CA1320826C - Electrostatic spray coating apparatus for applying two component mixture - Google Patents
Electrostatic spray coating apparatus for applying two component mixtureInfo
- Publication number
- CA1320826C CA1320826C CA000614312A CA614312A CA1320826C CA 1320826 C CA1320826 C CA 1320826C CA 000614312 A CA000614312 A CA 000614312A CA 614312 A CA614312 A CA 614312A CA 1320826 C CA1320826 C CA 1320826C
- Authority
- CA
- Canada
- Prior art keywords
- set forth
- further characterized
- motor
- components
- applicator
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B5/00—Electrostatic spraying apparatus; Spraying apparatus with means for charging the spray electrically; Apparatus for spraying liquids or other fluent materials by other electric means
- B05B5/16—Arrangements for supplying liquids or other fluent material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B12/00—Arrangements for controlling delivery; Arrangements for controlling the spray area
- B05B12/14—Arrangements for controlling delivery; Arrangements for controlling the spray area for supplying a selected one of a plurality of liquids or other fluent materials or several in selected proportions to a spray apparatus, e.g. to a single spray outlet
- B05B12/1418—Arrangements for controlling delivery; Arrangements for controlling the spray area for supplying a selected one of a plurality of liquids or other fluent materials or several in selected proportions to a spray apparatus, e.g. to a single spray outlet for supplying several liquids or other fluent materials in selected proportions to a single spray outlet
Abstract
ELECTROSTATIC SPRAY COATING
APPARATUS FOR APPLYING TWO COMPONENT MIXTURE
ABSTRACT OF THE DISCLOSURE
A spray coating apparatus (10) for applying a paint composed of a controlled mixture of two liquid components. A first gear pump (32) is disposed in a spray booth (30) and pumps the first component to an applicator (14). A second gear pump (36) in the spray booth (30) pumps the second component to the applicator (14). A manifold (44) is disposed between the two gear pumps (32, 36) and the applicator (14) for mixing the two paint components.
A variable speed motor (16, 20) controls the rate of fluid pumped by each of the gear pumps (32, 36).
Each motor (16, 20) includes an encoder (27, 29) sending feedback signals to an adjustor module (24) which compares the instantaneous speed of each motor (16, 20) with a reference speed, then adjusts the instantaneous speed of each motor (16, 20) to conform with the reference speeds thereby adjusting the ratio between the volumetric flow rates of the first and second components with respect to a reference ratio.
APPARATUS FOR APPLYING TWO COMPONENT MIXTURE
ABSTRACT OF THE DISCLOSURE
A spray coating apparatus (10) for applying a paint composed of a controlled mixture of two liquid components. A first gear pump (32) is disposed in a spray booth (30) and pumps the first component to an applicator (14). A second gear pump (36) in the spray booth (30) pumps the second component to the applicator (14). A manifold (44) is disposed between the two gear pumps (32, 36) and the applicator (14) for mixing the two paint components.
A variable speed motor (16, 20) controls the rate of fluid pumped by each of the gear pumps (32, 36).
Each motor (16, 20) includes an encoder (27, 29) sending feedback signals to an adjustor module (24) which compares the instantaneous speed of each motor (16, 20) with a reference speed, then adjusts the instantaneous speed of each motor (16, 20) to conform with the reference speeds thereby adjusting the ratio between the volumetric flow rates of the first and second components with respect to a reference ratio.
Description
E~CTRO8TA~IC P~Y COATING
APPARAT~ FOR APPLYING ~WO COMPON~NT MXXTURB
TECHNICAL FIELD
The subject invention relates to electrostatic spray coating apparatuses, and more particularly to an apparatus for applying a coating material composed of a controlled mixture o~ at least two liquid components.
BACKGROUND ART
Electrostatic spray coating apparatuses are typically supplied with a fluid which is electrically charged either before or after atomization, then applied to an electrically yrounded workpart~
In non-electrostatic coating applications, coating materials composed of a mixture of two components have been found to provide superior results. The two component coating materials, typically, comprise a paint component and a hardener component which are thoroughly mixed together at a predetermined optimum ratio to provide a fast-drying, hard material.
There are generally two reasons why two component coating materials are considered nonadaptable to the electrostatic spray coating art.
The first is that, because two component materials harden very fast when mixed at the proper proportions, they cannot be mixed together until just prior to application. Therefore, the mixing must take place within the spray booth at a location proximately upstream of the applicator. This ' .
requirement leads to the second, and more basic, reason why two component systems are rare in the electrostatic spray coating art. Namely, the two components must be mixed together at very precise proportions in order to achieve their advantageous results over single component materials. Even minute variations from the optimum mixing ratios can result in serious coating flaws, e.g., inability to harden, cracking, peeling, etc.
The prior art Behr Industrieanlaegen Audi 001~ spray coating apparatus mixes two paint components prior to application. This system employs two 5-phase 60 volt DC stepper motors to drive separate gear pumps through a 3:1 gearbox. Proximity sensors are used to sense motor speed.
SUMMARY OF THE INVENTION AND ADVANTAGES
The subject invention provides a spray coating apparatus of the type for applying a coating material composed of a controlled mixture of at least two liquid components onto a workpart. The apparatus comprises a first pump means for pumping an adjustable volumetric flow rate of the first component to an applicator. The first pump me~ns includes a first motor having an adjustable speed for controlling the rata of fluid pumped by the first pump means and providing feedback signals in response to the instantaneous speed thereof. A second pump means is provided for pumping an ad~usting volumetric flow rate of the second component to the applicator.
The second pump means includes a second motor having an adjustable speed for controlling the rata of fluid pumped by the second pump mPans and providing feedback signals in response to the instantaneous speed thereof. A motor drive means is responsive to input signals including reference speed signals for individually controlling the speeds of the first and second motors. The su~ject invention is characteri~ed by including an automatic adjustor maans responsive to the feedback signals from the first and second motors for comparing the instantaneous speeds of the first and second motors with the reference speeds and individually adjusting the speeds of the first and second motors in conformity with the reference speeds to continually adjust the ratio between the volumetric flow rates of the first and second components with respect to a reference ratio.
The subject invention also contemplates a method for spray coating workparts with a coating material composed of a controlled mixture o* at least two liquid components, comprising the steps of pumping a first component to an applicator, controlling the flow rate of the first component with an adjustable speed first motor, sending feedback signals in response to the instantaneous speed of the flrst motor, pumping a second component to the applicator, controllin~ the flow rate of the second component with an adjustable speed second motor, sending feedbacX signals in response to the instantaneous speed of the second motor, and individually controlling the speeds of the first and second motors in response to input reference signals.
The method is characterized by including the steps of comparing the feedback signals of the instantaneous speads of the first and second motors wlth the reference speeds and individually adjusting the speeds of the first and second motors in conformity , 1 32~826 with the re~erence speeds to continuously adjust the ratio between the flow rates of the ~irst and second components with resp~ct to a reference ratio.
The subject invention continuously ensures that the precise prçdat~rmined ratio between two components is maintained throughout the coating operation. The automatic adjustor means constantly compares the speeds of the Xirst and second motors and makes adjustments in response to the comparisons made, so that the reference ratio o~ the two components mixed is continually maintained.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages of the present invention will be readily appreciated as the same becomes better understood by referance to the following detailed description when considered in connection with the accompanying drawings wherein:
Figure 1 is a diagramatic view of an electrostatic spray coating apparatus according to the subject invention including an automatically operated applicator;
Figure 2 is a diagramatic view of a spray coating apparatus according to the subject invention i~cluding a manually operated applicator; and Figure 3 is a schematic diagram o~ the host controller means, the control panel, and the valve actuator means according to the subject invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, a spray oating ., , . ~ .. . :
apparatus of the type for applying a coating material composed of a controlled mixtuxe o~ at least two liquid components is generally shown at 10. The apparatus 10 is particularly adapted for electrostatically coating workparts, and more specifically to coating automotive vehicle bodies.
In the coating of motor vehicle bodi~s, it has been found desirable to apply a coating material which is composed of a precisely contr-olled mixture, or ratio, of two liquid components. Typically, these components comprise a paint and a hardener. The paint and hardener are mixed at an exact ratio and then immediately sprayed onto the worXpart to provide a fast-drying hard coating. If the ratio between the paint and the hardener varies even slightly during the coating of a workpart, undesirable results may occur. For example, the appearance of the finished workpart may become visibly flawed, the coating may never fully harden, the coating may bubble or peel, or the resultant color of the coating may be impaired. Therefore, it is critical that the ratio between the paint and hardener be continually monitored to ensure that the precise mixture ratio is maintained throughout the entire coating process.
The subject apparatus 10 includes a first pump means, generally indicated at 12 in Figures 1 and 2, ~or pumping an adjustable volumetric flow rate of the first component, i.e., paint. An applicator means, generally indicated at 14, is provided downstream of the first pump means 12. The first pump means 12 includes a first motor 16 having an adjustahle speed for controlling the rate of fluid pumped by the first pump means 12. The first motor . , . ~
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~ 320~26 16 also provides feedback signals along line 16a in response to the instantaneous speed thereof, as will be described in detail subsequently.
The apparatus 10 also includes a second pump means, generally indicated at 18, for pumping an adjustable volumetric flow rate of the second component, i.e., hardener, to the applicator means ~4. The second pump means 18 includes a second motor 20 having an adjustable speed for controlling the rate of fluid pumped by the second pump means 18.
Similar to the first motor 16, the second motor 20 also provides feedback signals along line 20a in response to the instantaneous speed thereof.
The first 16 and second 20 motors are brushless servomotors operating on AC current. This gives excellent control of the RPM of each motor 16, 20 so that the first 12 and second 18 pump means can 20 be accurately controlled. ~-A motor drive means, generally indicated at 22 in Figure 3, is response to input signals, including reference speed sig~lals, for individually controlling the speeds of the first 16 and second 20 motors. An operator of the spray coating apparatus 10 can program the precise reference speeds into a host controller means 23, which in turn, provides an input signal to the motor drive means 22. These reference speeds are directly proportional to the specific ratios at which the paint and hardener components are mixed to yield the final coating material. As best shown in Figure 3, an interface 25 is provided between the motor drive means 22 and the host controller means 23. Information in the form of computer language is transferred along the line 23a , -.P-307 _ 7 ~
from the host controller means 23 to the interface 25. The interface 25 converts this information to machine language and sends it to the motor drive means 22 via line 25a. Preferably, the line 23a is a data bus for quickly conveying the information to the motor drive means ~2.
The first 16 and second 20 motors each include a tachometer 26, 28, respectively, which send motor speed feedback signals directly to the motor drive means 22, along respective lines 16a and 20a, so that the motor drive means 22 can continuously readjust the instantaneous speed of each motor to the preprogrammed reference speeds. The tachometers 26, 28, in other words, provide feadback to the motor ; drive means 22 to ensure that the first 16 and second 20 motors are operating at the speeds commanded by : the motor drive means 22. The first 16 and second 20 ~:~ motors are also provided with optical encoders 27, 29, respectively, for sending feedback signals 16b, 20b, respectively, as will be described presently.
The subject invention is characterized by : including automatic adjustor means, generally : 25 indicated at 24 in Figure 3, which is responsive to feedback siynals 16b, 20b from the encoders 27, 29 of on the first 16 and ~econd 20 motors, respectively, ~or comparing the instantaneous speeds of the first 16 and second 20 motors with the reference speeds from the host controller means 23 and individually adjusting the speeds of the first 16 and the second 20 motors into conformity with the reference speeds to continually adjust the ratio between the volumetric flow rates of the first and second cumponent~ with respect to a reference ratio.
1 320~26 The reference speeds and ratios are provided the adjustor means 24 from the host controller means 23. These re~erences originally travel through the line 23a and into the inter~ace 25. The interface then supplies the references to the adjustor means 24 via a line 25b. The adjustor means 24, in other words, receives instantaneous speed feedback signals 16b, 20b from each of the first 16 and second 20 motors. The adjustor means 24 then compares these instantaneous speeds with the reference speeds, corresponding to the paint and hardener mixing ratios, to ensure that the mixture of the first and second components conforms to the precise predetermined ratio. If discrepancies are determined, the adjustor means 24 will then send a signal via line 24a to the motor drive means 22 instructing the motor drive means 22 to adjust the speed of one or both of the first 16 and second 20 motors. In this manner, the predQtermined ratio between the paint and hardener can be precisely mixed ; at all times during the coating operation.
Pre~erably, the adjustor means 24, motor drive means 22 and interface 25 are contained within one control panel, generally indicated at 31 in Figures 1, 2 and 3. The control panel 31 is constructed so as to be readily replaceable in the event a malfunction occurs. A ser~ice technician need not trace the problem to a specific one of the elements 22, 24, 25 within the control panel 31, but instead can quickly install a new control panel 31 and thereby reduce system down time. Although the control panel 31 is shown in the Figures as controlling only one applicator means 14, the control panel 31 is capable of controlling up to four appli¢ator means 14 simultaneouslyO
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A spray booth 30 is provided for containing the sprayed flammable coating material in an isolated zone. In Figures l and 2, only one wall of the spray booth 30 is represented, but it will be appreciated 5 that the spray booth 30 defines a complete enclosure. ~ -The spray booth 30 encloses the automobile bodies while they are painted to contain the over-sprayed coating material. The atmosphere inside the spray booth 30 is considered hazardous due to the highly ignitable mixture of air and atomized paint particles. For this reason, the atmosphere inside the spray booth is constantly circulated by using large fans. The emissions exhausted from the spray booth 14 are directed out of a stack.
The first pump means 12 includes a first gear pump 32 having intermeshing rotors supported within a first housing 34 and operatively connected to the f~rst motor 16. Simi].arly, the second pump means 18 includes a second gear pump 36 having intermeshing rotors supported within a second housing 38 and operatively connected to the second motor 20.
The first 32 and second 36 cJear pumps are of the positive displacement volumetric type wherein the volumetric flow rate of the paint components therethrough is proportional to the angular velocity of the rotors, as controlled by the motors 16, 20. ~ ~
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As shown in Figures 1 and 2, the first 32 and second 36 gear pumps are disposPd inside of the spray booth 30 while the first 16 and second 20 motors are disposed outside of the spray booth. The first 16 and second 20 motors are positioned outside of the spray booth 30 so that they can operate in a non-hazardous environment. Therefore, a first coupler means 37 is disposed between the first motox .
:, 16 and first g~ar pump 32 for providing an el~ctrically insulated machanical coupling through the spray booth ~0. ~ikewise, a second coupler means 39 is disposed between the second motor 20 and the econd g~ar pump 36 for providing an electrically insulat~d mechanical coupling through the spray booth 30.
A mixer means, gPnerally indicated at 40 in Figures 1 and 2, is disposed in the spray booth 30 for mixing the first and second components of the coating material and discharging the mixture from an output 42 thereof. Preferably, the mixer means 40 is of the kinetics type to effectively and efficiently mix the two components as they travel to the applicator means 14. The inlet to the mixer means 40 comprises a five medium inlet manifold block 44.
A first conduit 46 is associated with the first gear pump 32 and extends from a first componant supply outside of the spray booth 30 to the manifold 44 of the mixer means ~0. Lik~swise, a second conduit 48 is associated with a second gear pump 36 and extends from a second component supply outside of the spray booth 32 to the manifold 44 of the mixer means 40. The applicator means 14 communicates with the output 42 from the mixer means 40 for applying the mixed first and second components of the coating material onto the workpart. That is, the applicator means 14 is downstream of the mixer means 40 and thereby receives the mixed coating material for application onto a workpart.
The first 34 and second 38 housings of the gear pumps 32, 36 each include an upstream inlet 50, 52, respectively, and a downstream outlet 54, 56, :
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respectively. The first conduit 46 includes a recirculation line 58 disposed between the first component supply and the first housing inlet 50.
Similarly, the second conduit 48 includes a recirculation line 60 disposed between the second component supply and the second housing inlet 52~
The recirculation lines 58, 60 allow each of the unmixed components to continue flowing even while the associated gear pump 34, 38 is not pumping so that the component of the coating material will not harden or allow particulate suspended therein to precipitate out.
A manually operated fluid regulator 62, 64 is disposed on each of the first 46 and second 48 conduits between their respective supplies in the inlets 50, 52 to their respective housings 54, 58.
These flow regulators 62, 64 are adjusted to an optimal setting and remain at that setting throughout the coating operation. The regulators 62, 64 can be completely closed when servic:ing the gear pumps 34, 38 to prevent waste.
The first 12 and second 18 pump means each include an upstream pressure sensing means 66, 68, respec~ively, disposed adjacent the upstream inlets 50, 52 of the respectiv~ first 34 and second 38 housings for sensing when the static pressure in the respective first 46 and second 48 conduits, upstream of the inlets 50, 52 falls below a predetermined value. Preferably, the upstream pressure sensing means 66, 68 comprise pressure transducers which send a signal to a fault indicator 70 when the pressure falls below a predetermined value.
' p 307 - 12 -Similarly, the first 12 and second 18 pump means also include downstream pressure sensing means 72, 74, respectively/ disposed adjacent the downstream outlets 54, 56 of the respective first 34 and second 38 housings for sensing when the static prassure in the respective first 46 and second 48 conduits, downstream of the outlets 54, 56, rises above a predetermined value. Like the upstream pressure sensing means 66, 68, the downstream pressure sensing means 72, 74 comprise pressure transducers relaying a fault signal to a fault indicator 70 when the pressure rises above a predetermined value.
A plurality of pneumatically actuated valves are disposed in the spray booth 30 for opening and closing flow passages at predetermined times.
More specifically, a valve actuator means 76 is provided for individually actuating the valves at ~20 predetermined times in the wor~piece coating process.
;The valve actuator means 76 preferably comprises an array of solenoid valves communicating with the main air supply for individually supplying a pneumatic signal to an associated one of the valves 78, 80.
For example, a pneumatically actuated valve 78 is associated with each inlet to the manifold 44 for allowing the associated flow to enter the mixer means 40. Similarly, two pneumatically actuated valves 80 are associated with a two-way select valve 82 between the mixer means 40 and the applicator means 14 for selecting between the coating material mixed from the two components or from an alternative single component fluid control system (not shown). Further, -not shown, a pneumatically actuated valve is disposed in the applicator means 14 for shutting off the flow of coating material to be discharged.
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1 320~26 A flushing means, generally indicated at 88 in Figures 1 and 2, is associated with the mixer means 40 ~or flushing residual coating material from the mixer means 40 and the applicator means 14. One of the valves 78 of the manifold 44, when pneumatically actuated, allows the flow of solvent through the manifold 44 and into the mixing means 40 to clean residual paint therefrom. The solvent travels through the outlet 42 of the mixer means 40, than through the two-way select valve 82 and into the applicator means 14. A recovery line 90 is provided from both the applicator means 14 and the manifold 44 for allowing spent solvent to be conducted to a waste collection system.
As referred to previously, a host controller means, generally indicated at 90 in Figures 1 and 3, is provided outside of the spray booth 30 for supplying reference values to the motor drive means 22 and the adjustor means 24 and for controlling the valve actuator means 76 in response to praprogrammed commands. An operator of the subject assembly 10 controls and monitors the spray coating operation, including the designation o~ the reference valves and other parameters, through the host controller means 90. Although in the described embodiment only one control panel 31 is shown, the host controller means 23 is capable of controlling a plurality of control panels 31, and each control panel 31 is capable of controlling up to fo-lr applicator means 14. Numerous fault indicators 70 provide indicia of important occurrences.
Information of these important occurrences is relayed to the host controller means 90 via line 24b of the adjustor means 24. Preferably, the line 24b comprises an RS-232 transmission line.
1 3208~6 As shown in Figure 1, the applicator means 14 may include a rotary atomizer 92 fixedly mounted in the spray booth 30. Electrostatic charging means 94 is associated with the applicator means 14 for applying an electrostatic charge to the spray coating material. As shown, the electrostatic charging means 14 may comprise an annular ring disposed about the rotary atomizer ~2 including a plurality of circum~erentially disposed charging electrodes which impart a high electrical potential to the sprayed coating material by corona discharge.
Alternatively, as shown in Figure 2, the applicator means 14 may include a manually controllable atomizer which is hand operated inside the spray booth. In the manually controllable embodiment, the host controller means 90 can be eliminated as all coating decisions are made by the operator. The ratios between the two components need only be stored as a reference value in the adjustor means 24. The downstream pres;sure sensing means 72, 74 becomes extremely important in this embodiment due to tendency of the operator to only partially pull the atomizer trigger. This can cause significant pressure build-up in the conduits 46, 48 downstream of the gear pumps 34, 38 and result in rupture of the lines. The downstream pressure sensors 72, 74, therefore, provide warning signals or supply a signal to shut down the first 16 and second 20 motors when the static pressure in the conduits 46~ 48 exc~eds a maximum value.
The method for spray coating workparts with a coating material composed of a controlled mixture of two liquid components will be addressed presently. The steps comprise pumping the first -~
P-307 - lS -component through the ~irst gear pump 32 to the applicator means 14; controlling the flow rate of the first component pumped by the first gear pump 32 with an adjustable speed first motor 16; sending feedback signals to the adjustor means 24 in response to the instantaneous speed of the first motor 16; pumping the second component through the :~ second gear pump 36 to the applicator means 14;
controlling the flow rate of the second component pumped by the second gear pump 36 with an adjustable speed second motor 20: sending feedback signals to the adjustor means 24 in response to the instantaneous speed of the second motor 20; and then individually controlling the speeds of the first 16 and second 20 motors with the motor drive means 22 in response to an input reference signal from the host controller means 23. The method of the subject : invention is characterized by including the steps of comparing the feedback signals of the instantaneous speeds of the first 16 and second 20 motors with the re~erence speeds in the adjustor means 24 and then : individually adjusting the speeds of the first 16 and second 20 motors via the motor drive means 22 into conformity with the reference speeds so that ~;~ 25 the ratio between the flow rates of the first and ~: second components is continuously adjusted with respect to a re~erence ratio also supplied from the host controller means 23. :`
The adjustor means 24, in other words, acts as a liaison between the host controller means 23, the two motors 16, 20 and the motor drive means 22 by monitoring the ~performance of each of the motors 16, 20, then comparing their performance to the reference commands of the host controller means 23 and finally instructing the motor drive means 22 '.
1 32(~826 to make any necessary corrections. By making these continuous comparisons between the operating speeds o~ the first 16 and second 20 motors, the adjustor means 24 ultimately ensures that tha mixing ratio of the two components of the coating material remain at the optimum value throughout the entire spray coating process.
As the speeds of the motors 16, 20 are individually controlled by the motor drive means 22 in response to the input reference signals from the host controller means 23, the motor drive means 22 performs the additional function of continuously readjusting the instantaneous speeds of each of the first 16 and second 20 motors to the reference speeds. This step is distinguished from the .omparison steps performed by the adjustor means 24 in that the motor drive means 22 considers the instantaneous speed of one motor without reference to the speed of the other moto:r. That is, the motor drive means 22 does not compare the operating speeds between the two motors lb, 20, but merely receives a feedback signal from respective tachometers 26, 28 to ensure that the motors 16, 20 are operating at : 25 the speeds commanded by either the host controller means 23 or the adjustox means 2~.
As the first and second components are pumped through the respective gear pumps 32, 36, the upstream pressure sensing means 66, 58 continually measure the static pressure of the components at positions upstream of the gear pumps 32, 36 to signal the appropriate fault indicators 70 in the event the static pressure of either of the first and second components falls below a predetermined value.
This will provide a warning in the event an ..
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insufficient supply of the components is available from the associated supply and there~y prevent the gear pumps 32, 36 from becoming damaged. Similarly, the downstream pressure sensing means 72, 74 continually measure the static pressure of the components at positions downstream of the gear pumps 32, 36 to signal the appropriate fault indicators 70 in the event the static pressure of either of the first or second components rises above a predetermined value. This will provide warning or will shut down the first 16 and second 20 motors in the event excessive pressure builds up in the first 46 and second 48 conduits downstream of the gear pumps 32, 36 such as when the applicator means 14 is manually operated and the operator fails to fully actuate the trigger.
After traveling through the gear pumps 32, 36, the separate components are fed into the manifold 44 where the mixing takes place. The mixer means 40 is disposed a sufficient distance upstream of the applicator means 14 so that the kinetics type mixing of the components may be fully performed.
The mixed coating material is then conducted directly to the applicator means 14 where it is immediately applied to a worXpart. As the coating material is discharged, the corona discharge method is used to electrostatically charge the sprayed coating material.
To prevent the unmixed first and second components from becoming unusable due to prolonged stagnation during periods when the gear pumps 32, 36 are not operating, the respective recirculation lines 58, 60 are provided for circulating the components to and from respective supplies.
1 320~26 p_307 - 18 -The invention has been described in an : illustrative manner, and it is to be understood that the terminoloqy which has been used is intended to ~
be in the nature of words of description rather than ~-of limitation.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims wherein reference numerals are merely for convenience and are not to be in any way limiting, :: :
the invention may be practiced otherwise than as specifically described.
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APPARAT~ FOR APPLYING ~WO COMPON~NT MXXTURB
TECHNICAL FIELD
The subject invention relates to electrostatic spray coating apparatuses, and more particularly to an apparatus for applying a coating material composed of a controlled mixture o~ at least two liquid components.
BACKGROUND ART
Electrostatic spray coating apparatuses are typically supplied with a fluid which is electrically charged either before or after atomization, then applied to an electrically yrounded workpart~
In non-electrostatic coating applications, coating materials composed of a mixture of two components have been found to provide superior results. The two component coating materials, typically, comprise a paint component and a hardener component which are thoroughly mixed together at a predetermined optimum ratio to provide a fast-drying, hard material.
There are generally two reasons why two component coating materials are considered nonadaptable to the electrostatic spray coating art.
The first is that, because two component materials harden very fast when mixed at the proper proportions, they cannot be mixed together until just prior to application. Therefore, the mixing must take place within the spray booth at a location proximately upstream of the applicator. This ' .
requirement leads to the second, and more basic, reason why two component systems are rare in the electrostatic spray coating art. Namely, the two components must be mixed together at very precise proportions in order to achieve their advantageous results over single component materials. Even minute variations from the optimum mixing ratios can result in serious coating flaws, e.g., inability to harden, cracking, peeling, etc.
The prior art Behr Industrieanlaegen Audi 001~ spray coating apparatus mixes two paint components prior to application. This system employs two 5-phase 60 volt DC stepper motors to drive separate gear pumps through a 3:1 gearbox. Proximity sensors are used to sense motor speed.
SUMMARY OF THE INVENTION AND ADVANTAGES
The subject invention provides a spray coating apparatus of the type for applying a coating material composed of a controlled mixture of at least two liquid components onto a workpart. The apparatus comprises a first pump means for pumping an adjustable volumetric flow rate of the first component to an applicator. The first pump me~ns includes a first motor having an adjustable speed for controlling the rata of fluid pumped by the first pump means and providing feedback signals in response to the instantaneous speed thereof. A second pump means is provided for pumping an ad~usting volumetric flow rate of the second component to the applicator.
The second pump means includes a second motor having an adjustable speed for controlling the rata of fluid pumped by the second pump mPans and providing feedback signals in response to the instantaneous speed thereof. A motor drive means is responsive to input signals including reference speed signals for individually controlling the speeds of the first and second motors. The su~ject invention is characteri~ed by including an automatic adjustor maans responsive to the feedback signals from the first and second motors for comparing the instantaneous speeds of the first and second motors with the reference speeds and individually adjusting the speeds of the first and second motors in conformity with the reference speeds to continually adjust the ratio between the volumetric flow rates of the first and second components with respect to a reference ratio.
The subject invention also contemplates a method for spray coating workparts with a coating material composed of a controlled mixture o* at least two liquid components, comprising the steps of pumping a first component to an applicator, controlling the flow rate of the first component with an adjustable speed first motor, sending feedback signals in response to the instantaneous speed of the flrst motor, pumping a second component to the applicator, controllin~ the flow rate of the second component with an adjustable speed second motor, sending feedbacX signals in response to the instantaneous speed of the second motor, and individually controlling the speeds of the first and second motors in response to input reference signals.
The method is characterized by including the steps of comparing the feedback signals of the instantaneous speads of the first and second motors wlth the reference speeds and individually adjusting the speeds of the first and second motors in conformity , 1 32~826 with the re~erence speeds to continuously adjust the ratio between the flow rates of the ~irst and second components with resp~ct to a reference ratio.
The subject invention continuously ensures that the precise prçdat~rmined ratio between two components is maintained throughout the coating operation. The automatic adjustor means constantly compares the speeds of the Xirst and second motors and makes adjustments in response to the comparisons made, so that the reference ratio o~ the two components mixed is continually maintained.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages of the present invention will be readily appreciated as the same becomes better understood by referance to the following detailed description when considered in connection with the accompanying drawings wherein:
Figure 1 is a diagramatic view of an electrostatic spray coating apparatus according to the subject invention including an automatically operated applicator;
Figure 2 is a diagramatic view of a spray coating apparatus according to the subject invention i~cluding a manually operated applicator; and Figure 3 is a schematic diagram o~ the host controller means, the control panel, and the valve actuator means according to the subject invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, a spray oating ., , . ~ .. . :
apparatus of the type for applying a coating material composed of a controlled mixtuxe o~ at least two liquid components is generally shown at 10. The apparatus 10 is particularly adapted for electrostatically coating workparts, and more specifically to coating automotive vehicle bodies.
In the coating of motor vehicle bodi~s, it has been found desirable to apply a coating material which is composed of a precisely contr-olled mixture, or ratio, of two liquid components. Typically, these components comprise a paint and a hardener. The paint and hardener are mixed at an exact ratio and then immediately sprayed onto the worXpart to provide a fast-drying hard coating. If the ratio between the paint and the hardener varies even slightly during the coating of a workpart, undesirable results may occur. For example, the appearance of the finished workpart may become visibly flawed, the coating may never fully harden, the coating may bubble or peel, or the resultant color of the coating may be impaired. Therefore, it is critical that the ratio between the paint and hardener be continually monitored to ensure that the precise mixture ratio is maintained throughout the entire coating process.
The subject apparatus 10 includes a first pump means, generally indicated at 12 in Figures 1 and 2, ~or pumping an adjustable volumetric flow rate of the first component, i.e., paint. An applicator means, generally indicated at 14, is provided downstream of the first pump means 12. The first pump means 12 includes a first motor 16 having an adjustahle speed for controlling the rate of fluid pumped by the first pump means 12. The first motor . , . ~
.. ... . .
:
~ 320~26 16 also provides feedback signals along line 16a in response to the instantaneous speed thereof, as will be described in detail subsequently.
The apparatus 10 also includes a second pump means, generally indicated at 18, for pumping an adjustable volumetric flow rate of the second component, i.e., hardener, to the applicator means ~4. The second pump means 18 includes a second motor 20 having an adjustable speed for controlling the rate of fluid pumped by the second pump means 18.
Similar to the first motor 16, the second motor 20 also provides feedback signals along line 20a in response to the instantaneous speed thereof.
The first 16 and second 20 motors are brushless servomotors operating on AC current. This gives excellent control of the RPM of each motor 16, 20 so that the first 12 and second 18 pump means can 20 be accurately controlled. ~-A motor drive means, generally indicated at 22 in Figure 3, is response to input signals, including reference speed sig~lals, for individually controlling the speeds of the first 16 and second 20 motors. An operator of the spray coating apparatus 10 can program the precise reference speeds into a host controller means 23, which in turn, provides an input signal to the motor drive means 22. These reference speeds are directly proportional to the specific ratios at which the paint and hardener components are mixed to yield the final coating material. As best shown in Figure 3, an interface 25 is provided between the motor drive means 22 and the host controller means 23. Information in the form of computer language is transferred along the line 23a , -.P-307 _ 7 ~
from the host controller means 23 to the interface 25. The interface 25 converts this information to machine language and sends it to the motor drive means 22 via line 25a. Preferably, the line 23a is a data bus for quickly conveying the information to the motor drive means ~2.
The first 16 and second 20 motors each include a tachometer 26, 28, respectively, which send motor speed feedback signals directly to the motor drive means 22, along respective lines 16a and 20a, so that the motor drive means 22 can continuously readjust the instantaneous speed of each motor to the preprogrammed reference speeds. The tachometers 26, 28, in other words, provide feadback to the motor ; drive means 22 to ensure that the first 16 and second 20 motors are operating at the speeds commanded by : the motor drive means 22. The first 16 and second 20 ~:~ motors are also provided with optical encoders 27, 29, respectively, for sending feedback signals 16b, 20b, respectively, as will be described presently.
The subject invention is characterized by : including automatic adjustor means, generally : 25 indicated at 24 in Figure 3, which is responsive to feedback siynals 16b, 20b from the encoders 27, 29 of on the first 16 and ~econd 20 motors, respectively, ~or comparing the instantaneous speeds of the first 16 and second 20 motors with the reference speeds from the host controller means 23 and individually adjusting the speeds of the first 16 and the second 20 motors into conformity with the reference speeds to continually adjust the ratio between the volumetric flow rates of the first and second cumponent~ with respect to a reference ratio.
1 320~26 The reference speeds and ratios are provided the adjustor means 24 from the host controller means 23. These re~erences originally travel through the line 23a and into the inter~ace 25. The interface then supplies the references to the adjustor means 24 via a line 25b. The adjustor means 24, in other words, receives instantaneous speed feedback signals 16b, 20b from each of the first 16 and second 20 motors. The adjustor means 24 then compares these instantaneous speeds with the reference speeds, corresponding to the paint and hardener mixing ratios, to ensure that the mixture of the first and second components conforms to the precise predetermined ratio. If discrepancies are determined, the adjustor means 24 will then send a signal via line 24a to the motor drive means 22 instructing the motor drive means 22 to adjust the speed of one or both of the first 16 and second 20 motors. In this manner, the predQtermined ratio between the paint and hardener can be precisely mixed ; at all times during the coating operation.
Pre~erably, the adjustor means 24, motor drive means 22 and interface 25 are contained within one control panel, generally indicated at 31 in Figures 1, 2 and 3. The control panel 31 is constructed so as to be readily replaceable in the event a malfunction occurs. A ser~ice technician need not trace the problem to a specific one of the elements 22, 24, 25 within the control panel 31, but instead can quickly install a new control panel 31 and thereby reduce system down time. Although the control panel 31 is shown in the Figures as controlling only one applicator means 14, the control panel 31 is capable of controlling up to four appli¢ator means 14 simultaneouslyO
. : , . . ~ .
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, ~ :
.
A spray booth 30 is provided for containing the sprayed flammable coating material in an isolated zone. In Figures l and 2, only one wall of the spray booth 30 is represented, but it will be appreciated 5 that the spray booth 30 defines a complete enclosure. ~ -The spray booth 30 encloses the automobile bodies while they are painted to contain the over-sprayed coating material. The atmosphere inside the spray booth 30 is considered hazardous due to the highly ignitable mixture of air and atomized paint particles. For this reason, the atmosphere inside the spray booth is constantly circulated by using large fans. The emissions exhausted from the spray booth 14 are directed out of a stack.
The first pump means 12 includes a first gear pump 32 having intermeshing rotors supported within a first housing 34 and operatively connected to the f~rst motor 16. Simi].arly, the second pump means 18 includes a second gear pump 36 having intermeshing rotors supported within a second housing 38 and operatively connected to the second motor 20.
The first 32 and second 36 cJear pumps are of the positive displacement volumetric type wherein the volumetric flow rate of the paint components therethrough is proportional to the angular velocity of the rotors, as controlled by the motors 16, 20. ~ ~
' ..
As shown in Figures 1 and 2, the first 32 and second 36 gear pumps are disposPd inside of the spray booth 30 while the first 16 and second 20 motors are disposed outside of the spray booth. The first 16 and second 20 motors are positioned outside of the spray booth 30 so that they can operate in a non-hazardous environment. Therefore, a first coupler means 37 is disposed between the first motox .
:, 16 and first g~ar pump 32 for providing an el~ctrically insulated machanical coupling through the spray booth ~0. ~ikewise, a second coupler means 39 is disposed between the second motor 20 and the econd g~ar pump 36 for providing an electrically insulat~d mechanical coupling through the spray booth 30.
A mixer means, gPnerally indicated at 40 in Figures 1 and 2, is disposed in the spray booth 30 for mixing the first and second components of the coating material and discharging the mixture from an output 42 thereof. Preferably, the mixer means 40 is of the kinetics type to effectively and efficiently mix the two components as they travel to the applicator means 14. The inlet to the mixer means 40 comprises a five medium inlet manifold block 44.
A first conduit 46 is associated with the first gear pump 32 and extends from a first componant supply outside of the spray booth 30 to the manifold 44 of the mixer means ~0. Lik~swise, a second conduit 48 is associated with a second gear pump 36 and extends from a second component supply outside of the spray booth 32 to the manifold 44 of the mixer means 40. The applicator means 14 communicates with the output 42 from the mixer means 40 for applying the mixed first and second components of the coating material onto the workpart. That is, the applicator means 14 is downstream of the mixer means 40 and thereby receives the mixed coating material for application onto a workpart.
The first 34 and second 38 housings of the gear pumps 32, 36 each include an upstream inlet 50, 52, respectively, and a downstream outlet 54, 56, :
.:
. ' . ~
respectively. The first conduit 46 includes a recirculation line 58 disposed between the first component supply and the first housing inlet 50.
Similarly, the second conduit 48 includes a recirculation line 60 disposed between the second component supply and the second housing inlet 52~
The recirculation lines 58, 60 allow each of the unmixed components to continue flowing even while the associated gear pump 34, 38 is not pumping so that the component of the coating material will not harden or allow particulate suspended therein to precipitate out.
A manually operated fluid regulator 62, 64 is disposed on each of the first 46 and second 48 conduits between their respective supplies in the inlets 50, 52 to their respective housings 54, 58.
These flow regulators 62, 64 are adjusted to an optimal setting and remain at that setting throughout the coating operation. The regulators 62, 64 can be completely closed when servic:ing the gear pumps 34, 38 to prevent waste.
The first 12 and second 18 pump means each include an upstream pressure sensing means 66, 68, respec~ively, disposed adjacent the upstream inlets 50, 52 of the respectiv~ first 34 and second 38 housings for sensing when the static pressure in the respective first 46 and second 48 conduits, upstream of the inlets 50, 52 falls below a predetermined value. Preferably, the upstream pressure sensing means 66, 68 comprise pressure transducers which send a signal to a fault indicator 70 when the pressure falls below a predetermined value.
' p 307 - 12 -Similarly, the first 12 and second 18 pump means also include downstream pressure sensing means 72, 74, respectively/ disposed adjacent the downstream outlets 54, 56 of the respective first 34 and second 38 housings for sensing when the static prassure in the respective first 46 and second 48 conduits, downstream of the outlets 54, 56, rises above a predetermined value. Like the upstream pressure sensing means 66, 68, the downstream pressure sensing means 72, 74 comprise pressure transducers relaying a fault signal to a fault indicator 70 when the pressure rises above a predetermined value.
A plurality of pneumatically actuated valves are disposed in the spray booth 30 for opening and closing flow passages at predetermined times.
More specifically, a valve actuator means 76 is provided for individually actuating the valves at ~20 predetermined times in the wor~piece coating process.
;The valve actuator means 76 preferably comprises an array of solenoid valves communicating with the main air supply for individually supplying a pneumatic signal to an associated one of the valves 78, 80.
For example, a pneumatically actuated valve 78 is associated with each inlet to the manifold 44 for allowing the associated flow to enter the mixer means 40. Similarly, two pneumatically actuated valves 80 are associated with a two-way select valve 82 between the mixer means 40 and the applicator means 14 for selecting between the coating material mixed from the two components or from an alternative single component fluid control system (not shown). Further, -not shown, a pneumatically actuated valve is disposed in the applicator means 14 for shutting off the flow of coating material to be discharged.
`~ :
;
1 320~26 A flushing means, generally indicated at 88 in Figures 1 and 2, is associated with the mixer means 40 ~or flushing residual coating material from the mixer means 40 and the applicator means 14. One of the valves 78 of the manifold 44, when pneumatically actuated, allows the flow of solvent through the manifold 44 and into the mixing means 40 to clean residual paint therefrom. The solvent travels through the outlet 42 of the mixer means 40, than through the two-way select valve 82 and into the applicator means 14. A recovery line 90 is provided from both the applicator means 14 and the manifold 44 for allowing spent solvent to be conducted to a waste collection system.
As referred to previously, a host controller means, generally indicated at 90 in Figures 1 and 3, is provided outside of the spray booth 30 for supplying reference values to the motor drive means 22 and the adjustor means 24 and for controlling the valve actuator means 76 in response to praprogrammed commands. An operator of the subject assembly 10 controls and monitors the spray coating operation, including the designation o~ the reference valves and other parameters, through the host controller means 90. Although in the described embodiment only one control panel 31 is shown, the host controller means 23 is capable of controlling a plurality of control panels 31, and each control panel 31 is capable of controlling up to fo-lr applicator means 14. Numerous fault indicators 70 provide indicia of important occurrences.
Information of these important occurrences is relayed to the host controller means 90 via line 24b of the adjustor means 24. Preferably, the line 24b comprises an RS-232 transmission line.
1 3208~6 As shown in Figure 1, the applicator means 14 may include a rotary atomizer 92 fixedly mounted in the spray booth 30. Electrostatic charging means 94 is associated with the applicator means 14 for applying an electrostatic charge to the spray coating material. As shown, the electrostatic charging means 14 may comprise an annular ring disposed about the rotary atomizer ~2 including a plurality of circum~erentially disposed charging electrodes which impart a high electrical potential to the sprayed coating material by corona discharge.
Alternatively, as shown in Figure 2, the applicator means 14 may include a manually controllable atomizer which is hand operated inside the spray booth. In the manually controllable embodiment, the host controller means 90 can be eliminated as all coating decisions are made by the operator. The ratios between the two components need only be stored as a reference value in the adjustor means 24. The downstream pres;sure sensing means 72, 74 becomes extremely important in this embodiment due to tendency of the operator to only partially pull the atomizer trigger. This can cause significant pressure build-up in the conduits 46, 48 downstream of the gear pumps 34, 38 and result in rupture of the lines. The downstream pressure sensors 72, 74, therefore, provide warning signals or supply a signal to shut down the first 16 and second 20 motors when the static pressure in the conduits 46~ 48 exc~eds a maximum value.
The method for spray coating workparts with a coating material composed of a controlled mixture of two liquid components will be addressed presently. The steps comprise pumping the first -~
P-307 - lS -component through the ~irst gear pump 32 to the applicator means 14; controlling the flow rate of the first component pumped by the first gear pump 32 with an adjustable speed first motor 16; sending feedback signals to the adjustor means 24 in response to the instantaneous speed of the first motor 16; pumping the second component through the :~ second gear pump 36 to the applicator means 14;
controlling the flow rate of the second component pumped by the second gear pump 36 with an adjustable speed second motor 20: sending feedback signals to the adjustor means 24 in response to the instantaneous speed of the second motor 20; and then individually controlling the speeds of the first 16 and second 20 motors with the motor drive means 22 in response to an input reference signal from the host controller means 23. The method of the subject : invention is characterized by including the steps of comparing the feedback signals of the instantaneous speeds of the first 16 and second 20 motors with the re~erence speeds in the adjustor means 24 and then : individually adjusting the speeds of the first 16 and second 20 motors via the motor drive means 22 into conformity with the reference speeds so that ~;~ 25 the ratio between the flow rates of the first and ~: second components is continuously adjusted with respect to a re~erence ratio also supplied from the host controller means 23. :`
The adjustor means 24, in other words, acts as a liaison between the host controller means 23, the two motors 16, 20 and the motor drive means 22 by monitoring the ~performance of each of the motors 16, 20, then comparing their performance to the reference commands of the host controller means 23 and finally instructing the motor drive means 22 '.
1 32(~826 to make any necessary corrections. By making these continuous comparisons between the operating speeds o~ the first 16 and second 20 motors, the adjustor means 24 ultimately ensures that tha mixing ratio of the two components of the coating material remain at the optimum value throughout the entire spray coating process.
As the speeds of the motors 16, 20 are individually controlled by the motor drive means 22 in response to the input reference signals from the host controller means 23, the motor drive means 22 performs the additional function of continuously readjusting the instantaneous speeds of each of the first 16 and second 20 motors to the reference speeds. This step is distinguished from the .omparison steps performed by the adjustor means 24 in that the motor drive means 22 considers the instantaneous speed of one motor without reference to the speed of the other moto:r. That is, the motor drive means 22 does not compare the operating speeds between the two motors lb, 20, but merely receives a feedback signal from respective tachometers 26, 28 to ensure that the motors 16, 20 are operating at : 25 the speeds commanded by either the host controller means 23 or the adjustox means 2~.
As the first and second components are pumped through the respective gear pumps 32, 36, the upstream pressure sensing means 66, 58 continually measure the static pressure of the components at positions upstream of the gear pumps 32, 36 to signal the appropriate fault indicators 70 in the event the static pressure of either of the first and second components falls below a predetermined value.
This will provide a warning in the event an ..
'~
~. ~
', ~
insufficient supply of the components is available from the associated supply and there~y prevent the gear pumps 32, 36 from becoming damaged. Similarly, the downstream pressure sensing means 72, 74 continually measure the static pressure of the components at positions downstream of the gear pumps 32, 36 to signal the appropriate fault indicators 70 in the event the static pressure of either of the first or second components rises above a predetermined value. This will provide warning or will shut down the first 16 and second 20 motors in the event excessive pressure builds up in the first 46 and second 48 conduits downstream of the gear pumps 32, 36 such as when the applicator means 14 is manually operated and the operator fails to fully actuate the trigger.
After traveling through the gear pumps 32, 36, the separate components are fed into the manifold 44 where the mixing takes place. The mixer means 40 is disposed a sufficient distance upstream of the applicator means 14 so that the kinetics type mixing of the components may be fully performed.
The mixed coating material is then conducted directly to the applicator means 14 where it is immediately applied to a worXpart. As the coating material is discharged, the corona discharge method is used to electrostatically charge the sprayed coating material.
To prevent the unmixed first and second components from becoming unusable due to prolonged stagnation during periods when the gear pumps 32, 36 are not operating, the respective recirculation lines 58, 60 are provided for circulating the components to and from respective supplies.
1 320~26 p_307 - 18 -The invention has been described in an : illustrative manner, and it is to be understood that the terminoloqy which has been used is intended to ~
be in the nature of words of description rather than ~-of limitation.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims wherein reference numerals are merely for convenience and are not to be in any way limiting, :: :
the invention may be practiced otherwise than as specifically described.
::: :
~: ' ; ~ ,' ~;~ , .. ', , .
:
, "' :
Claims (28)
1. A spray coating apparatus of the type for applying a coating material composed of a controlled mixture of at least two liquid components onto a workpart, comprising: first pump means for pumping an adjustable volumetric flow rate of the first component to an applicator, said first pump means including a first motor having an adjustable speed for controlling the rate of fluid pumped by said first pump means and providing feedback signals in response to the instantaneous speed thereof; second pump means for pumping an adjustable volumetric flow rate of the second component to the applicator, said second pump means including a second motor having an adjustable speed far controlling the rate of fluid pumped by said second pump means and providing feedback signals in response to the instantaneous speed thereof; and characterized by including automatic adjustor means responsive to said feedback signals from said first and second motors for computing an instantaneous ratio of the volumetric flow rates of the first and second components and comparing said instantaneous ratio with a reference ratio of the volumetric flow rates of the first and second components and individually adjusting the speeds of the first and second motors to continually adjust said instantaneous ratio into conformity with said reference ratio.
2. An apparatus as set forth in claim 1 further characterized by each of said first and second motors including a tachometer for sending motor speed feedback signals, and motor drive means for receiving the feedback signals from said tachometers and continuously readjusting the instantaneous speed of each of said first and second motors into conformity with a reference speed.
3. An apparatus as set forth in claim 2 further characterized by said first pump means including a first gear pump having intermeshing rotors supported within a first housing and operatively connected to said first motor, and said second pump means including a second gear pump having intermeshing rotors supported within a second housing and operatively connected to said second motor.
4. An apparatus as set forth in claim 3 further characterized by including a spray booth defining an isolated internal spray zone.
5. An apparatus as set forth in claim 4 further characterized by said first and second gear pumps disposed inside said spray booth and said first and second motors disposed outside of said spray booth.
6. An apparatus as set forth in claim 5 wherein said apparatus includes a plurality of pneumatically actuated valves disposed in said spray booth for opening and closing fluid flow passages, further characterized by including valve actuator means for individually actuating said valves at predetermined times in the workpiece coating process.
7. An apparatus as set forth in claim 6 further characterized by including mixer means disposed in said spray booth for mixing the first and second components of the coating material and discharging the mixture from an output thereof.
8. An apparatus as set forth in claim 7 further characterized by including a first conduit associated with said first gear pump and extending from a first component supply outside of said spray booth to said mixer means, and a second conduit associated with said second gear pump and extending from a second component supply outside of said spray booth to said mixer means.
9. An apparatus as set forth in claim 8 further characterized by including applicator means communicating with said output from said mixer means for applying the mixed first and second components of the coating material onto the workpart.
10. An apparatus as set forth in claim 9 wherein said first and second gear pump housings each include an upstream inlet and a downstream outlet, further characterized by said first conduit including a recirculation line disposed between the first component supply and said first housing inlet, and said second conduit including a recirculation line disposed between the second component supply and said second housing inlet.
11. An apparatus as set forth in claim 10 further characterized by each of said first and second pump means including upstream pressure sensing means disposed adjacent said upstream inlet of respective said first and second housings for sensing when the static pressure in respective said first and second conduits upstream of said inlets falls below a predetermined value.
12. An apparatus as set forth in claim 11 further characterized by each of said first and second pump means including downstream pressure sensing means disposed adjacent said downstream outlet of respective said first and second housings for sensing when the static pressure in respective said first and second conduits downstream of said outlets rises above a predetermined value.
13. An apparatus as set forth in claim 12 further characterized by including first coupler means for providing an electrically insulated mechanical coupling through said spray booth between said first motor and said first gear pump.
14. An apparatus as set forth in claim 13 further characterized by including second coupler means for providing an electrically insulated mechanical coupling through said spray booth between said second motor and said second gear pump.
15. An apparatus as set forth in either of claims 7 or 14 further characterized by including a host controller means disposed outside of said spray booth for supplying reference values to said motor drive means and said adjustor means and controlling said valve actuator means in response to preprogrammed commands.
16. An apparatus as set forth in claim further characterized by including flushing means associated with said mixer means for flushing residual coating material from said mixer means and said applicator means.
17. An apparatus as set forth in claim 16 further characterized by said applicator means including a rotary atomizer fixedly mounted in said spray booth.
18. An apparatus as set forth in claim 17 further characterized by including electrostatic charging means associated with said applicator means for applying an electrostatic charge to the sprayed coating material.
19. An apparatus as set forth in claim 18 further characterized by said applicator means including a manually controllable atomizer.
20. An apparatus as set forth in claim 19 further characterized by said host controller means including a fault indicator associated with each of said first and second upstream sensing means and said first and second downstream sensing means.
21. A method for spray coating workparts with a coating material composed of a controlled mixture of at least two liquid components, comprising the steps of: pumping a first component to an applicator; controlling the flow rate of the first component with an adjustable speed first motor; sending feedback signals in response to the instantaneous speed of the first motor: pumping a second component to the applicator: controlling the flow rate of the second component with an adjustable speed second motor; sending feedback signals in response to the instantaneous speed of the second motor; and characterized by computing an instantaneous ratio of the volumetric flow rate of the first and second components and comparing the instantaneous ratio to a reference ratio of the volumetric flow rate of the first and second components and individually adjusting the speeds of the first and second motors to continuously adjust the ratio between the flow rates of the first and second components into conformity with the reference ratio.
22. A method as set forth in claim 21 further characterized by including the step of electrostatically charging the sprayed coating material.
23. A method as set forth in claim 22 further characterized by continuously readjusting the instantaneous speed of each of the first and second motors to a reference speed.
24. A method as set forth in claim 23 wherein a first gear pump pumps the first component and a second gear pump pumps the second component, further characterized by measuring the static pressure of the first and second components at positions upstream and downstream of the respective first and second gear pumps.
25. A method as set forth in claim 24 further characterized by signalling a fault indicator in the event the static pressure of at least one of the first and second components upstream of the respective first and second gear pumps falls below a predetermined value.
26. A method as set forth in claim 25 further characterized by signalling a fault indicator in the event the static pressure of at least one of the first and second components downstream of the respective first and second gear pumps rises above a predetermined value.
27. A method as set forth in claim 26 further characterized by mixing the first and second components at a position upstream of the applicator.
28. A method as set forth in claim 27 further characterized by circulating the first and second coating materials to and from respective supplies during periods when the first and second gear pumps are not operating.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US32257789A | 1989-03-13 | 1989-03-13 | |
| US322,577 | 1989-03-13 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1320826C true CA1320826C (en) | 1993-08-03 |
Family
ID=23255494
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000614312A Expired - Lifetime CA1320826C (en) | 1989-03-13 | 1989-09-28 | Electrostatic spray coating apparatus for applying two component mixture |
Country Status (4)
| Country | Link |
|---|---|
| EP (1) | EP0387978A3 (en) |
| JP (1) | JPH03196861A (en) |
| AU (1) | AU608466B2 (en) |
| CA (1) | CA1320826C (en) |
Families Citing this family (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5318065A (en) * | 1992-11-20 | 1994-06-07 | Ransburg Corporation | Color valve multiplexer |
| US6238746B1 (en) * | 1998-08-27 | 2001-05-29 | Honda Giken Kogyo Kabushiki Kaisha | Method of and apparatus for painting vehicle bodies with various color paints |
| US6733842B1 (en) * | 2003-05-01 | 2004-05-11 | E. I. Du Pont De Nemours And Company | Process for the high-speed rotary application of liquid coating agents |
| US6929823B2 (en) | 2003-05-01 | 2005-08-16 | E. I. Du Pont De Nemours And Company | Process for the high-speed rotary application of liquid, pigmented coating agents |
| DE102019121347A1 (en) * | 2019-08-07 | 2021-02-11 | Atlas Copco Ias Gmbh | Monitoring process and application device for multi-component viscous material |
Family Cites Families (12)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US294673A (en) * | 1884-03-04 | Grinding mill | ||
| US209258A (en) * | 1878-10-22 | Improvement in oil-well pumps | ||
| DE1171312B (en) * | 1959-07-17 | 1964-05-27 | Metallgesellschaft Ag | Electrostatic painting device with a paint changing device |
| US3147137A (en) * | 1960-10-31 | 1964-09-01 | Dow Chemical Co | Electrostatic spraying of polyurethane foam |
| US4167151A (en) * | 1974-11-01 | 1979-09-11 | Sumitomo Heavy Industries, Ltd. | Automatic spraying apparatus for forming hard polyurethane foam coating |
| US4019653A (en) * | 1975-08-22 | 1977-04-26 | Graco Inc. | Automatic proportioning paint spray system |
| US4209258A (en) * | 1978-02-14 | 1980-06-24 | Oakes W Peter | Automatic continuous mixer apparatus |
| US4263091A (en) * | 1980-01-25 | 1981-04-21 | Phillips Petroleum Company | Fluid flow control |
| US4324812A (en) * | 1980-05-29 | 1982-04-13 | Ransburg Corporation | Method for controlling the flow of coating material |
| US4789100A (en) * | 1980-11-04 | 1988-12-06 | Adhesive Engineering Company | Multiple fluid pumping system |
| JPS59213468A (en) * | 1983-05-16 | 1984-12-03 | Nippon Ranzubaagu Kk | Painting method of reaction curing type |
| JPS60161768A (en) * | 1984-01-30 | 1985-08-23 | Toyota Motor Corp | Painting apparatus |
-
1989
- 1989-09-28 CA CA000614312A patent/CA1320826C/en not_active Expired - Lifetime
- 1989-11-02 AU AU44357/89A patent/AU608466B2/en not_active Ceased
-
1990
- 1990-01-03 EP EP19900300047 patent/EP0387978A3/en not_active Withdrawn
- 1990-02-20 JP JP2039539A patent/JPH03196861A/en active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| AU608466B2 (en) | 1991-03-28 |
| EP0387978A2 (en) | 1990-09-19 |
| AU4435789A (en) | 1990-09-13 |
| JPH03196861A (en) | 1991-08-28 |
| EP0387978A3 (en) | 1991-10-02 |
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|---|---|---|---|
| MKEX | Expiry |
Effective date: 20100803 |