DE19641524C2 - Coating system for large parts, especially for the surface treatment of metal and plastic parts - Google Patents

Description

The invention relates to a coating system for Large parts, especially for treating the surfaces Metal and plastic parts through different types Surface techniques, such as B.

• - Clean,
• - pretreatment (sandblasting, wet chemical etc.),
• - powder coating,
• - enamelling,
• - Paint,
• - Metallize.

It will be a technical improvement for the Order processing for both the area Surface treatment as well as for the powder supply and Recovery system implemented.

State of the art

Plants for the aforementioned work purposes are in principle known, among other things, for powder coating technology or for coating with metallic and metallic colors. Of the characteristic meaning of such systems is the respective one Transport or conveyor system, which due to its flexibility determines which working speeds depending for example the furnace system or the color change times etc. are mobile and whether the individual transport routes to technological requirements can be varied sufficiently, especially according to the space requirements of the different Workpieces and product carriers coming for treatment. A Equally important is the design of such systems the supply lines for the powder coating or others  Coating, rust removal and cleaning materials and the Facilities within the recovery and Disposal systems for this too.

A tried and tested for powder coating automatic transport system, on which for the same Purpose also known circular conveyor drive waived the use of transport gliders, the so-called Shuttles, in front, on guide rails with roller conveyors slide and driven by separate low voltage modules become. This coating system has one central part with oven and cooling buffer, work platform, Table tops and a spray stand at a work position each movable to the right and left of the furnace Shuttle magazines. All shuttles move as independent units and are in terms of their position to be taken and their travel speed of controlled by appropriate software. This System configuration is except for the automated drive the shuttles are identical to the known manual pushing techniques. There is a spray stand magazine in the edge area of the system can be fed to several downstream spray stands. These are executed so that an exchange of the spray stand in Working position carried out with the help of the shuttle magazine can be. The necessary working parameters and the respective processing conditions of the powder coatings for one batch each, depending on weight and size the parts are also controlled by a program. This Transport and conveyor system provides for parts of lower mass and size a very practical solution for the semi-automated operation of coating systems, for Parts of relatively large mass and structural size are there, though at all, but only partially applicable. The same is true Variation of the technological process on the Limited use of different coating materials.  

It is also known the coating processes longitudinally along a rail or conveyor system to be implemented according to the technological process. This Conveyor systems are usually closed chains, Tapes or ropes that are either continuous or timed Circulation through all technologically necessary Processing stations must complete. So it is from the DE 38 38 927 A1 and CA 2103329 A1 known the disadvantages of technological process related to funding change. By the patent DE 41 27 580 C1 finally a coating system for a fully automatic Controlled transport system for surface treatment of large-scale metal parts known as car bodies, in which cross-shaped transport routes in several superimposed levels. In doing so at the same time a working level for occupied and one Return level used for empty transport devices, the using at the respective end of the transport route arranged lifting and lowering stations in the empty state in the each other plane of movement are transferred.

However, the state of the art documented here is still before being tied to a well-defined workflow that along a conveyor line with several work stations is realized. The existing ones Workstations in the order of technological Drive through the process, leading to long transport routes in front of and leads behind the treatment stations and especially at Large parts require a large area of the entire system required. The transport systems of such plants are in the Rule directional (e.g. circular conveyor systems) or have a preferred direction of transportation, which is flexibility with regard to the releasable transport tasks limited. The arrangement of the processing stations in the The order of the technological process is often one  optimal design of the fuel supply and the Recovery and disposal systems. The The total throughput time for plants of this type is the longest processing sequence determined, even if in the concrete technological process the associated processing step is not carried out. Deviations from the design given technological process are therefore either not possible or uneconomical. For these reasons especially for parts with large dimensions or mass only known surface treatment plants that a fixed technological process for a narrowly defined Parts range (e.g. car bodies, standard parts for the Steel construction), which are manufactured in large quantities become. You can only find these conditions typically also an integrated pretreatment. This must otherwise be realized externally, which u. U. too suboptimal Coating results can lead.

Aim of the invention

The aim of the invention is to realize a Coating plant for large parts (parts with large Dimensions and / or large mass) compared to the stand the technology in terms of space requirements and the Flexibility of technological processes essential advantages having. In particular, are efficient in a plant various pretreatment and coating processes integrable. Resulting different technological processes can be implemented simultaneously, whereby the total lead time only by the actually required Work steps is determined. To this flexibility minimal loss of efficiency (measured on each concrete technological process) compared to the state of the It is imperative to achieve technology-related systems  real-time program-controlled, automatic transport system required. As a result, even small quantities are up to to produce individual parts economically. The arrangement of the Processing stations do not have to (anyway not established) technological process are designed, but can follow higher-level considerations, such as B. occupational safety, environmental protection requirements and an optimal arrangement of fuel supplies, Recovery and disposal systems. This task will according to the invention in the first claim characterized characteristics of the coating system solved, whereby further solution ideas are set out in the subclaims are.

The effect of the present invention lies primarily in the application of the coating system equipped with an automatically operating transport system, which for large parts, for large-scale, bulky and excessively long parts made of steel, cast iron and aluminum for producing a primary and / or secondary surface protection or for producing decorative surfaces of all kinds are suitable and designed. The use of an automatically locking coupling 11 , by means of which several individual traverses 10 can be combined, simultaneously enables the treatment of smaller parts up to mass parts, the deliberately chosen modular structure of the overall system guaranteeing high flexibility and availability of the individual treatment stations and thus the overall system . The parallel arrangement of the individual treatment stations 2 a to 2 i on both sides along the transport path "T" of the transverse transport bridges 7 on one or more spatially superimposed transport levels "A" and "R" minimizes the space requirement of the overall system, z. B. compared to circular conveyors.

It is common for the above. Well-known range of materials Such a system is a cost-intensive wet chemical Process, e.g. B. the iron or zinc phosphating Primer, adhesion promoter and for corrosion protection is subjected. It also happens, especially in steel and Metal construction, often before that galvanized hot and sediment Materials are used. The system presented here consciously renounces these initial premises and is preferred to the application of new methods of Surface technology aligned. It's about that so-called thermal zinc powder system for steel parts and that Water-based primer powder system for aluminum parts. Farther is the system for the hot coating of heavy castings or for corrosion protection of steel parts and for one Enamel coating designed.

This technical-technological conception, connected with the system type shown leads to concrete technological processes that are explained with the here Large parts coating system can be realized. The Connection of system configuration, transport system and Technology and its interaction lead to the fact that geometrically complex large parts in one system minimum space and cost can be processed. The coating system according to the invention is based on the associated drawing explained and briefly below described.  

System description

The graphic representations show in

FIG. 1 shows the layout (schematic plan view) of the plant with indicated transport system 3 and a in the object buffer 1 a and 1 b transverse transport bridge 7 being, as well as on both sides arranged in parallel processing stations 2 a to 2 i;

FIG. 2 shows the cross section of the system in the viewing direction "X" from FIG. 1;

Fig. 3 is a partial longitudinal section through the system with the indicated return level "R" and the working level "A" for the parts to be treated, each with a cross transport bridge 7 , in the viewing direction "Y" of Fig. 1, it will continue to be the arrangement the lifting and lowering stations 4 a and 4 b illustrates;

Figure 4 is a partial longitudinal section through the system at the indicated return plane "R" and the working plane "A" for the parts to be treated in the viewing direction "Z" of Figure 1, there are 2 to recognize the furnaces 2 g and h..;

Figure 5 shows the transverse transport bridge 7 guided in running rails 8.1 to 8.5 traverses, in the example formed from two individual transverse members 10 coupled, with a schematic representation of the individual transverse members 10 hinged parts.

Fig. 6 shows two individual transverse members 10 coupled with schematically illustrated partition 15, the (preferably the powder booths 2 d and 2 e) realizes a longitudinal and, if necessary, in addition, a transverse partition of a processing booth;

Fig. 7 automatically locking coupling 11, which connects the individual transverse members 10 in case of need, in the coupled state of two individual transverse members 10 and a schematic representation of the required separation actuating element 14.

The exemplary embodiment shows a surface coating system in connection with a computer-assisted transport system. This system is divided into the task and acceptance area 1 and 6 with several task buffers 1 a and 1 b, the processing area 2 with the individual processing stations 2 a to 2 i as well as in the transport system 3 with the provided cross transport bridges 7 and the lifting and lowering stations 4 a, 4 b and the cooling and storage buffers 5 . The arrangement of a system shown in FIG. 1 has a cross-shaped transport system 3 , with which in a working plane "A", see FIGS. 2, 3 and 4, to the right and left of the transport path "T", any processing stations in the manner of free jet cabin 2 a, a wet paint booth 2 b, wet chemical pre-treatment booth 2 c, powder booths 2 d and 2 e, ovens 2 f and 2 g, intermediate buffers 2 h and drying area 2 i up to loading and removal buffers 1 a, 1 b and 6 a, 6 b can be approached, in each of which a specific, technologically necessary processing task is implemented. A plurality of successive processing steps for creating a surface treatment using the respective processing stations 2 a to 2 i required and work through the necessary technology as following.

The processing stations 2 a to 2 i including the necessary cooling and storage buffers 5 as well as the loading and removal buffers 1 a, 1 b and 6 a, 6 b are arranged on both sides parallel to one another along the transport path "T" of the transverse transport bridges 7 and are connected to the cross transport bridge 7 attached rails 8.1 to 8.5 with processed material and disposed of. The individual processing stations 2 a to 2 i are therefore not traversed with the parts 9 to be treated, but rather the parts 9 are suspended on traverses each guided by running rails (in the example 8.1 to 8.5), which are inserted by the transverse transport bridge 7 into the processing stations and after the processing in the same way brought back to the cross transport bridge 7 . In the individual processing stations 2 a to 2 i, the usual treatment is carried out on the parts in the idle state on the individual cross members 10 . The processing is carried out with movable tools or by hand. When the treatment process is completed, the transverse transport bridges 7 are returned to the starting position using a return plane R arranged above the working plane A with the aid of lifting and lowering stations 4 a arranged on both sides at the end of the transport path.

The above-mentioned sections of the coating system designed for large parts in the form of

• - Task and acceptance area 1 and 6 and the
• - Processing area 2 with the processing stations 2 a to 2 i and des
• - Transport system 3

are explained in more detail below.

Task and acceptance area 1 and 6

This area of the coating system for large parts shown in the exemplary embodiment is of particular importance for the economical operation of the system. The following parameters must be recorded in task area 1 and processed in terms of data technology:

• 1. Order-related detection of the mass of the individual cross members 10 and the determination of the type of material (e.g. steel, aluminum, cast iron).
• 2. Computational determination of the total mass of the accumulated task buffer 1 a, 1 b before taking over the coupled individual traverses 10 on the transverse transport bridge 7 to determine the necessary technological parameters paired with the type of material, such as. B. the oven residence time.
• 3. Determination of the technological parameters determined by the type of material and application characteristics of the parts 9 to be machined and the process selection.
• 4. Determination of technologically sensible combinations for the coupling of the individual traverses 10 and their transfer to the running rails 8.1 to 8.5 of the transverse transport bridge 7 .
• 5. In the acceptance area 6 there is a quality control and the order-related further processing (eg rework, packaging, shipping).

Processing area with the individual treatment stations

The processing area of the overall system is shown schematically in FIG. 1. The individual processing stations 2 a to 2 i in their already mentioned parallel arrangement next to each other guarantee a minimal space requirement. This is also achieved in that the grid dimensions of the steel construction of the building construction are used in a sensible manner for the construction of the individual processing stations, in that two identical uses are provided in the processing area, starting from a common central wall. A special feature of the processing stations 2 a, 2 b and 2 c further consists in the fact that lifting and lowering stations 4 b are provided here, which enable the working level of the treatment stations provided there to be increased by approximately 2 m. This has an advantageous effect if, for example, truck or bus bodies are to be processed. Furthermore, this results in the possibility of realizing an inclined position of the individual cross members 10 in the pretreatment booths 2 b and 2 c, so that attached individual parts run off and dry faster after treatment with liquids.

For reasons of manufacturing flexibility, the treatment stations can be subdivided again in the longitudinal direction by moving in a partition 15 , so that there is the possibility of increasing the simultaneity factor when treating similar parts from different orders. In the area of the powder booths 2 d and 2 e in particular, this concept, as shown schematically in FIG. 6, is expanded once again in that a transverse division can also be achieved with the aid of a folding partition 15 . This construction of the large booth with the indicated subdivision into four sub-booths gives the possibility to process several different colors in a powder booth 2 d or 2 e at the same time. The prerequisite for this is that the respective cabin part is also assigned a suction system or powder recovery system in the form of a filter or cyclone which is to be operated separately. As already mentioned, this solution significantly increases the flexibility of the overall system.

The cooling and storage buffer ( 5 ) and the removal buffer ( 6 a, 6 b), also shown, see. Fig. 1, are important for the technological process, as can be realized with their help, the intermediate or Endpufferung of crossbeams and their technologically useful compilation of individual transverse members 10th This is particularly important for a sensible utilization of the 2 g and 2 h powder baking ovens. The furnaces should be fully utilized in terms of space or weight in each heating cycle, ie as a rule that five filled individual cross members are inserted into the furnace. This desired furnace regime means that after processing via the transverse transport bridge 7 , these are either completely passed directly to the acceptance 6 a, 6 b or parked in the cooling and final buffer 5 . The then empty cross transport bridge 7 then goes back into the processing area 2 or is moved with the aid of the lifting and lowering stations 4 b, 4 a via the return level "R" into the area of task 1 .

Transport system with cross transport bridges, lifting and Lowering stations as well as cooling and storage buffers

The schematic representation of the superimposed working, transport and return levels "A" and "R" shown in FIG. 2 shows a possible sequence for a coating or transport process. After the parts 9 have been weighed in the associated task, the individual traverses 10 are coupled and transferred to the running rails 8.1 to 8.5 . The required treatment steps are now carried out in working level "A" with the aid of the computer-aided transport system and, in accordance with the technology to be processed, the respective crossbeams, which are located on the running rails 8.1 to 8.5, are brought into overlap with the transport rails of the treatment stations and by the transverse transport bridge 7 retracted or inserted into the treatment stations. Immediately after the individual traverse 10 has been moved in , the transverse transport bridge 7 can move to the next obvious treatment step and operate a further treatment station or a buffer. Is the transverse transport bridge 7 in the region of the removal buffer 6a, 6b arrived and the individual transverse members are pushed into the pick-buffer 10, by means of a lifting and lowering station 4 b the blank transverse transport bridge 7 in the return plane "R" is raised and returned to the task pane 1 . The lifting and lowering station 4 a there transports the transverse transport bridge 7 back to the working level A.

As shown in the exemplary embodiment according to FIGS. 1, 2, 3 and 4, it is possible and technologically sensible to work with a plurality of transverse transport bridges 7 . It may also be necessary to work on working level A with at least two transverse transport bridges 7 and with intermediate buffers 2 h because this divides the technological process into a pre-treatment and finishing section, which enables shorter operating times for the transport processes.

Automatically locking coupling element

The schematic representation in FIG. 7 shows the basic arrangement of the coupling mechanism 11 , by means of which the individual cross members 10 , at least two in number, are coupled. It is a pawl 12 which acts mechanically for the coupling process and which engages automatically in the locking bolt 13 of the projecting individual crossbar 10 for fixing the position of the individual housing. The individual traverse 10 is unlocked in the receiving or removal stations from the transverse transport bridge 7 . The unlocking process is carried out with the aid of an electrohydraulic, electropneumatic or electromagnetic actuating element 14 which can be used optionally. The system and the transport processes are controlled by computers.

List of reference symbols

1

Task area

1

a feed buffer

1

b Task buffer

2nd

Processing area with the processing stations

2nd

a Free jet cabin

2nd

b Wet paint booth

2nd

c wet chemical pre-treatment booth

2nd

d powder coating booth

1

2nd

e powder coating booth

2nd

2nd

f oven

1

2nd

g oven

2nd

2nd

h Intermediate buffer

2nd

i drying area

3rd

Transport system

4

Lifting and lowering stations

4

a lifting and lowering stations in the areas

1

and

6

4

b Lift and lower stations in the area

2nd

5

Cooling and storage buffer

6

Acceptance area

6

a Acceptance buffer

6

b Acceptance buffer

7

Cross transport bridge

8th

Tracks (

8.1

to

8.5

)

9

parts to be treated

10th

Single traverse

11

automatic clutch

12th

Pawl

13

Locking bolt

14

Actuator

15

Partitions
A working level
T transport routes
R feedback level

Claims (5)

1. Coating system, in particular with an automatically controllable transport system for large-scale parts for surface treatment of metal and plastic parts, with a transport system ( 3 ) which is formed with transport paths (T) or guides which run in a cross shape and which are in two or more superimposed ones Movement planes (A; R) are arranged, whereby these movement planes (A; R) can be used as working plane (A) for the parts to be treated ( 9 ) and as return plane (R) for the empty cross transport bridges ( 7 ) and both planes (A ; R) with transversal transport bridges ( 7 ) can be occupied at the same time, which, using lifting and lowering stations ( 4 a; 4 b) arranged at the respective end of the transport path, permit the approach of the respective movement plane (A; R), characterized in that the Cross transport bridge ( 7 ) is designed as a carrier of several individual cross members ( 10 ) and several individual cross members ( 10 ) arranged one behind the other and can be coupled to one another by an automatically acting coupling ( 11 ). 2. Coating plant according to claim 1, characterized in that the individual treatment stations ( 2 a to 2 i) by longitudinally and transversely to the transport routes (T) adjustable, displaceable and pivotable cabin walls or partitions ( 15 ) can be set up in several working cabins or coating sectors . 3. Coating system according to claim 1 and 2, characterized in that one or more treatment stations ( 2 a to 2 i) are arranged one above the other in one or more movement planes (A, R). 4. Coating system according to claim 1 and 2, characterized in that each processing station ( 2 a to 2 i) is assigned a size appropriate air supply and / or cleaning and there is an independent, independent supply of the operating materials. 5. Coating plant according to claim 4, characterized in that the air flows for powder cleaning and recovery under the cabin floor and / or on the cabin ceiling are arranged.