurality of parts; and a frame (15), at least indirectly connecting the container (14) to the transporter (16) to allow the transporter (16) to carry the container (14) at a level below the runners (39a,b,40a,b), wherein the frame (15) comprises a respective frame part (23a,b) at at least one of opposite axial ends of the container (14) with respect to an axis (18) of the container (14), wherein the container (14) is liquid-pervious between the axial ends to allow liquid to flood the interior when the container (14) is immersed in the liquid, wherein the axis (18) of the container (14) extends in a direction (x) transverse to the second and third directions (y,z), wherein the device further comprises a mechanism (32a,b,33a-d) for guiding movement of at least one of the frame (15) and the container (14) in the third direction (z) relative to the transporter (16), wherein the mechanism comprises at least one elongate part (32a,b) of the frame (15) and at least one respective bearing (33a-d) for guiding movement of the elongate part of the frame (15) through or next to the transporter (16).

2. Device according to claim 1, wherein the runners (39a,b,40a,b) comprise at least one first runner (39a,40a) and at least one second runner (39b,40b), wherein the first runners (39a,40a) and second runners (39b,40b) are arranged for movingly supporting the transporter (16) along first tracks (5a) and second tracks (5b), respectively, and wherein the first runners (39a,40a) are positioned at a distance in the second direction (y) to the second runners (39b,40b).

3. Device according to claim 1, comprising at least one drive (25,31,41) and at least one controller (30) for controlling operation of at least one of the at least one drives (25,31,41).

4. Device according to claim 3, comprising a data storage device (47) for storing instructions defining a series of operations effected by operating at least one of the at least one drives (25,31,41) at at least one processing station in the apparatus for wet-chemical treatment, wherein at least one of the at least one controllers (30) is arranged to access the data storage device (47) to obtain and give effect to the instructions.

5. Device according to claim 1, further comprising at least one contact shoe assembly (29) for contacting a live rail (13) extending along at least one of the tracks (5a,b).

6. Device according to claim 1, wherein the frame (15) is provided with at least one first electrical contact (35) at a distal position with respect to the container (14), seen in the third direction (z), and with a conductor (34) from the first electrical contact (35) to at least one electrode (20) arranged within the container (14), wherein the first electrical contact (35) is positioned to move towards the transporter (16) when the container (14) moves away from the transporter (16), and wherein the transporter (16) is provided with a second electrical contact (36a,b), arranged to contact the first electrical contact (35) at a limit of movement of the container (14) away from the transporter (16).

7. Device according to claim 1, wherein the container (14) is a barrel journalled to the frame (15) for rotation about the axis (18).

8. Device according to claim 7, further comprising at least one transmission mechanism (26) for transmitting rotary movement from a barrel drive (25) to the container (14).

9. Device according to claim 8, further comprising the barrel drive (25).

10. Device according to claim 1, wherein the device further comprises a drive for driving the device in the first direction and/or a mechanism for guiding movement of at least one of the frame and the container in the third direction relative to the transporter and a drive for driving the movement in at least one of the third direction and a direction opposite to the third direction, and wherein the barrel drive is independent of the other drives.

11. System for transporting a plurality of parts to be treated through an apparatus for wet-chemical treatment, comprising: a frame (3) supporting at least one track (5a,b); and at least one device (2a-d) according to claim 1.

12. System according to claim 11, wherein each track (5a,b) is provided by an elongate bar (4a,b), wherein the frame (3) comprises at least one upright post (9a-d), each arranged to support at least one of the bars (4a,b), and wherein connections between the bars (4a,b) and the upright posts (9a-d) are completely below a level of a top of the bar (4a,b).

13. Apparatus for wet-chemical treatment of a plurality of parts, including at least one tank (7a-c) for forming a bath, and a system according to claim 11 for transporting the plurality of parts through the apparatus.

14. Method of transporting a plurality of parts to be treated through an apparatus for wet-chemical treatment, wherein the plurality of parts are accommodated in a container (14) of a device (2a-d) according to claim 1 and the device (2a-d) is moved on the at least one track (5a,b) through the apparatus.

15. Method according to claim 14 wherein the device is provided with at least one drive for driving at least one of the device and a component of the device and at least one controller for controlling at least one of the drives further comprises providing instructions to the controller during movement of the device through the apparatus.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0094] The invention will be explained in further detail with reference to the accompanying drawings, in which:

[0095] FIG. 1 is a perspective view of parts of a segment of a treatment line of an apparatus for wet-chemical treatment of loose parts, shown in combination with four product carriers arranged to move the parts through the apparatus;

[0096] FIG. 2 is a perspective view of the segment with only one product carrier present;

[0097] FIG. 3 is a top view of the segment and product carrier of FIG. 2, with certain parts of processing station removed;

[0098] FIG. 4 is a side view of the segment and product carriers of FIGS. 2 and 3 with the same parts of the processing stations removed.

[0099] FIG. 5 is a top view of the segment in the configuration of FIGS. 2-4 without the product carrier;

[0100] FIG. 6 is a perspective view of the product carrier;

[0101] FIG. 7 is a first side view of the product carrier;

[0102] FIG. 8 is a second side view of the product carrier;

[0103] FIG. 9 is a first detailed perspective view of part of the product carrier;

[0104] FIG. 10 is a second detailed perspective view of part of the product carrier;

[0105] FIG. 11 is a third detailed perspective view of part of the product carrier;

[0106] FIG. 12 is a fourth detailed perspective view of part of the product carrier, with certain housing parts removed;

[0107] FIG. 13 is a front view of part of the product carrier with certain housing parts removed;

[0108] FIG. 14 is a detailed view of a mechanism for guiding movement of a frame for connecting a barrel of the product carrier to a transporter comprised in the product carrier;

[0109] FIG. 15 is a detailed view of the transporter with certain parts removed to show supporting wheels of the transporter;

[0110] FIG. 16 is a perspective view of the frame and the barrel;

[0111] FIG. 17 is a front view of the barrel and part of the frame with a peripheral wall of the barrel removed; and

[0112] FIG. 18 is a schematic block diagram illustrating components for controlling the operation of the product carrier.

DESCRIPTION OF EMBODIMENTS

[0113] An apparatus for wet-chemical treatment of loose parts (not shown) is built up out of apparatus segments 1, one of which is shown (FIGS. 1 and 2). Pumps, pipes and cabling have been removed for clarity. The apparatus comprises a system for transporting the parts to be treated through the apparatus. This system is also built up out of stationary segments and further includes a plurality of product carriers 2a-d. Within each segment, the system comprises a system frame 3 and a pair of elongate bars 4a,b defining tracks 5a,b along and on which the product carriers 2a-d are arranged to move. In the illustrated embodiment, the bars 4a,b are extruded profiles having a quadrilateral cross-section. In other embodiments, rails may be used instead of bars 4a,b. The quadrilateral shape allows for side surfaces of the bars 4a,b to perform a guidance function, as will be explained. The bars 4a,b have end faces 6a-d (FIGS. 3 and 5) at an angle to their longitudinal axes. This allows for smoother transitions between the apparatus segments 1. The angle may between 20° and 70°, e.g. between 40° and 50°, for example.

[0114] In the illustrated example, the apparatus segment 1 further comprises three tanks 7a-c for accommodating liquid in which the parts to be treated are immersible. One or more processing stations are defined in each tank 7a-c. In a method of operating the apparatus, processing is synchronised, in that a fixed unit of processing time is defined. Each product carrier 2 remains at a processing station for one unit of processing time or a multiple of the unit of processing time. An effect of this synchronised method of processing is that there is less risk of collision between the product carriers 2a-d. It is, however, noted that product carriers 2a-d may skip processing stations or even tanks 7a-c as they move through the apparatus. In an embodiment, a product carrier 2 stays at a first position above one of the tanks 7a-c for a first unit of time, then moves to a second position above that tank 7a-c and remains at the second position for a second unit of time. The parts to be treated remain immersed in the liquid in the tank 7a-c during movement from the first position to the second position, so that treatment can essentially continue.

[0115] It is convenient to define a first direction x as a direction of movement of the product carriers 2a-d through the apparatus segment 1. This direction x is parallel to the longitudinal axes of the tracks 5a,b. A second direction y is transverse to the first direction in the plane of movement. A third direction z is transverse to the first and second directions x,y. With the system frame 3 in place on a supporting surface, the third direction z is parallel to the vertical. The dimensions of the apparatus segment 1 or at least the system segment are such that the segment fits into a standard intermodal container in assembled state, in the absence of the product carriers 2a-d. This imposes limits on the dimensions of the system segment or apparatus segment 1 in the first and second directions x,y.

[0116] Each product carrier 2 is supported on the tracks 5a,b such as to be positioned adjacent and between the tracks 5a,b. The product carrier 2 extends in the third direction z from below the level of the tracks 5a,b to above the level of the tracks 5a,b when in place on the tracks 5a,b. This is possible, because the system frame 3 leaves the area above a space 8 (FIGS. 3 and 5) between the tracks 5a,b free of obstructions. Instead, the system frame 3 comprises at least two upright posts 9a-d at each of at least one location in the first direction x, on top of which a pair of cross-bars 10a-d are supported. Ends of the cross-bars 10a,b are spaced apart and located on either side of the space 8. Each cross-bar 10 of a pair supports one of the bars 4a,b defining a respective track 5a,b from below. Struts 11a,b (FIG. 4) are also provided below the level of the tracks 5a,b, i.e. below the level of the top of the bars 4a,b.

[0117] The system frame 3 supports a high-voltage live rail 12 and a low-voltage live rail 13 (FIG. 5). A power supply system (not shown in detail) maintains the low-voltage live rail 13 at an Extra Low Voltage, meaning a voltage below 50 V, e.g. 24 V. The high-voltage live rail 12 is arranged to supply electrical power at a higher voltage and to support currents necessary for electrolytic processing, in particular electroplating. The current may have a value up to 500 A.

[0118] The product carrier 2 comprises a barrel 14, a barrel holding frame 15 and a transporter 16.

[0119] The barrel 14 forms a container of which the interior is arranged to accommodate the parts to be treated. The barrel 14 comprises opposing end walls 17a,b, located at opposite axial ends with respect to a barrel axis 18 (FIG. 17) corresponding to a body axis of the barrel 14. The barrel 14 further comprises a side wall 19, which may be generally cylindrical but need not be circle-cylindrical. Indeed, in the illustrated example, the barrel side wall 19 is comprised of panels. One or more of the panels of the barrel side wall 19 can be removed to insert and remove the parts to be treated.

[0120] The barrel side wall 19 comprises perforated panels rending the barrel side wall 19 pervious to liquid. When the barrel 14 is immersed in liquid in one of the tanks 7a-c, the liquid can flood the interior of the barrel 14 through the perforations. In the illustrated example, the barrel end walls 17a,b are impervious to liquid, but this is not essential.

[0121] A dangler electrode 20 (FIG. 17) extends into the barrel 14 for electrically contacting parts to be treated that are accommodated in the interior of the barrel 14.

[0122] The barrel axis 18 has an orientation that is approximately or exactly parallel to the first direction x, in use.

[0123] The barrel 14 is held by a barrel holding frame 15 comprising an, in use, lower frame section 21 and an upper frame section 22 (FIGS. 16 and 17). The lower frame section 21 comprises two frame parts 23a,b, located at opposite axial ends of the barrel 14. The barrel 14 is held between the two frame parts 23a,b. An interconnecting frame part 24 interconnects the two frame parts 23a,b and connects them to the upper frame section 22. The extent of the upper frame section 22 in the first direction x is much smaller than that of the lower frame section 21.

[0124] In the illustrated embodiment, the barrel 14 is rotatably journalled to the frame parts 23a,b. The parts to be treated are loosely arranged in the interior of the barrel 14. Rotating the barrel 14 during treatment allows for a more uniform treatment of the parts, because tumbling the parts to be treated exposes different areas of these parts to the liquid.

[0125] In contrast to product carriers commonly used in plating apparatus, the barrel 14, although movable with respect to the barrel holding frame 15, is inseparable from the barrel holding frame 15. In turn, the barrel holding frame 15, although movable with respect to the transporter 16, is inseparable from the transporter 16. The product carrier 2 thus forms a unit. As a consequence, the product carrier 2 remains with the parts to be treated throughout the treatment process. This means that devices for receiving the barrel 14 are not required at the processing stations. The transporter 16 need not move back and forth to collect the barrel 14. In a synchronised method of processing, the unit of time can be smaller.

[0126] Drives for rotating the barrel 14 are not required at the processing station either. Instead, the barrel holding frame 15 has an electrical motor forming a barrel drive 25 (FIGS. 16, 17) mounted thereto. The barrel drive 25 is connected to the barrel 14 via a gear train 26, in this case comprising three gear wheels 27a-c rotatably mounted to one of the frame parts 23a,b. The gear wheels 27a-c may be made of plastic or ceramic material, for example. The gear train 26 provides for separation in the third direction z between the barrel 14 and the barrel drive 25. A cable carrier 28 (FIG. 14) is arranged to protect one or more electrical cables for supplying power to the barrel drive 25. The power is obtained from the low-voltage live rail 13 via a first shoe assembly 29 supported by the transporter 16.

[0127] A controller 30 (FIG. 18) controls the operation of the barrel drive 25. The operation of the barrel drive 25 is controllable independently of other drives that the product carrier 2 comprises. In particular, the barrel 14 may be rotated whilst immersed in processing liquid, but also whilst suspended above one of the tanks 7a-c, in order to shake off processing liquid. The movement may be reciprocating movement. The term controller is used herein in a functional sense: such a controller will generally comprise at least one microprocessor and memory.

[0128] The tracks 5a,b are at one level in the third direction z within the system segment. So as not to have to provide devices at each processing station for raising and lowering the barrel 14, the product carrier 2 comprises a lifting drive 31 (FIGS. 13, 14) for driving movement of the barrel 14 relative to the transporter 16 in the third direction z. In the illustrated embodiment, the barrel holding frame 15 is arranged to move with the barrel 14 in the third direction z and the opposite direction. In other embodiments, the barrel holding frame 15 may remain partly or completely stationary with respect to the transporter 16, with the barrel 14 moving with respect to the barrel holding frame 15. However, this alternative embodiment is more complicated. The illustrated embodiment also allows the product carrier 2 to clear obstacles such as walls of the tanks 7a-c more easily. Because the upper frame section 22 is relatively narrow, the upper frame section 22 can pass through the transporter 16 relatively easily. The lower frame section 21 remains below the transporter 16 at all times.

[0129] In the illustrated embodiment, the upper frame section 22 comprises a pair of guide shafts 32a,b that pass through linear bearings 33a-d (FIG. 14) fixedly mounted to the transporter 16. Two aligned linear bearings 33a-d are provided for each guide shaft 32a,b in the illustrated embodiment. The guide shafts 32a,b extend substantially in parallel to the third direction z.

[0130] A current-carrying bar 34 (FIGS. 13, 14, 16, 17) extends between the guide shafts 32a,b. The current-carrying bar 34 is bent at an end distal to the barrel 14 to define a contact point 35 (FIGS. 13, 16) . The current-carrying bar 34 is connected to the dangler electrode 20 at an end of the current-carrying bar 34 proximal to the barrel 14. When the barrel-holding frame 15 is in a position at an end of a range of movement at which the barrel 14 is furthest apart from the transporter 16, the contact point 35 makes electrical contact with electrical contacts 36a,b mounted on the transporter 16 to supply current to the dangler electrode 20. In other positions of the barrel-holding frame 15 the power supply to the dangler electrode 20 is consequently interrupted. The current-carrying bar 34 may be a solid structure made of electrically conductive material, e.g. copper or a copper alloy. Alternatively, the current-carrying bar 34 may comprise a shielding in which a conductor is provided, the shielding leaving only the contact point 35 exposed.

[0131] A second shoe assembly 37 is mounted on the transporter 16. The second shoe assembly 37 is arranged to contact the high-voltage live rail 12 and is electrically connected to the electrical contacts 36a,b mounted on the transporter 16.

[0132] The transporter 16 comprises a base 38 on which are mounted the various transporter components referred to above.

[0133] A pair of driven wheels 39a,b and a pair of further supporting wheels 40a,b are rotatably mounted to the transporter base 38. These four wheels 39a,b,40a,b are arranged to support the transporter 16, and thus the product carrier 2, on the tracks 5a,b. A first set of two wheels 39a,40a is supported on a first track 5a and a second set of two wheels 39b,40b is supported on a second track 5b. The transporter 16 extends between the first set and the second set, which sets are spaced apart in the second direction y. The upper frame section 22 of the barrel holding frame 15 is movable in the third direction z in between the first and the second sets of supporting wheels 39a,b,40a,b

[0134] A transporter drive 41 comprises an electric motor coupled to a transmission 42 (FIG. 12) for driving drive axles 43a,b on which the driven wheels 39a,b are mounted. The controller 30 also controls the operation of the transporter drive 41.

[0135] The further supporting wheels 40a,b are arranged on axles 44a,b (FIG. 15) as well. The axes of rotation defined by the orientation of the axles 43a,b,44a,b extend essentially in the second direction y, transverse to the first direction x and lie in a common plane transverse to the third direction z.

[0136] Guide wheels 45a-c (FIGS. 12, 15) are arranged to rotate about axes aligned or approximately aligned with the third direction z. These guide wheels 45a-c are arranged to contact respective opposite lateral surfaces of the bars 4a,b when the supporting wheels 39a,b,40a,b are positioned on the tracks 5a,b. In this manner, the product carrier 2 is positioned more accurately.

[0137] Thus, the wheels 39a,b,40a,b form runners arranged to support the product carrier 2 on at least one track 5a,b such as to allow the product carrier 2 to move in the first direction x, this direction being defined by the configuration, in particular the orientation, of the runners. The guide wheels 45a-c form runners arranged to guide movement of the product carrier 2 along the at least one track 5a,b in the first direction x. These support and guidance functions may be combined in alternative embodiments, e.g. in an embodiment employing sledges arranged to slide along a track instead of wheels.

[0138] The controller 30 and other electronic and electrical parts may be housed in a cabinet 46 situated above a level of the transporter base 38, for example.

[0139] The controller 30 is able to access a non-volatile data storage device 47 (FIG. 18) to retrieve instructions defining at least one of a route and a series of operations in the apparatus for wet-chemical processing of parts to be treated. These instructions may in particular identify the processing stations at which the product carrier 2 is to stop and immerse the barrel 14 in processing liquid. They may include a definition of the length of time for which the barrel 14 is to remain immersed. In an embodiment in which the treatment is synchronised, this time period may be defined in terms of a multiple of the unit of time used to synchronise the operation of the multiple product carriers 2a,b. The instructions may further define whether the barrel 14 is to be rotated when immersed and/or when in transit. Where multiple processing stations are defined for one tank 7a-c, the instructions may cause the product carrier 2 to move from a position associated with a first processing station to a position associated with a second, different processing station whilst keeping the barrel 14 immersed in the processing liquid contained in the tank 7a-c.

[0140] A sensor interface 48 to one or more sensor devices 49 is provided to enable the controller 30 to control operations or parts of operations autonomously, i.e. independently of a central control system of the apparatus for wet-chemical processing. Such sensors may include, for example, photoelectric sensors for detecting light emitted or reflected by beacons (not shown) positioned along the tracks 5a,b, magnetic sensors for detecting magnetic beacons (not shown) positioned along the tracks 5a,b, feelers deflected by beacons positioned along the tracks 5a,b, one or more motion sensors (accelerometers) or rotation sensors for implementing dead reckoning, etc.

[0141] In the illustrated embodiment, data can also be obtained through a network communication interface 50. This can include the data stored in the data storage device 47, thus allowing the product carrier 2 to be reprogrammed with a different series of operations and/or a different route. The data can also include control commands directly affecting the operation of one or more of the drives 25,31,41. Thus, it is also or alternatively possible to control the operation of the multiple product carriers 2a-d centrally. Furthermore, the product carrier 2 can communicate error messages to a central control system, for example. The same or a further network communication interface 50 can also or alternatively be used to enable the product carriers 2a-d to communicate amongst each other. This can be of use in avoiding collisions, for example. The network communication interface 50 may in particular be a wireless network communication interface 50. The wireless network communication interface 50 may be in accordance with one or more of the IEEE 802.11 standards, for example.

[0142] Regardless of how movement of the product carrier 2 is controlled, this movement is in a direction aligned or approximately aligned with the barrel axis 18. The frame parts 23a,b therefore do not add to the extent of the product carrier 2 in the second direction y, that is to say the width of the product carrier 2. This in turn allows the tanks 7a-c, and therefore also the system frame 3, to be narrower. At least the system frame 3, potentially also a large part or all of the apparatus segment 1, can be pre-assembled and tested at a factory operated by the equipment supplier. Disassembly for shipping to the site where the apparatus will be deployed is not necessary, since the entire segment 1 or at least the system frame 3 is compact enough to fit into a standard intermodal container. The product carriers 2a-d can be shipped separately, so that the fact that they extend in the third direction z above the top of the tracks 5a,b, in use, does not matter for shipping purposes. Because the product carriers 2a-d are placed on top and move above the tanks 7a-c, the system frame 3 need not support the tracks 5a,b adjacent the tanks 7a-c. Furthermore, safety is improved, because the product carriers 2a-d will move above the level at which operating personnel is likely to be present. This saves on cages and other shielding measures.

[0143] The invention is not limited to the embodiment described above, which may be varied within the scope of the accompanying claims. For example, the high-voltage live rail 12 may be interrupted in sections where processing stations are defined that are not arranged for effecting electrolytic treatment of the parts to be treated. Operations that may be carried out in the apparatus for wet-processing included one or more of: (chemical) degreasing, electrolytic degreasing, rinsing, pickling, brightening and passivation, as well as electroplating to deposit, for example, a zinc or zinc alloy coating. The product carrier 2 may be provided with a central controller in addition to separate controllers for the transporter drive 41, barrel drive 25 and lifting drive 31, with the central controller controlling and co-ordinating between the separate controllers for the drives 25,31,41.

TABLE-US-00001 List of reference numerals 1 - apparatus segment 2a-d - product carrier 3 - system frame 4a,b - bars 5a,b - tracks 6a-d - bar end faces 7a-c - tanks 8 - space between bars 9a-d - upright posts 10a-d - cross-bars 11a,b - struts 12 - high-voltage live rail 13 - low-voltage live rail 14 - barrel 15 - barrel holding frame 16 - transporter 17a,b - barrel end walls 18 - barrel axis 19 - barrel side wall 20 - dangler electrode 21 - lower frame section 22 - upper frame section 23a,b - frame parts 24 - interconnecting frame part 25 - barrel drive 26 - gear train 27a-c - gear wheels 28 - cable carrier 29 - first shoe assembly 30 - controller 31 - lifting drive 32a,b - guide shafts 33a-d - linear bearings 34 - current-carrying bar 35 - contact point 36a,b - electrical contacts 37 - second shoe assembly 38 - transporter base 39a,b - driven wheels 40a,b - further supporting wheels 41 - transporter drive 42 - transmission 43a,b - drive axles 44a,b - further supporting wheel axles 45a-c - guide wheels 46 - cabinet 47 - data storage device 48 - sensor interface 49 - sensor device 50 - network communication interface