SPRAY APPLICATING LINE AND ASSEMBLY FOR PRODUCING A COATED PART AND INCLUDING MULTIPLE OVERSPRAY AND RECAPTURE/RECYCLE CONFIGURATIONS
20180065135 ยท 2018-03-08
Inventors
Cpc classification
B05B14/44
PERFORMING OPERATIONS; TRANSPORTING
B05B16/20
PERFORMING OPERATIONS; TRANSPORTING
Y02P70/10
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B05B14/41
PERFORMING OPERATIONS; TRANSPORTING
B05B14/20
PERFORMING OPERATIONS; TRANSPORTING
B05B16/405
PERFORMING OPERATIONS; TRANSPORTING
B05B13/0457
PERFORMING OPERATIONS; TRANSPORTING
B05B14/465
PERFORMING OPERATIONS; TRANSPORTING
B05B14/48
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
An overspray spray capture structure integrated into a paint spray operation integrates at least one reception surface for receiving an overspray of the spray coating operation. The overspray is communicated through a merging location established between the receiving surfaces and adapted to being removed or recycled. The at least one reception surface further includes first and second oriented reception surfaces not limited to a pair of horizontal and vertical closed loop belt curtains which are traversable supported about a pair of spaced apart rotating shafts. The first and second reception surfaces can include traversing paper rolls for capturing the overspray therebetween at the merging location. Other variants include water curtain or vacuum removal assist assemblies for removing the overspray prior to it setting.
Claims
1. An overspray capture booth for use in a part spray coating operation, comprising: a structure integrating at least one reception surface for receiving an overspray of the spray coating operation; and the overspray being communicated through a merging location established between the receiving surfaces and adapted to being removed or recycled.
2. The invention as described in claim 1, said at least one reception surface further comprising first and second oriented reception surfaces
3. The invention as described in claim 2, said reception surfaces further comprising a pair of horizontal and vertical closed loop belt curtains which are traversable supported about a pair of spaced apart rotating shafts.
4. The invention as described in claim 3, said closed loop belt curtains further comprising a passageway interior through which is communicated a chilling fluid for cooling said overspray reception surfaces.
5. The invention as described in claim 4, further comprising a pair of knife blades in contact with said reception surfaces.
6. The invention as described in claim 4, said closed loop belt curtains further comprising pluralities of offset ribs extending within said passageway interior from opposing inner surfaces to facilitate event chilling fluid dispersal.
7. The invention as described in claim 1, said at least one reception surface further comprising a waterfall curtain.
8. The invention as described in claim 7, a collection reservoir located beneath said water curtain.
9. The invention as described in claim 8, further comprising a water pump and filtration system integrated into said structure and pumping a steady fluid flow to a supply manifold located above said waterfall curtain. 10, The invention as described in claim 1, further comprising first and second blowers arrayed at respective forward and upper edges thereof of said first and second reception surfaces, an air curtain created by said blowers in a direction towards the overspray merging location.
11. The invention as described in claim 10, further comprising a bottom end collection location within said structure for removing solid particulates from the collected overspray.
12. The invention as described in claim 10, further comprising a plurality of centrifugal force inducing tubes integrated into said structure and converting said blower induced air curtain into a cyclonic vacuum through said merging location.
13. The invention as described in claim 2, said first and second reception surfaces further comprising traversing paper rolls for capturing the overspray therebetween at said merging location.
14. The invention as described in claim 13, said paper rolls further comprising first and second feed rolls and a common take up roll.
15. A spray coating assembly, comprising: a closed loop overhead conveyor including an inlet location for acquiring, in succession, a plurality of inserts to be coated; a main conveyor portion extending in substantially circular fashion and passing a plurality of stations for coating the inserts; a plurality of individual branching locations extending from said main conveyor portion to each of said stations, said branching locations including each of inlet and exit locations for receiving selected inserts while permitting other inserts to pass along said main conveyor for delivery to succeeding stations; and an outlet location for removing the coated inserts.
16. The invention as described in claim 15, each of said coating stations further comprising a spray applicating robot and an elevated and overspray capture structure, between which is positioned the overhead conveyed insert.
17. The invention as described in claim 16, further comprising a first conveyor for transporting the inserts to said conveyor inlet and a second conveyor for removing the coated inserts from said conveyor outlet.
18. The invention as described in claim 15, further comprising an inspection/repair station located at said conveyor inlet, a secondary operations (branding or labeling) station located at said outlet.
19. The invention as described in claim 15, further comprising a two part plasticized mixture delivered to a central location of said coating stations and subsequently distributed to said individual stations.
20. The invention as described in claim 15, said overhead conveyor further comprising a plurality of hangers extending downwardly therefrom, and on/off robot positioned in proximity to each of said inlet and outlet conveyor locations for both acquiring and removing the inserts.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Reference will now be made to the attached drawings, when read in combination with the following detailed description, wherein like reference numerals refer to like parts throughout the several views, and in which:
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] As previously described, the present invention discloses a multi-station robotic spray applicating line and assembly. With particular reference to the attached and below described illustrations, the invention optimizes a variety of configurations of overspray retrieval station booths, these operating in combination with an overhead conveyor and numerically controlled spray applicating robot for recapturing any atomized plastic overspray and associated particulates, including vapors, resulting from the spray robot coating a part suspended in front of the spray booth station.
[0028] As is known, the spray coating of irregular shaped parts, examples of which include a wire harness 2 and a pallet 4 (see
[0029] Without limitation, the iso/poly mixture can also include any singular or multiple feed lines of material including any of a polyuria, polyurethane or other plasticized mixture, such further including any particulate/aggregate, any catalyst or other additive for providing desired properties to the coated article. The present invention further contemplates the ability to spray apply any known plasticized compositions as well as proprietary blends which provide desirable features in use with given inserts/parts, such as which can again include any type of furniture or other article of a suitable shape and size which can be traversed upon the suspended carousal (or otherwise supported) and which can be coated in any fashion envisioned which is consistent with the present description.
[0030] As further shown in
[0031] Without further elaboration, the individual spray robots 12-22 are of a known construction and include multi-articulating and/or rotating axes of motion which, in combination with a remote programmable processor/numerical controller (not shown) operates a spray applicating head associated with each NC robot in order to distribute the iso/poly spray mixture (see again at 10) upon the surface of a given part (see again at 2, 4, 6, et seq.). Advancing of the parts is further accomplished, in one non-limiting example depicted in the illustrated variant, by an overhead carousal which is constructed of a closed loop support hanger.
[0032] Further depicted in
[0033] Additional features include a first infeed conveyor 60 upon which are conveyed the uncoated parts 6 (or blanks). A checking or repair station 62 is depicted at the inlet location and at which the precoated inserts or blanks can be inspected and any blemishes repaired prior to the overhead conveyor distributing the same to the several sub-stations.
[0034] A plurality of hooks 64, 66, 68, et seq., are depicted extending downwardly from the main overhead conveyor and, in combination with a suitable lift or acquiring mechanism. This is further depicted by a lift on/lift off robot 69 which is positioned in proximity to each of the inlet 54 and outlet 58 locations and which is further rotatable to sequentially place uncoated inserts from the inlet conveyor 60 onto the overhead carousal at a first location and to remove completed spray coated inserts at the outlet 58 for placement upon an outlet conveyor (see as further described below at 96).
[0035] In this fashion, the robot 69 operates initially to elevate or position the individual inserts 6 so that they are suspended in successively fed fashion upon the hooks in the manner shown. The conveyor is further understood to integrate any suitable belt or chain feed (not shown), such operating to advance each succeeding in-fed insert 6 to a spray coat substation (this further defined by a spray robot and opposing positioned and corresponding overspray capture booths 70, 72, 74, 76, 78 and 80).
[0036] As further shown in
[0037] The chain drive integrated into the overhead carousal is further configured in order to extend throughout the main conveyor 56 and the associated branching sections 82-92, with the understanding that an associated controller can be provided for directing the inserts to each station, such as in combination with directional switching tracks integrated into the inlet end of each branch and so that, upon a selected uncoated insert being delivered from the main conveyor 56, the inlet is switch to permit successive inserts to traverse past and for delivery to the downstream located stations.
[0038] Upon completion of a coating operation at any of the branching stations, the coated insert is thence shuttled back onto the main conveyor 56 for traversing around and past the succeeding located stations (again via the track at each branching inlet being switched to the desired position). Upon the coated inserts reaching the outlet location 58 of the carousal, a secondary operation station is located for likewise inspecting/remedying any issues with the now coated inserts (see at 6). Such outlet end secondary operations can also include applying any desired labeling, stamping or branding to the completed parts, following which these are in succession removed from the overhead conveyor at the outlet and deposited upon the removal conveyor 96.
[0039] Beyond the examples of inserts or articles, 2, 4, 6 et seq., illustrated, it is further understood that any other insert or article can be provided to be spray coated, such including any of an encapsulating wood, bamboo, composite, metal, foam, furniture, pallet or other article, and such as further which can be applied to any of a cardboard material, including a rigid paperboard and/or honeycomb construction. As further previously described, any type of insert or part can be spray coated, not limited to the pallet, wire harness or furniture examples depicted herein. To this end, the associated programming of a given software code or command sequence for directing the motion and angle of application of the spray applicating head of each articulating robot assembly, such also envisioned the ability to adjust the pattern of spray (wide versus narrow) and in the attempt to maximize the percentage of spray being applied to the unique configuration of the part or insert
[0040] The above stated, it is further understood that, all efforts to the contrary, a (typically small) percentage of the applied spray will inevitably result as an overspray which misses the part and which will need to captured and removed. This percentage of overspray can often range from 1-2% upwards, depending upon the complexity of the part being coated, in response to which the present invention illustrates a series of overspray capture station booth configurations (such as again initially provided at 70-80 in the initial variant of
[0041] The overspray capture booths each, as shown, exhibit a three dimensional body within which is configured a recessed forward facing surface volume (this opposing the articulating robot spray nozzle with the insert positioned therebetween). A pair of widened and closed loop conveyor belts are integrated into each of the overspray booths and include a first lower horizontal positioned belt 98 and a second rear end and vertically extending belt 100 (see as further shown in
[0042] As further shown in successive
[0043]
[0044] Each of the closed loop conveyors 98/100 further includes a pair of opposite end supported rollers, see at 114/116 for conveyor 98 and further at 118/120 for conveyor 100. A closed loop open interior of the conveyor supported belts is further configured to be accessed by inlet and outlet fluid ports (see in/out ports 122/124 for belt 98 and further in/out ports 126/128 for belt 100).
[0045] Conduits (see at 125 and 127) extend to/from the ports and which circulate, on an inlet side, a gas such as a liquid nitrogen (see tank at 129 designated as LN.sub.2) for chilling the belts, such as in order to provide the exterior surfaces of the belts with a cold capture surface and in order to prevent drying or curing of overspray splatter 10 adhering to the surfaces of the belts 98/100 as there are driven/conveyed rearwardly. This is further represented by horizontal arrow 130 in
[0046] Although not shown, the overspray and associated particles 10 drop off the rear interior of the housing at the merging location of the belts 98/100 and are collected in a separate bin or conveyed to a further recycling area. In combination, the vacuum blower 102 may additionally withdraw associated vapors, microscopic sized particles and the like for filtering and venting.
[0047] Additional conduits are connected to selected outlet ports 124 and 128 of the belts and, in combination with the inlet ports 122 and 126, provide for continuous circulation of the desired chilling fluid to prevent premature curing of the overspray splatter upon the surface of the collecting/conveying belts 98/100. The present invention further contemplates the use of any other environmentally conditioning fluid or application to the belt surfaces, such including heating, cooling or modulating other physical characteristics thereof in order to retard the drying and curing of the overspray 10 until collected and removed in the manner described.
[0048]
[0049] The construction of the continuous and closed loop belts 98/100 can include any of a rubber, plastic, metal or any flexible composite. The scraping edge positioned knife edge blades 110 and 112 can further be supported within the station booth interiors in such a fashion that they may be tensioned or biased into an adequate surface contact with their respective belts, such occurring without damaging the belts or prematurely wearing down of the sharpened blade edges.
[0050] Proceeding to
[0051] As further depicted in the rotated rear perspective and partial cutaway of
[0052] In order to maintain the continuous water curtain flow, an outlet/elevating side of the fluid pump 146 includes any plurality of upwardly extending fluid conduits (these depicted by conduits 150, 152 and 154) which upwardly feed fluid to an additional reservoir 155 established by an upper and horizontal length extending manifold 156, into which the conduits 150-154 empty. The forward and vertically extending collection face of the curtain 140 can include any fixed/rigid or flexible material including again a polymer or even a nylon, Teflon or other non-adhering consistency and which, in combination with the continuous downward water cascade along its forward face, causes any plastic overspray and particles to be captured and quickly descended into the lower reservoir, 144, following which the same is filtered, removed and/or recycled in the manner described.
[0053] Proceeding to
[0054] Unlike the belt driven and liquid nitrogen chilled curtains of the previous embodiment, the air curtains can include any type of solid or weave material and it is further envisioned that the curtains can also be constructed as closed and traversable belts supported upon end rollers and traversable along inward 168 and downward 170 directions which are consistent with the travel of the overspray and associated particulates for collection within the interior of the booth 158. A width extending gap 172 (see again
[0055] As best shown in
[0056] Finally,
[0057] As best shown in
[0058] As depicted in the preceding embodiments, a suitable blower and/or vacuum retrieval architecture can be built into the overspray housing to assist the advancing paper curtains in the retrieval, removal or recycling of the plastic overspray and spray particulates or other contaminants. The ability to capture the overspray and particulates in sandwiched fashion between the opposing adhering surfaces of the paper curtains at the take up roll 200 further provides for ease of disposal or recycling.
[0059] Further, and as with any of the other embodiments described herein, the paper curtains can be operated/advanced continuously concurrent with the ongoing part spraying/advancing operation or can be iteratively advanced following each discrete spray coating operation. Additionally, and while referencing the various orientation of the various curtain or overspray reception surfaces as being vertical and horizontal, it is further understood and envisioned that such can be oriented in any angled or offset fashion consistent with the pattern of overspray and associated particulates.
[0060] Having described my invention, other and additional preferred embodiments will become apparent to those skilled in the art to which it pertains, and without deviating from the scope of the appended claims.