EP3263227B1 - Device for thermally coating a surface, and method for measuring the position or shape of a wire end in a device for thermally coating a surface - Google Patents

Device for thermally coating a surface, and method for measuring the position or shape of a wire end in a device for thermally coating a surface Download PDF

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Publication number
EP3263227B1
EP3263227B1 EP17177565.3A EP17177565A EP3263227B1 EP 3263227 B1 EP3263227 B1 EP 3263227B1 EP 17177565 A EP17177565 A EP 17177565A EP 3263227 B1 EP3263227 B1 EP 3263227B1
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Prior art keywords
wire
thermal coating
measuring device
wire end
electrode
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EP17177565.3A
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German (de)
French (fr)
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EP3263227A1 (en
Inventor
Christian Klimesch
Leander Schramm
Andreas Schaller
Josef Laibel
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KS Huayu Alutech GmbH
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KS Huayu Alutech GmbH
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Priority to PL17177565T priority Critical patent/PL3263227T3/en
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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
    • B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
    • B05B7/16—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed
    • B05B7/22—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc
    • B05B7/222—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc using an arc
    • B05B7/224—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc using an arc the material having originally the shape of a wire, rod or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B13/00—Machines or plants for applying liquids or other fluent materials to surfaces of objects or other work by spraying, not covered by groups B05B1/00 - B05B11/00
    • B05B13/06—Machines or plants for applying liquids or other fluent materials to surfaces of objects or other work by spraying, not covered by groups B05B1/00 - B05B11/00 specially designed for treating the inside of hollow bodies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
    • B05B7/16—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed
    • B05B7/1606—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed the spraying of the material involving the use of an atomising fluid, e.g. air
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/134—Plasma spraying

Definitions

  • the invention relates to a device for thermal coating of a surface with a spray gun, a wire feed device with at least one guide element for guiding a wire, a plasma gas source, a nozzle device with a nozzle opening for generating a plasma gas jet, which is directed towards a wire end, a first electrode and a second electrode, the wire acting as the second electrode, and an adjusting device, whereby the wire end can be adjusted relative to the plasma gas jet by a defined adjustment path.
  • the invention also relates to a method for improving the quality of a thermal coating with a device for thermal coating of a surface.
  • Such devices are known from the prior art and are used, for example, in the automotive industry to coat the running surfaces of the cylinder bores in an internal combustion engine and thereby in particular to improve the sliding properties of the pistons on the running surfaces of the cylinder bores.
  • the treads are coated using the PTWA (Plasma Transferred Wire Arc Spraying) process, in which a metal wire is melted and melted using a plasma Metal wire for generating the treads is distributed on the cylinder bores.
  • PTWA Laser Transferred Wire Arc Spraying
  • the device comprises a wire feed device and a nozzle device.
  • the wire feed device has a plurality of guide elements over which a wire is guided and continuously conveyed.
  • the nozzle device comprises a nozzle body, in which a nozzle opening is formed, which is connected to a plasma gas source and generates a plasma gas stream directed towards the wire end.
  • the device has two electrodes, a first electrode being arranged in the nozzle body and a second electrode being formed by the wire, so that an arc arises between the first electrode and the wire and the resulting high temperature means that Wire end melts.
  • the wire feed device has adjustment elements by means of which the wire end can be adjusted relative to the nozzle opening.
  • the adjusting device comprises adjusting screws arranged radially to the longitudinal axis of the wire, which engage a guide element. By screwing in or unscrewing the adjusting screws, the guide element is moved together with the wire, as a result of which the wire end is aligned relative to the plasma gas jet.
  • thermal arc spraying system in which the conveying speed of the wire is adjustable depending on the position of the arc measured by means of a sensor.
  • a coating device in which a wire end or a wire residue quantity is detected by a sensor in order to detect one end of the wire and thus to be able to change the wire reels in good time.
  • the invention is therefore based on the object of further developing a device for the thermal coating of a surface in such a way that the alignment of the wire end relative to the plasma gas jet takes place more precisely and in a time-saving manner.
  • a device for the thermal coating of a surface with the features of the main claim is provided which is attached to the spray gun in a defined position, the position or shape of the wire end being ascertainable via the measuring device, the shape or position of the wire end can be determined precisely and reliably, with only one measurement of the Measuring device determines the adjustment path of the wire end required for the complete melting of the wire end, thus saving a lot of time.
  • the object is achieved by a method for improving the quality of a thermal coating with the features of claim 9.
  • the measuring device is designed as an optical measuring system with at least one optical sensor. This enables non-contact measurement of the wire and, if necessary, the nozzle opening, so that measurements can be taken immediately after the wire end has been melted without having to consider the cooling time.
  • the measuring device is designed as a tactile measuring system with at least one pushbutton, as a result of which the measurements of the measuring device are insensitive to environmental influences and material properties, for example lighting conditions or surface properties.
  • the measuring device is arranged on the side of the wire facing the first electrode.
  • the melting process begins on the side facing the first electrode and progresses to the opposite side of the wire.
  • the measuring device is preferably arranged at the location of the first electrode, the electrode being removable in the meantime.
  • the measuring device can be arranged inexpensively on the spray gun, since the measuring device is automatically correctly aligned with the nozzle opening.
  • the measuring device is arranged on the side of the wire facing away from the first electrode, as a result of which the measuring device can be easily assembled and disassembled.
  • the adjusting device is preferably a mechanically driven system, as a result of which the wire end is adjusted in a simple and inexpensive manner, for example by means of a screw which runs transversely to the wire axis.
  • the adjustment device is an electrically driven system.
  • the measuring device and the adjusting device can be coupled to one another in a simple manner, so that the measurement and adjustment of the wire end takes place automatically.
  • the adjustment of the wire end is monitored by the measuring device, so that an incorrect adjustment of the wire end, for example by a worker, is avoided.
  • the measurement of the measuring device and the adjustment of the wire end are preferably carried out automatically by the adjustment device. This reduces the time required for measuring the shape or position of the wire end and the time required for adjusting the wire end.
  • the in the Figures 1 and 2nd The device shown has a spray burner 2 with a wire feed device 4 and a nozzle device 6.
  • the wire guide device 4 comprises a first ring-shaped guide element 8 and a second ring-shaped guide element 10 for guiding a wire 16.
  • the nozzle device 6 has a nozzle body 7 with a nozzle opening 14 which is transverse to the Axis of the wire 16 is arranged and is directed to the wire end 18.
  • a fluid channel 21 is formed in the nozzle body 7, which opens into the nozzle opening 14 and is connected with the end facing away from the nozzle opening 14 to a plasma gas source, not shown in the figures.
  • a first electrode 20 Arranged in the fluid channel 21 is a first electrode 20, which is fastened to the nozzle body 7 via webs 19, 19 ′ and is connected to a power source (not shown).
  • a second electrode 22 is formed by the wire 16, which is also connected to a current source not shown in the figures.
  • the plasma gas flowing into the fluid channel 21 and required for the formation of plasma flows through the nozzle opening 14 in the direction of the wire end 18.
  • the two electrodes 20, 22 With a corresponding high voltage and current intensity acting on the two electrodes 20, 22, the two electrodes 20, 22 are formed an arc extending through the nozzle opening 14 to the wire end 18.
  • the arc thus causes a high temperature at the wire end 18, causing the wire end 18 to melt.
  • the melted wire material is atomized through the plasma jet and in particular through air nozzle openings 24 in the direction of a surface of a cylinder bore.
  • the air nozzle openings 24 are formed in the nozzle body 7 and are arranged in a circle around the nozzle opening 14.
  • the air nozzle openings 24 are fluidly connected via an air nozzle channel 25 formed in the nozzle body 7 to an air pressure supply, not shown in the figures.
  • the device has an adjusting device 26, which acts on the second guide element 10 and moves the guide element 10 together with the wire 16 transversely to the longitudinal axis of the wire 16.
  • the wire 16 can be adjusted electrically, for example by piezo elements, or mechanically.
  • a mechanical embodiment of the adjusting device 26 is shown, the adjusting device 26 being composed of a first adjusting screw 28 and a first pin 32 as well as a second adjusting screw 30 and a second pin 34.
  • the pins 32, 34 engage radially on the second annular guide element 10, which are each guided in a bore 36, 38 and can be displaced by a respective adjusting screw 28, 30.
  • the adjusting screws 28, 30 are also arranged in the bores 36, 38, the bores 36, 38 each having an internal thread, which enable the adjusting screws 28, 30 to be screwed in and out.
  • the pins 32, 34 and the guide element 10 are displaced radially to the longitudinal axis of the wire 16 and the wire end 18 is displaced relative to the nozzle opening 14.
  • One of the two adjusting screws 28, 30 for the displacement of the guide element 10 must be screwed in and the other of the two adjusting screws 28, 30 must be unscrewed.
  • a measuring device 40 is attached to the spray gun 2 according to the invention.
  • Figure 3 shows such an arrangement of the measuring device 40.
  • the measuring device 40 is an optical system and is arranged at the point at which the second electrode 22 is arranged in the coating process. The second electrode 22 is thus removed between the coating processes and a measuring device 40 is used.
  • the measuring device 40 has an optical sensor 42, which measures the shape of the wire end 18. If the wire end 18 is poorly positioned in relation to the nozzle opening 14, a so-called melting flank arises, which is detected by the measuring device 40. The determined geometry of the melting flank makes it known in which direction the wire has to be displaced in order to melt the entire wire end 18. With a newly inserted wire 16, the device is briefly actuated so that a first melting process takes place and the shape of the wire end 18 changes due to the melting process. This change in shape is detected by the measuring device 40 and the wire end 18 is adjusted based on the measurement of the measuring device 40 by a worker. During the adjustment of the wire 16, the measuring device 40 is still active and monitors the adjustment.
  • the described device for thermal coating of a surface is characterized by the arrangement of the measuring device according to the invention, in that the shape of the wire end 18 is precisely determined, based on this the wire end 18 is adjusted by the worker or, if necessary, automatically and the adjustment by the measuring device 40 is monitored. This prevents defects in the coating.
  • the nozzle device or the wire feed device can be designed differently.
  • the measuring device can also be carried out, for example, using a tactile system with a button.
  • the adjustment device can also be operated electrically and, if necessary, automatically, so that a worker does not have to intervene.

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  • Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Electromagnetism (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Nozzles (AREA)

Description

Die Erfindung betrifft eine Vorrichtung zum thermischen Beschichten einer Oberfläche mit einem Spritzbrenner, der eine Drahtzuführvorrichtung mit mindestens einem Führungselement zum Führen eines Drahts, eine Plasmagasquelle, eine Düseneinrichtung mit einer Düsenöffnung zur Erzeugung eines Plasmagasstrahls, welcher auf ein Drahtende gerichtet ist, eine erste Elektrode und eine zweite Elektrode, wobei der Draht als zweite Elektrode wirkt, und eine Verstellvorrichtung, wodurch das Drahtende um einen definierten Verstellweg relativ zum Plasmagasstrahl verstellbar ist, aufweist.The invention relates to a device for thermal coating of a surface with a spray gun, a wire feed device with at least one guide element for guiding a wire, a plasma gas source, a nozzle device with a nozzle opening for generating a plasma gas jet, which is directed towards a wire end, a first electrode and a second electrode, the wire acting as the second electrode, and an adjusting device, whereby the wire end can be adjusted relative to the plasma gas jet by a defined adjustment path.

Außerdem betrifft die Erfindung ein Verfahren zur Verbesserung der Qualität einer thermischen Beschichtung mit einer Vorrichtung zum thermischen Beschichten einer Oberfläche.The invention also relates to a method for improving the quality of a thermal coating with a device for thermal coating of a surface.

Derartige Vorrichtungen sind aus dem Stand der Technik bekannt und werden beispielsweise in der Automobilindustrie dazu verwendet, um die Laufflächen der Zylinderbohrungen in einem Verbrennungsmotor zu beschichten und dadurch insbesondere die Gleiteigenschaften der Kolben auf den Laufflächen der Zylinderbohrungen zu verbessern. Die Beschichtung der Laufflächen erfolgt dabei durch das PTWA (Plasma Transferred Wire Arc Spraying) -Verfahren, in dem mit Hilfe eines Plasmas ein Metalldraht geschmolzen und dieser geschmolzene Metalldraht zur Erzeugung der Laufflächen auf den Zylinderbohrungen verteilt wird.Such devices are known from the prior art and are used, for example, in the automotive industry to coat the running surfaces of the cylinder bores in an internal combustion engine and thereby in particular to improve the sliding properties of the pistons on the running surfaces of the cylinder bores. The treads are coated using the PTWA (Plasma Transferred Wire Arc Spraying) process, in which a metal wire is melted and melted using a plasma Metal wire for generating the treads is distributed on the cylinder bores.

Eine derartige Vorrichtung zum thermischen Beschichten von Oberflächen ist in der WO 2012/095371 offenbart. Die Vorrichtung umfasst eine Drahtzuführeinrichtung und eine Düseneinrichtung. Die Drahtzuführeinrichtung weist mehrere Führungselemente auf, über die ein Draht geführt und stetig gefördert wird. Die Düseneinrichtung umfasst einen Düsenkörper, in dem eine Düsenöffnung ausgebildet ist, die mit einer Plasmagasquelle verbunden ist und einen auf das Drahtende gerichteten Plasmagasstrom erzeugt. Für die Erzeugung eines Plasmas weist die Vorrichtung zwei Elektroden auf, wobei eine erste Elektrode im Düsenkörper angeordnet ist und eine zweite Elektrode durch den Draht gebildet wird, so dass ein Lichtbogen zwischen der ersten Elektrode und dem Draht entsteht und durch die daraus resultierende hohe Temperatur das Drahtende aufschmilzt. Nach dem Aufschmelzen des Drahtendes wird die Schmelze durch den Plasmagasstrahl und insbesondere durch im Düsenkörper ausgebildete Sekundärluftdüsen in Richtung der Lauffläche der Zylinderbohrung zerstäubt. Dabei sinkt die Qualität der Beschichtung, wenn das Drahtende nicht vollständig aufgeschmolzen wird und die nicht aufgeschmolzenen Metallpartikel zusammen mit der Schmelze auf die Lauffläche verteilt werden. Um das Drahtende vollständig aufzuschmelzen und eine daraus resultierende hohe Qualität der Beschichtung der Lauffläche zu erreichen, weist die Drahtzuführeinrichtung Verstellelemente auf, durch die das Drahtende relativ zur Düsenöffnung verstellbar ist. Dabei umfasst die Verstellvorrichtung radial zur Drahtlängsachse angeordnete Verstellschrauben, die auf ein Führungselement angreifen. Durch das Ein- bzw. Ausschrauben der Verstellschrauben erfolgt eine Verschiebung des Führungselements gemeinsam mit dem Draht, wodurch das Drahtende relativ zum Plasmagasstrahl ausgerichtet wird.Such a device for the thermal coating of surfaces is in the WO 2012/095371 disclosed. The device comprises a wire feed device and a nozzle device. The wire feed device has a plurality of guide elements over which a wire is guided and continuously conveyed. The nozzle device comprises a nozzle body, in which a nozzle opening is formed, which is connected to a plasma gas source and generates a plasma gas stream directed towards the wire end. For the generation of a plasma, the device has two electrodes, a first electrode being arranged in the nozzle body and a second electrode being formed by the wire, so that an arc arises between the first electrode and the wire and the resulting high temperature means that Wire end melts. After the wire end has melted, the melt is atomized in the direction of the running surface of the cylinder bore by the plasma gas jet and in particular by secondary air nozzles formed in the nozzle body. The quality of the coating drops if the wire end is not completely melted and the non-melted metal particles are distributed together with the melt onto the tread. In order to completely melt the wire end and to achieve a resulting high quality of the coating of the running surface, the wire feed device has adjustment elements by means of which the wire end can be adjusted relative to the nozzle opening. The adjusting device comprises adjusting screws arranged radially to the longitudinal axis of the wire, which engage a guide element. By screwing in or unscrewing the adjusting screws, the guide element is moved together with the wire, as a result of which the wire end is aligned relative to the plasma gas jet.

Nachteilig an der in der WO 2012/095371 beschriebenen Ausführung ist die ungenaue und zeitaufwendige Ausrichtung des Drahtes relativ zum Plasmagasstrahl, wobei ein Werker die Form des Drahtendes nach dem Aufschmelzen prüft, den für die vollständige Aufschmelzung des Drahtendes benötigten Verstellweg abschätzt und über die Verstellschrauben das Drahtende relativ zum Plasmagasstrahl um den abgeschätzten Verstellweg verstellt. Dieser Ablauf wird solange wiederholt, bis das Drahtende derart zum Plasmagasstrahl ausgerichtet ist, dass im Schmelzvorgang das Drahtende vollständig schmilzt.Disadvantage of the in the WO 2012/095371 The version described is the inaccurate and time-consuming alignment of the wire relative to the plasma gas jet, with a worker checking the shape of the wire end after melting, estimating the adjustment path required for the complete melting of the wire end and adjusting the wire end relative to the plasma gas jet by the estimated adjustment path using the adjustment screws . This process is repeated until the wire end is aligned with the plasma gas jet in such a way that the wire end completely melts in the melting process.

Des Weiteren ist aus der DE 42 10 798 A1 eine thermische Lichtbogenspritzanlage bekannt, bei der die Fördergeschwindigkeit des Drahtes in Abhängigkeit der mittels eines Sensors gemessenen Position des Lichtbogens verstellbar ist.Furthermore, from the DE 42 10 798 A1 a thermal arc spraying system is known in which the conveying speed of the wire is adjustable depending on the position of the arc measured by means of a sensor.

Zusätzlich ist aus der DE 10 2008 024 237 A1 eine Beschichtungsvorrichtung bekannt, bei der über einen Sensor ein Drahtende oder eine Drahtrestmenge detektiert wird, um ein Ende des Drahtes zu detektieren und so die Drahtrollen rechtzeitig wechseln zu können.In addition, from the DE 10 2008 024 237 A1 a coating device is known in which a wire end or a wire residue quantity is detected by a sensor in order to detect one end of the wire and thus to be able to change the wire reels in good time.

Der Erfindung liegt daher die Aufgabe zugrunde, eine Vorrichtung zum thermischen Beschichten einer Oberfläche derart weiterzuentwickeln, dass die Ausrichtung des Drahtendes relativ zum Plasmagasstrahl genauer und zeitsparender erfolgt.The invention is therefore based on the object of further developing a device for the thermal coating of a surface in such a way that the alignment of the wire end relative to the plasma gas jet takes place more precisely and in a time-saving manner.

Außerdem liegt der Erfindung die Aufgabe zugrunde, ein Verfahren zur Verbesserung der Qualität einer thermischen Beschichtung mit einer Vorrichtung zum thermischen Beschichten einer Oberfläche bereitzustellen.It is also an object of the invention to provide a method for improving the quality of a thermal coating with a device for thermal coating of a surface.

Diese Aufgabe wird durch eine Vorrichtung zum thermischen Beschichten einer Oberfläche mit den Merkmalen des Hauptanspruchs gelöst. Dadurch, dass eine Messvorrichtung vorgesehen ist, welche in einer definierten Position am Spritzbrenner befestigt ist, wobei über die Messvorrichtung die Lage oder Form des Drahtendes ermittelbar ist, kann die Form oder Lage des Drahtendes genau und zuverlässig ermittelt werden, wobei mit nur einer Messung der Messvorrichtung der für die vollständige Aufschmelzung des Drahtendes erforderliche Verstellweg des Drahtendes ermittelt und so viel Zeit eingespart wird.This object is achieved by a device for the thermal coating of a surface with the features of the main claim. The fact that a measuring device is provided which is attached to the spray gun in a defined position, the position or shape of the wire end being ascertainable via the measuring device, the shape or position of the wire end can be determined precisely and reliably, with only one measurement of the Measuring device determines the adjustment path of the wire end required for the complete melting of the wire end, thus saving a lot of time.

Außerdem wird die Aufgabe durch ein Verfahren zur Verbesserung der Qualität einer thermischen Beschichtung mit den Merkmalen des Anspruchs 9 gelöst.In addition, the object is achieved by a method for improving the quality of a thermal coating with the features of claim 9.

In einer bevorzugten Ausgestaltung der Vorrichtung ist die Messvorrichtung als ein optisches Messsystem mit mindestens einem optischen Sensor ausgeführt. Dadurch wird ein berührungsloses Vermessen des Drahtes und ggfs. der Düsenöffnung ermöglicht, so dass direkt nach der Aufschmelzung des Drahtendes gemessen werden kann, ohne die Abkühlzeit beachten zu müssen.In a preferred embodiment of the device, the measuring device is designed as an optical measuring system with at least one optical sensor. This enables non-contact measurement of the wire and, if necessary, the nozzle opening, so that measurements can be taken immediately after the wire end has been melted without having to consider the cooling time.

Alternativ ist die Messvorrichtung als ein taktiles Messsystem mit mindestens einem Taster ausgeführt, wodurch die Messungen der Messvorrichtung unempfindlich gegen Umwelteinflüsse und Werkstoffeigenschaften, beispielsweise Lichtverhältnisse oder Oberflächenbeschaffenheit, sind.Alternatively, the measuring device is designed as a tactile measuring system with at least one pushbutton, as a result of which the measurements of the measuring device are insensitive to environmental influences and material properties, for example lighting conditions or surface properties.

In einer vorteilhaften Ausgestaltung ist die Messvorrichtung an der der ersten Elektrode zugewandten Seite des Drahts angeordnet. Der Schmelzvorgang beginnt an der der ersten Elektrode zugewandten Seite und schreitet sich zur entgegengesetzten Seite des Drahtes fort. Durch die Anordnung der Messvorrichtung in gleicher Ausrichtung wie die erste Elektrode entspricht die Messrichtung der Messvorrichtung der Richtung des Plasmagasstrahls, so dass die Form oder die Lage des Drahtendes zuverlässig gemessen werden kann, wobei vermieden wird, dass Metallteile, die möglicherweise im Schatten anderer stehen geblieben sind, nicht erfasst werden.In an advantageous embodiment, the measuring device is arranged on the side of the wire facing the first electrode. The melting process begins on the side facing the first electrode and progresses to the opposite side of the wire. By arranging the measuring device in the same orientation as the first electrode, the measuring direction of the measuring device corresponds to the direction of the plasma gas jet, so that the shape or position of the wire end can be measured reliably, while avoiding metal parts that may remain in the shadow of others are not recorded.

Vorzugsweise ist die Messvorrichtung an der Stelle der ersten Elektrode angeordnet, wobei die Elektrode zwischenzeitlich entfernbar ist. Dadurch kann die Messvorrichtung kostengünstig am Spritzbrenner angeordnet werden, da die Messvorrichtung automatisch korrekt zur Düsenöffnung ausgerichtet ist.The measuring device is preferably arranged at the location of the first electrode, the electrode being removable in the meantime. As a result, the measuring device can be arranged inexpensively on the spray gun, since the measuring device is automatically correctly aligned with the nozzle opening.

In einer bevorzugten Ausgestaltung ist die Messvorrichtung an der der ersten Elektrode abgewandten Seite des Drahtes angeordnet, wodurch die Messvorrichtung einfach montierbar und demontierbar ist.In a preferred embodiment, the measuring device is arranged on the side of the wire facing away from the first electrode, as a result of which the measuring device can be easily assembled and disassembled.

Vorzugsweise ist die Verstellvorrichtung ein mechanisch angetriebenes System, wodurch auf eine einfache und kostengünstige Weise, beispielsweise durch eine Schraube, die quer zur Drahtachse verläuft, die Verstellung des Drahtendes erfolgt.The adjusting device is preferably a mechanically driven system, as a result of which the wire end is adjusted in a simple and inexpensive manner, for example by means of a screw which runs transversely to the wire axis.

Alternativ ist die Verstellvorrichtung ein elektrisch angetriebenes System. Dadurch kann die Messvorrichtung und die Verstellvorrichtung auf eine einfache Weise miteinander gekoppelt werden, so dass die Vermessung und Verstellung des Drahtendes automatisiert erfolgt.Alternatively, the adjustment device is an electrically driven system. As a result, the measuring device and the adjusting device can be coupled to one another in a simple manner, so that the measurement and adjustment of the wire end takes place automatically.

In einer bevorzugten Ausführung des Verfahrens wird die Verstellung des Drahtendes durch die Messvorrichtung überwacht, so dass eine inkorrekte Verstellung des Drahtendes, beispielsweise durch einen Werker, vermieden wird.In a preferred embodiment of the method, the adjustment of the wire end is monitored by the measuring device, so that an incorrect adjustment of the wire end, for example by a worker, is avoided.

Vorzugsweise erfolgt die Messung der Messvorrichtung und die Verstellung des Drahtendes durch die Verstellvorrichtung automatisiert. Dadurch wird die für die Messung der Form oder der Lage des Drahtendes und die für die Verstellung des Drahtendes erforderliche Zeit reduziert.The measurement of the measuring device and the adjustment of the wire end are preferably carried out automatically by the adjustment device. This reduces the time required for measuring the shape or position of the wire end and the time required for adjusting the wire end.

Es wird somit eine Vorrichtung und ein Verfahren geschaffen, wodurch die Ausrichtung des Drahtes relativ zum Plasmagasstrahl genauer und zeitsparender ausgeführt und die Qualität einer thermischen Beschichtung einer Oberfläche verbessert werden kann.

  • Figur 1 zeigt eine Ausführung einer Vorrichtung zum thermischen Beschichten von Oberflächen im Längsschnitt des Drahtes und quer zur Düsenöffnung.
  • Figur 2 zeigt eine Ausführung einer Vorrichtung zum thermischen Beschichten von Oberflächen mit eingesetzter Elektrode im Längsschnitt des Drahtes und längs der Düsenöffnung.
  • Figur 3 zeigt eine erfindungsgemäße Ausführung einer Vorrichtung zum thermischen Beschichten von Oberflächen mit eingesetzter Messvorrichtung im Längsschnitt des Drahtes und längs der Düsenöffnung.
A device and a method are thus created, whereby the alignment of the wire relative to the plasma gas jet can be carried out more precisely and in a time-saving manner and the quality of a thermal coating of a surface can be improved.
  • Figure 1 shows an embodiment of a device for the thermal coating of surfaces in the longitudinal section of the wire and transverse to the nozzle opening.
  • Figure 2 shows an embodiment of a device for thermal coating of surfaces with an inserted electrode in the longitudinal section of the wire and along the nozzle opening.
  • Figure 3 shows an inventive embodiment of a device for thermal coating of surfaces with inserted measuring device in the longitudinal section of the wire and along the nozzle opening.

Die in den Figuren 1 und 2 dargestellte Vorrichtung weist einen Spritzbrenner 2 mit einer Drahtzuführvorrichtung 4 und einer Düseneinrichtung 6 auf. Die Drahtführvorrichtung 4 umfasst ein erstes ringförmiges Führungselement 8 und ein zweites ringförmiges Führungselement 10 zum Führen eines Drahtes 16. Die Düseneinrichtung 6 weist einen Düsenkörper 7 mit einer Düsenöffnung 14 auf, die quer zur Achse des Drahtes 16 angeordnet ist und auf das Drahtende 18 gerichtet ist.The in the Figures 1 and 2nd The device shown has a spray burner 2 with a wire feed device 4 and a nozzle device 6. The wire guide device 4 comprises a first ring-shaped guide element 8 and a second ring-shaped guide element 10 for guiding a wire 16. The nozzle device 6 has a nozzle body 7 with a nozzle opening 14 which is transverse to the Axis of the wire 16 is arranged and is directed to the wire end 18.

Im Düsenkörper 7 ist ein Fluidkanal 21 ausgebildet, der in die Düsenöffnung 14 mündet und mit dem der Düsenöffnung 14 abgewandten Ende mit einer nicht in den Figuren dargestellten Plasmagasquelle verbunden ist. In dem Fluidkanal 21 ist eine über Stege 19, 19' am Düsenkörper 7 befestigte erste Elektrode 20 angeordnet, die mit einer nicht dargestellten Stromquelle verbunden ist. Eine zweite Elektrode 22 bildet der Draht 16, der ebenfalls mit einer nicht in den Figuren dargestellten Stromquelle verbunden ist.A fluid channel 21 is formed in the nozzle body 7, which opens into the nozzle opening 14 and is connected with the end facing away from the nozzle opening 14 to a plasma gas source, not shown in the figures. Arranged in the fluid channel 21 is a first electrode 20, which is fastened to the nozzle body 7 via webs 19, 19 ′ and is connected to a power source (not shown). A second electrode 22 is formed by the wire 16, which is also connected to a current source not shown in the figures.

Im Betrieb der Vorrichtung strömt das in den Fluidkanal 21 einströmende und für die Plasmaentstehung benötigte Plasmagas durch die Düsenöffnung 14 in Richtung des Drahtendes 18. Bei entsprechender an den beiden Elektroden 20, 22 wirkenden hoher Spannung und Stromstärke bildet sich zwischen den beiden Elektroden 20, 22 ein Lichtbogen, der sich durch die Düsenöffnung 14 bis zum Drahtende 18 erstreckt. Der Lichtbogen verursacht somit am Drahtende 18 eine hohe Temperatur, wodurch ein Aufschmelzen des Drahtendes 18 erfolgt. Das aufgeschmolzene Drahtmaterial wird durch den Plasmastrahl und insbesondere durch Luftdüsenöffnungen 24 in Richtung einer Oberfläche einer Zylinderbohrung zerstäubt.During operation of the device, the plasma gas flowing into the fluid channel 21 and required for the formation of plasma flows through the nozzle opening 14 in the direction of the wire end 18. With a corresponding high voltage and current intensity acting on the two electrodes 20, 22, the two electrodes 20, 22 are formed an arc extending through the nozzle opening 14 to the wire end 18. The arc thus causes a high temperature at the wire end 18, causing the wire end 18 to melt. The melted wire material is atomized through the plasma jet and in particular through air nozzle openings 24 in the direction of a surface of a cylinder bore.

Die Luftdüsenöffnungen 24 sind im Düsenkörper 7 ausgebildet und kreisförmig um die Düsenöffnung 14 angeordnet. Die Luftdüsenöffnungen 24 sind über jeweils einen im Düsenkörper 7 ausgebildeten Luftdüsenkanal 25 mit einer in den Figuren nicht dargestellten Luftdruckversorgung fluidisch verbunden.The air nozzle openings 24 are formed in the nozzle body 7 and are arranged in a circle around the nozzle opening 14. The air nozzle openings 24 are fluidly connected via an air nozzle channel 25 formed in the nozzle body 7 to an air pressure supply, not shown in the figures.

Entscheidend für die Qualität einer Beschichtung ist, dass Fehlstellen in der Beschichtung vermieden werden, die durch nicht oder nur teilweise aufgeschmolzenes Drahtmaterial verursacht werden und zu Einschlüssen und Lunkern in der dünnen Beschichtungsschicht führen. Daher weist die Vorrichtung eine Verstellvorrichtung 26 auf, die auf das zweite Führungselement 10 wirkt und das Führungselement 10 zusammen mit dem Draht 16 quer zur Längsachse des Drahtes 16 verschiebt.It is crucial for the quality of a coating that defects in the coating are avoided that are caused by wire material that has not or only partially melted and that leads to inclusions and cavities in the thin coating layer. Therefore, the device has an adjusting device 26, which acts on the second guide element 10 and moves the guide element 10 together with the wire 16 transversely to the longitudinal axis of the wire 16.

Die Verstellung des Drahtes 16 kann elektrisch, beispielsweise durch Piezoelemente, oder mechanisch erfolgen. In der Figur 1 ist eine mechanische Ausführung der Verstellvorrichtung 26 dargestellt, wobei sich die Verstellvorrichtung 26 aus einer ersten Verstellschraube 28 und einem ersten Stift 32 sowie einer zweiten Verstellschraube 30 und einem zweiten Stift 34 zusammensetzt. Dabei greifen radial an das zweite ringförmige Führungselement 10 die Stifte 32, 34 an, die in jeweils einer Bohrung 36, 38 geführt sind und durch jeweils eine Verstellschraube 28, 30 verschiebbar sind. Die Verstellschrauben 28, 30 sind ebenfalls in den Bohrungen 36, 38 angeordnet, wobei die Bohrungen 36, 38 jeweils ein Innengewinde aufweisen, welches das Ein- und Ausschrauben der Verstellschrauben 28, 30 ermöglichen.The wire 16 can be adjusted electrically, for example by piezo elements, or mechanically. In the Figure 1 A mechanical embodiment of the adjusting device 26 is shown, the adjusting device 26 being composed of a first adjusting screw 28 and a first pin 32 as well as a second adjusting screw 30 and a second pin 34. The pins 32, 34 engage radially on the second annular guide element 10, which are each guided in a bore 36, 38 and can be displaced by a respective adjusting screw 28, 30. The adjusting screws 28, 30 are also arranged in the bores 36, 38, the bores 36, 38 each having an internal thread, which enable the adjusting screws 28, 30 to be screwed in and out.

Durch das Ein- bzw. Ausschrauben der Verstellschrauben 28, 30 werden die Stifte 32, 34 und das Führungselement 10 radial zur Längsachse des Drahtes 16 verschoben und das Drahtende 18 relativ zur Düsenöffnung 14 versetzt. Dabei muss eine der beiden Verstellschrauben 28, 30 für die Verschiebung des Führungselementes 10 zwingenderweise eingeschraubt und die andere der beiden Verstellschrauben 28, 30 ausgeschraubt werden.By screwing in or unscrewing the adjusting screws 28, 30, the pins 32, 34 and the guide element 10 are displaced radially to the longitudinal axis of the wire 16 and the wire end 18 is displaced relative to the nozzle opening 14. One of the two adjusting screws 28, 30 for the displacement of the guide element 10 must be screwed in and the other of the two adjusting screws 28, 30 must be unscrewed.

Um den für die Verstellung benötigten Verstellweg zu ermitteln, ist am Spritzbrenner 2 erfindungsgemäß eine Messvorrichtung 40 befestigt. Figur 3 zeigt eine derartige Anordnung der Messvorrichtung 40. Die Messvorrichtung 40 ist ein optisches System und an der Stelle angeordnet, an der die zweite Elektrode 22 im Beschichtungsvorgang angeordnet ist. So wird die zweite Elektrode 22 zwischen den Beschichtungsvorgängen entfernt und eine Messvorrichtung 40 eingesetzt.In order to determine the adjustment path required for the adjustment, a measuring device 40 is attached to the spray gun 2 according to the invention. Figure 3 shows such an arrangement of the measuring device 40. The measuring device 40 is an optical system and is arranged at the point at which the second electrode 22 is arranged in the coating process. The second electrode 22 is thus removed between the coating processes and a measuring device 40 is used.

Die Messvorrichtung 40 weist einen optischen Sensor 42 auf, der die Form des Drahtendes 18 misst. Bei einer schlechten Positionierung des Drahtendes 18 zur Düsenöffnung 14 entsteht eine sogenannte Schmelzflanke, die durch die Messvorrichtung 40 erfasst wird. Durch die ermittelte Geometrie der Schmelzflanke ist bekannt, in welche Richtung der Draht verschoben werden muss, um das gesamte Drahtende 18 aufzuschmelzen. Bei einem neu eingesetzten Draht 16 erfolgt eine kurze Betätigung der Vorrichtung, so dass ein erster Schmelzvorgang erfolgt und sich die Form des Drahtendes 18 aufgrund des Schmelzvorgangs verändert. Diese Formveränderung wird durch die Messvorrichtung 40 erfasst und das Drahtende 18 basierend auf der Messung der Messvorrichtung 40 durch einen Werker verstellt. Während der Verstellung des Drahtes 16 ist die Messvorrichtung 40 weiterhin aktiv und überwacht die Verstellung.The measuring device 40 has an optical sensor 42, which measures the shape of the wire end 18. If the wire end 18 is poorly positioned in relation to the nozzle opening 14, a so-called melting flank arises, which is detected by the measuring device 40. The determined geometry of the melting flank makes it known in which direction the wire has to be displaced in order to melt the entire wire end 18. With a newly inserted wire 16, the device is briefly actuated so that a first melting process takes place and the shape of the wire end 18 changes due to the melting process. This change in shape is detected by the measuring device 40 and the wire end 18 is adjusted based on the measurement of the measuring device 40 by a worker. During the adjustment of the wire 16, the measuring device 40 is still active and monitors the adjustment.

So zeichnet sich die beschriebene Vorrichtung zum thermischen Beschichten einer Oberfläche durch die erfindungsgemäße Anordnung der Messvorrichtung aus, indem die Form des Drahtendes 18 genau erfasst, basierend darauf eine Verstellung des Drahtendes 18 durch den Werker oder ggfs. automatisiert vorgenommen wird und die Verstellung durch die Messvorrichtung 40 überwacht wird. So werden Fehlstellen in der Beschichtung vermieden.For example, the described device for thermal coating of a surface is characterized by the arrangement of the measuring device according to the invention, in that the shape of the wire end 18 is precisely determined, based on this the wire end 18 is adjusted by the worker or, if necessary, automatically and the adjustment by the measuring device 40 is monitored. This prevents defects in the coating.

Es sollte deutlich sein, dass auch andere konstruktive Ausführungsformen im Vergleich zur beschriebenen Ausführungsform möglich sind, ohne den Schutzbereich des Hauptanspruchs zu verlassen. Grundsätzlich kann die Düseneinrichtung oder die Drahtzuführeinrichtung konstruktiv anders ausgeführt sein. Die Messvorrichtung kann beispielsweise auch über ein taktiles System mit einem Taster erfolgen. Auch kann die Verstellvorrichtung elektrisch und ggfs. automatisiert betätigt werden, so dass ein Werker nicht einzugreifen braucht.It should be clear that other constructive embodiments are possible in comparison to the described embodiment without leaving the scope of the main claim. In principle, the nozzle device or the wire feed device can be designed differently. The measuring device can also be carried out, for example, using a tactile system with a button. The adjustment device can also be operated electrically and, if necessary, automatically, so that a worker does not have to intervene.

Claims (11)

  1. Device for thermal coating of a surface with a spray gun (2) comprising a wire feed device (4) having at least one guide element (10, 12) for guiding a wire (14),
    a plasma gas source,
    a nozzle device (6) with a nozzle opening (14) for generating a plasma gas jet directed onto a wire end (18),
    a first electrode (20) and a second electrode (22), wherein the wire (16) acts as the second electrode (22), and
    an adjusting device (26) by which the wire end (18) is adjustable by a defined adjustment path,
    characterized in that
    a measuring device (40) is provided which is mounted to the spray gun (2) at a defined position, wherein the position or shape of the wire end (18) can be determined by means of the measuring device (40).
  2. Device for thermal coating of a surface of claim 1, characterized in that the measuring device (40) is designed as an optical measuring system with at least one optical sensor (42).
  3. Device for thermal coating of a surface of claim 1, characterized in that the measuring device (40) is designed as a tactile measuring system with at least one button.
  4. Device for the thermal coating of a surface of one of the preceding claims, characterized in that the measuring device (40) is arranged on the side of the wire (16) facing the first electrode (20).
  5. Device for the thermal coating of a surface of claim 4, characterized in that the measuring device (40) is arranged at the location of the first electrode (20), wherein the first electrode (20) is removable in the meantime.
  6. Device for thermal coating of a surface of one of claims 1 to 3, characterized in that the measuring device (40) is arranged on the side of the wire (16) facing away from the first electrode (20).
  7. Device for the thermal coating of a surface of one of the preceding claims, characterized in that the adjusting device (26) is a mechanically driven system.
  8. Device for the thermal coating of a surface of one of claims 1 to 6, characterized in that the adjusting device (26) is an electrically driven system.
  9. Method for improving the quality of a thermal coating with a device for thermal coating of a surface of one of the preceding claims,
    characterized in that
    after a first actuation of the spray gun (2), a measurement of the shape and/or the position of the wire end (18) relative to the nozzle opening (14) is performed by the measuring device (40) and, based on the measurement of the measuring device (40), the wire end (18) is adjusted accordingly by the adjusting device (26) with respect to the plasma gas jet.
  10. Method for improving the quality of a thermal coating with a device for thermal coating of a surface of claim 9, characterized in that the adjustment of the wire end (18) is monitored by the measuring device (40).
  11. Method for improving the quality of a thermal coating with a device for thermal coating of a surface of one of claims 9 or 10, characterized in that the measurement of the measuring device (40) and the adjustment of the wire end (18) is effected in an automated manner by the adjustment device (26).
EP17177565.3A 2016-07-01 2017-06-23 Device for thermally coating a surface, and method for measuring the position or shape of a wire end in a device for thermally coating a surface Active EP3263227B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PL17177565T PL3263227T3 (en) 2016-07-01 2017-06-23 Device for thermally coating a surface, and method for measuring the position or shape of a wire end in a device for thermally coating a surface

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE102016112098.7A DE102016112098A1 (en) 2016-07-01 2016-07-01 A device for thermally coating a surface and method for measuring the position or shape of a wire end in a device for thermally coating a surface

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EP3263227A1 EP3263227A1 (en) 2018-01-03
EP3263227B1 true EP3263227B1 (en) 2020-04-15

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Publication number Priority date Publication date Assignee Title
DE4210798A1 (en) * 1992-04-01 1993-10-07 Heinrich Dr Ing Kern Metal vapour deposition plant using thermal arcing process - uses two wires to generate arc observed by optical sensor to provide feedback to regulate feeding of wire
US6066833A (en) * 1998-07-29 2000-05-23 Howard Industries Apparatus and method for selectively changing welding wire
DE202008006784U1 (en) * 2008-05-19 2008-08-07 Daimler Ag coater
DE102008024237B4 (en) * 2008-05-19 2021-02-18 Daimler Ag Method for supplying a coating device with a coating wire
DE102011002501A1 (en) 2011-01-11 2012-07-12 Ford-Werke Gmbh Device for thermally coating a surface

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* Cited by examiner, † Cited by third party
Title
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