JP2012197493A - Arc spraying device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an arc spraying gun device which can perform spraying in such a manner that a sprayed coating thickness is made uniform even in a place inferior in workability.SOLUTION: The arc spraying gun device 100 melts metal wires 104a, 104b by arc discharge, atomizes the obtained metal droplets, and sprays the same on a base material as sprayed particles. The arc spraying gun device 100 includes: a driving part 110 having a motor 118 and a roller 120 paying out the metal wires 104a, 104b from a wire feeder 102; leader chips 138a, 138b guiding the metal wires 104a, 104b toward one point and arc-discharging them; a spraying nozzle unit 112 having air nozzle mouths 144a, 144b injecting compressed air from a compressor 106 to the vicinity of the leader chips and atomizing the metal droplets; and tubes 126a, 126b guiding the metal wires 104a, 104b from the driving part 110 to the spraying nozzle unit 112.

Description

  The present invention relates to an arc spraying apparatus in which a metal wire is melted by arc discharge, the resulting metal droplets are atomized with compressed air, and sprayed onto a substrate as spray particles.

  Thermal spraying is a type of coating technique in which a coating material called a thermal spray material is melted by heating and is finely divided (comminuted) with compressed air to be sprayed onto a workpiece called a substrate. Thermal spraying is widely used for the purpose of rust prevention treatment, wear resistance treatment, heat resistance treatment, and the like on metallic substrates. In addition, since thermal spraying has a relatively small thermal effect on the base material, it is performed for the purpose of decoration treatment on base materials of various materials other than metal.

  Thermal spraying is broadly divided into electric and gas types depending on the difference in the heat source for heating the thermal spray material. Arc spraying is an electric spraying method in which an arc discharge is generated between a pair of metal wires, which are the thermal spray material, these are melted by the amount of heat, and the resulting metal droplets are atomized with compressed air and sprayed as spray particles. It is a kind. Arc spraying has the advantages of better melting efficiency and larger film formation per unit time than flame spraying, which is a gas spraying method.

  Arc spraying is extremely safe because it does not use high-pressure combustible gas. In addition, general arc spraying is performed using a small-sized spray gun apparatus called a so-called handy type arc spray gun apparatus. As a result, arc spraying is much easier than flame spraying, and can be performed with stable work quality even in the field of spraying repair work with few skilled workers. As a thermal spraying apparatus used at such a thermal spraying work site, an on-site work arc spraying apparatus is now widely used.

  A general arc spraying apparatus for field work consists of a metal wire supply device, a spraying power supply device, and a hand-held arc spray gun device, and is configured to receive compressed air and electricity from an external supply source. . At present, since the arc spray gun apparatus has been developed to be small and light, it can be used at various work sites. For example, the arc spraying device described in Patent Document 1 is broadly divided into a spraying gun device main body, two spraying material conduits extending forward from the spraying gun device main body, and a spraying nozzle provided at the tip of these welding material conduits. It is composed of units.

Japanese Patent Laid-Open No. 04-99858

  By the way, when the rust prevention treatment is applied to the base material by arc spraying, if unevenness occurs in the adhesion strength and the coating amount of the metal coating (spray coating) at the processing location, the metal coating (spray coating) is unstable and uneven. As a result, the rust prevention performance is significantly reduced. In order to prevent this, it is necessary to operate the sprayed particles emitted from the arc spray gun apparatus so as to be sprayed substantially perpendicularly to the surface of the base material so that the thickness of the sprayed coating is made uniform.

  Here, since the arc spraying apparatus of patent document 1 is equipped with the spray nozzle unit reduced in size at the tip of the melt conduit extended forward from the spray gun apparatus main body, it was difficult to spray with the conventional arc spray gun apparatus. It is said that the thermal spraying to a place where it is difficult to reach at the construction site such as an object can be suitably performed. However, because it has a long melt conduit, it is a manhole where there are obstacles, is not flat or narrow, such as a construction site where many steel frames are built, or where manpower cannot enter In the case of a narrow place on the inner surface or near the wall, the freedom of handling is limited.

  In view of such a problem, the present invention provides a thermal spray nozzle that can be freely used in accordance with the processing location even in places where there are obstacles in the surroundings, in narrow locations, and in locations where the processing location is poor, such as when the processing location is not flat. An object of the present invention is to provide an arc spray gun apparatus capable of performing spraying so that the spray coating thickness is uniform with the direction of the unit directed.

  In order to solve the above problems, a typical configuration of an arc spray gun apparatus according to the present invention is an arc spray gun in which a metal wire is melted by arc discharge, and the resulting metal droplets are atomized and sprayed as spray particles on a substrate. In the apparatus, a drive unit having a motor and a roller for feeding out a pair of metal wires supplied from a wire feeder, a leader chip that guides the pair of metal wires toward one point and causing arc discharge, and compressed air supplied from a compressor A spray nozzle unit having an air nozzle port for blowing metal near the leader chip to atomize metal droplets, and a pair of flexibly bent tubes for guiding a pair of metal wires from the drive unit to the spray nozzle unit It is characterized by.

  The thermal spray nozzle unit has a small and light configuration because a relatively heavy element such as a motor is accommodated in the drive unit. Moreover, the tube which connects this thermal spray nozzle unit and a drive part can be bent flexibly. As a result, the thermal spray nozzle unit can be freely moved manually by personnel. Therefore, thermal spraying can be easily performed even in the back of a steel frame or in the back of a narrow place as long as it is within the reach of personnel. Further, for example, thermal spraying can be performed on the inner surface of a manhole or a place with a narrow width near a wall that an operator cannot enter. In addition, the spray nozzle unit can be operated freely so that it is almost perpendicular to the substrate, even for non-flat processing locations such as the periphery of bolts and holes, which was difficult with conventional arc spray gun equipment. It becomes possible to perform thermal spraying so that the thermal spray coating becomes uniform.

  The pair of tubes may be Teflon tubes. A Teflon tube (Teflon (registered trademark)) has flexibility, good sliding of a metal wire, and is excellent in heat resistance and chemical resistance. Therefore, if it is a Teflon tube, it can respond to various work sites.

  The drive unit may further include a belt unit that is attached to the waist of a person. Since the drive unit includes a motor and the like, it is heavier than the thermal spray nozzle unit. Therefore, the driving part can be attached to the waist part to reduce the fatigue of the worker. If it is this structure, it will become possible for a worker to perform thermal spraying work without a burden, moving freely.

  It is preferable that the air nozzle port is disposed on both sides of the leader chip, and the compressed air is blown out in a direction in which the pair of metal wires joins ahead of one point where the pair of metal wires are close to each other. Thereby, since the compressed air does not directly hit the generation point of the arc discharge, it is possible to suppress the loss of heat during the arc discharge. Here, the thermal sprayed particles, in which the metal droplets are atomized, are exposed to compressed air to reduce the amount of heat. Thereafter, the sprayed particles reaching the substrate are physically solidified and deposited on the surface of the substrate by mechanical engagement to form a sprayed coating. Therefore, if it is the said structure, it can be sprayed on a base material, for example, the temperature of a thermal spray particle can be lowered | hung to near normal temperature, and the thermal influence on a base material can further be suppressed. Further, there is no danger or inconvenience when the thermal spray nozzle unit is gripped by hand.

  According to the present invention, the direction of the thermal spray nozzle unit can be freely directed in accordance with the processing location even in places where there are obstacles in the surroundings, in narrow locations, and in locations where workability is poor, such as when the processing location is not flat. Thus, it is possible to provide an arc spray gun apparatus capable of spraying so that the thickness of the spray coating becomes uniform.

It is a figure showing the whole arc spraying device composition concerning this embodiment. It is a figure which shows the inside of the drive part of FIG. It is a figure which shows the thermal spray nozzle unit of FIG. 1 from each direction. It is AA sectional drawing of Fig.3 (a). It is a figure which shows the work scenery using the arc spraying apparatus concerning this embodiment. It is a figure which shows the work site using the arc spraying apparatus concerning this embodiment.

  Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. The dimensions, materials, and other specific numerical values shown in the embodiment are merely examples for facilitating understanding of the invention, and do not limit the present invention unless otherwise specified. In the present specification and drawings, elements having substantially the same function and configuration are denoted by the same reference numerals, and redundant description is omitted, and elements not directly related to the present invention are not illustrated. To do.

  FIG. 1 is a diagram showing an overall configuration of an arc spray gun apparatus 100 according to the present embodiment. An arc spray gun apparatus 100 shown in FIG. 1 is a hand-held spray gun apparatus in which a worker (worker) holds the hand to work. The arc spray gun apparatus 100 is obtained by using a pair of metal wires 104a and 104b (see FIG. 2) supplied from a wire feeder 102 as a thermal spray material and generating arc discharge on the metal wires 104a and 104b to melt them. Metal droplets are atomized using compressed air supplied from the compressor 106 in FIG. 1 and sprayed as spray particles onto the substrate.

  The arc spray gun apparatus 100 mainly connects a drive unit 110 including a motor 118 and the like (see FIG. 2), a spray nozzle unit 112 that blows out spray particles atomized by metal wires 104a and 104b, and these. Consists of cords and tubes.

  FIG. 2 is a diagram illustrating the inside of the driving unit 110 of FIG. FIG. 2 shows the inside of the housing 116 with the lid 122 of the housing 116 of the driving unit 110 opened. As shown in FIG. 2, two connecting tubes 114 a and 114 b extending from the wire feeder 102 (see FIG. 1) are connected to the driving unit 110. These communication tubes 114 a and 114 b supply a pair of metal wires 104 a and 104 b to the drive unit 110. The drive unit 110 includes a motor 118 and a roller 120 inside the casing 116, and these drive the metal wires 104a and 104b from the wire feeder 102 shown in FIG. 1 to the thermal spray nozzle unit 112. It is a mechanism to pay out.

  As shown in FIG. 2, the motor 118 is installed in the upper part of the housing | casing 116 so that a rotating shaft may face the downward direction. The roller 120 is coaxial with the motor 118 and is installed so as to cross the metal wires 104a and 104b. A pressing roller 124 that presses the metal wires 104 a and 104 b against the roller 120 is provided on the back side of the lid portion 122 of the casing 116. Accordingly, when the motor 118 is driven with the lid 122 closed, the driving unit 110 rotates the roller 120 to cause the metal wires 104a and 104b sandwiched between the roller 120 and the pressing roller 124 to spray the nozzle unit 112 (FIG. 1). Refer to).

  Refer to FIG. 1 again. As shown in FIG. 1, a pair of tubes 126 a and 126 b are connected from the drive unit 110 to the thermal spray nozzle unit 112. The tubes 126a and 126b guide the metal wires 104a and 104b (see FIG. 2) from the driving unit 110 to the thermal spray nozzle unit 112, respectively. In the present embodiment, Teflon tubes (Teflon (registered trademark)) are employed as the tubes 126a and 126b. The Teflon tube has flexibility, good sliding of the metal wire, and excellent heat resistance and chemical resistance. Therefore, if it is a Teflon tube, it can respond to various work sites. In the present embodiment, Teflon tubes are also used for the communication tubes 114 a and 114 b connected from the wire feeder 102 to the drive unit 110.

  FIG. 3 is a view showing the thermal spray nozzle unit 112 of FIG. 1 from each direction. FIG. 3A is a side view of the thermal spray nozzle unit 112. As will be described in detail later, the thermal spray nozzle unit 112 is a part that an operator holds and operates, and the thermal spray nozzle unit 112 is also a part where arc discharge occurs. Therefore, an arc cover 130a (130b) covering the vicinity of the arc discharge occurrence point (arc intersection P1) is provided as a safety measure on the side of the thermal spray nozzle unit 112. In FIG. 3A, the front side arc cover 130b (see FIG. 3B) is omitted, and the inside of the thermal spray nozzle unit 112 is shown.

  Inside the thermal spray nozzle unit 112, a pair of guide tubes 132a and 132b are provided. The aforementioned tubes 126a and 126b are connected to the guide tubes 132a and 132b, respectively, and the metal wires 104a and 104b are supplied.

  The guide tubes 132a and 132b are metallic tube materials and have conductivity. Here, as shown in FIG. 1, a total of two power cords 134 a and 134 b are connected to the thermal spray nozzle unit 112. The power cords 134 a and 134 b are supported by the drive unit 110 and connected to the power source 108. The drive unit 110 is supplied with power for the motor 118 by a power cord 134c. As shown in FIG. 3A, the power cords 134a and 134b are connected to the guide tubes 132a and 132b via the electrodes 136a and 136b, respectively. A voltage is applied to the metal wires 104a and 104b from the inner walls of the guide tubes 132a and 132b.

  Leader chips 138a and 138b are provided at the tips of the guide tubes 132a and 132b, respectively. The leader chips 138a and 138b are pipe members, and are installed obliquely toward one front point (arc intersection P1) so that the metal wires 104a and 104b are brought into contact with each other. As a result, the metal wires 104a and 104b are guided to the arc intersection P1, and an arc current flows between the metal wires 104a and 104b at the arc intersection P1, that is, arc discharge occurs. The metal wires 104a and 104b are melted into metal droplets by the amount of heat during the arc discharge.

  An air hose 140 that guides compressed air from an external compressor 106 (see FIG. 1) is connected to the thermal spray nozzle unit 112. The compressed air supplied through the air hose 140 passes through the inside of the air nozzle block 142 and is blown out from the air nozzle ports 144a and 144b (see FIG. 3B).

  FIG. 3B is a front view of the nozzle unit 112 of FIG. As shown in FIG. 3B, an opening 146 through which the leader chips 138 a and 138 b are passed is formed in the front center of the air nozzle block 142. The air nozzle ports 144a and 144b are elongated along the opening 146 and are provided on both sides of the leader chips 138a and 138b.

  FIG. 4 is a cross-sectional view taken along the line AA in FIG. As shown in FIG. 4, each of the air nozzle ports 144a and 144b is configured to blow compressed air obliquely toward one place (confluence region E1) ahead of the arc intersection P1. As a result, a negative pressure is generated from the arc intersection P1 toward the merging area E1 in front of the arc intersection P1. In the arc spray gun apparatus 100, the metal droplets (melted metal wires 104a and 104b) are sucked up to the compressed air layer by this negative pressure to be atomized in the merging zone E1 to form spray particles, and then the spray particles are compressed air. It is sprayed on the base material. That is, since the compressed air is not directly applied to the arc discharge occurrence point (arc intersection P1), it is possible to suppress a loss of heat during arc discharge.

  Here, it is ideal that the spray particles, which are made into a metal droplet state by arc heat and atomized by compressed air, maintain the droplet state just before reaching the substrate surface. The spray particles reaching the substrate are physically solidified and deposited on the surface of the substrate by mechanical engagement to form a spray coating. At that time, in the arc spray gun apparatus 100, since the metal droplets are exposed to the compressed air to reduce the amount of heat, it is possible to reduce the temperature of the spray particles sprayed onto the base material to near normal temperature. According to this, the thermal influence on the base material can be further suppressed, and it is preferable because there is no danger or inconvenience when the thermal spray nozzle unit 112 is gripped by hand.

  5 and 6 are views showing a working scene using the arc spray gun apparatus 100 according to the present embodiment. Fig.5 (a) is a figure which shows the example of mounting | wearing of a thermal spray gun apparatus. As shown in FIG. 5A, a belt unit 150 can be attached to the drive unit 110. The belt unit 150 allows the driving unit 110 to be attached to the waist of the worker 152. Since the driving unit 110 includes the motor 118 and the like, the driving unit 110 is heavier than the thermal spray nozzle unit 112. Therefore, in the arc spray gun apparatus 100, the fatigue of the operator 152 can be reduced by adopting a configuration in which the drive unit 110 is mounted on the waist. Further, with this configuration, the worker 152 can perform the thermal spraying work without burden while moving freely.

  FIG. 5B is a diagram illustrating an operation example of the thermal spray nozzle unit 112. As shown in FIG. 5B, the thermal spray nozzle unit 112 is a part that the operator 152 holds in his hand. The thermal spray nozzle unit 112 is configured to be small and light because a relatively heavy element such as the motor 118 is accommodated in the drive unit 110. Further, in the arc spray gun apparatus 100, the drive unit 110 and the spray nozzle unit 112 are connected by cords and tubes. These cords and tubes are made of a resin material. For example, the tubes 126a and 126b are Teflon tubes and can be bent flexibly. Thereby, the thermal spray nozzle unit 112 can be freely moved manually by the operator 152.

  With the above-described configuration, in the arc spray gun apparatus 100, if it is a place that can be reached by the worker 152, it can be easily sprayed even at a location where an obstacle exists around, for example, the back side of the steel frame 156 that intersects the steel frame 154. Is possible. In addition, the direction of the thermal spray nozzle unit 112 can be freely operated in accordance with the processing location of a non-flat processing location such as the bolt 158 or the hole 160, which is difficult with a conventional arc spray gun apparatus. Thus, it is possible to perform thermal spraying so that the sprayed coating is uniform and substantially perpendicular to the substrate.

  Further, according to the arc spray gun apparatus 100, spraying can be easily performed even in a narrow work site 200 as shown in FIG. For example, even when a plurality of structures 202a and 202b such as the work site 200 are installed adjacent to each other and it is desired to repair the surface 204 located in a narrow gap between them, the arc spray gun In the case of the apparatus 100, the spray nozzle unit 112 can be easily inserted, and spray particles can be sprayed substantially perpendicularly to the surface 204 to form a uniform spray coating. In addition, the thermal spraying operation can be suitably performed not only at the work site 200, but also at a place with poor workability such as a manhole inner surface or a narrow place near the wall where a worker cannot enter.

  As mentioned above, although preferred embodiment of this invention was described referring an accompanying drawing, it cannot be overemphasized that this invention is not limited to this embodiment. It will be apparent to those skilled in the art that various changes and modifications can be made within the scope of the claims, and these are naturally within the technical scope of the present invention. Understood.

  INDUSTRIAL APPLICABILITY The present invention can be used as an arc spray gun apparatus in which a metal wire is melted by arc discharge, and the resulting metal droplets are atomized with compressed air to form spray particles, which are sprayed on a substrate.

P1 ... Arc intersection point, E1 ... Junction zone, 100 ... Arc spraying device, 102 ... Wire feeder, 104a, 104b ... Metal wire, 106 ... Compressor, 108 ... Power source, 110 ... Drive unit, 112 ... Thermal spray nozzle unit, 114a, 114b ... Communication tube, 116 ... Case, 118 ... Motor, 120 ... Roller, 122 ... Cover, 124 ... Pressing roller, 126a, 126b ... Tube, 130a, 130b ... Arc cover, 130a, 130b ... Arc cover, 132a, 132b ... Guide tube, 134a, 134b, 134c ... Power cord, 136a, 136b ... Electrode, 138a, 138b ... Leader chip, 140 ... Air hose, 142 ... Air nozzle block, 144a, 144b ... Air nozzle port, 146 Opening, 150 ... belt portion, 152 ... workers, 154 and 156 ... steel, 158 ... bolts, 160 ... hole, 200 ... work site, 202a, 202b ... structures, 204 ... surface

Claims (4)

In an arc spray gun apparatus in which a metal wire is melted by arc discharge and the resulting metal droplets are atomized and sprayed onto the substrate as spray particles,
A drive unit having a motor and a roller for feeding out a pair of metal wires supplied from a wire feeder;
A leader chip that guides the pair of metal wires toward one point to cause the arc discharge, and an air nozzle opening that blows compressed air supplied from a compressor to the vicinity of the leader chip to atomize the metal droplets. Spray nozzle unit,
An arc spray gun apparatus comprising a pair of flexibly bent tubes for guiding the pair of metal wires from the drive unit to the spray nozzle unit.   The arc spray gun apparatus according to claim 1, wherein the pair of tubes are Teflon tubes.   The arc spray gun apparatus according to claim 1, wherein the driving unit further includes a belt unit attached to a waist portion of a person.   The air nozzle port is arranged on both sides of the leader chip, and blows out the compressed air in a direction in which the pair of metal wires joins ahead of one point adjacent to the pair of metal wires. The arc spray gun apparatus according to claim 1.

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