JP4688353B2 - High frequency induction heating type powder coating equipment - Google Patents

High frequency induction heating type powder coating equipment Download PDF

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JP4688353B2
JP4688353B2 JP2001197772A JP2001197772A JP4688353B2 JP 4688353 B2 JP4688353 B2 JP 4688353B2 JP 2001197772 A JP2001197772 A JP 2001197772A JP 2001197772 A JP2001197772 A JP 2001197772A JP 4688353 B2 JP4688353 B2 JP 4688353B2
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frequency induction
powder coating
hanger
high frequency
hook
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JP2003010737A (en
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孝四郎 吉野
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Yoshino Kosakujo KK
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Yoshino Kosakujo KK
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Priority to JP2001197772A priority Critical patent/JP4688353B2/en
Priority to US10/101,722 priority patent/US6797066B2/en
Priority to CNB021082596A priority patent/CN1247317C/en
Priority to AT02252483T priority patent/ATE277692T1/en
Priority to EP02252483A priority patent/EP1270089B1/en
Priority to DE60201380T priority patent/DE60201380T2/en
Priority to KR1020020020404A priority patent/KR100864684B1/en
Publication of JP2003010737A publication Critical patent/JP2003010737A/en
Priority to HK03103874A priority patent/HK1051663A1/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
    • 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
    • B05B13/02—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work
    • B05B13/0221—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work characterised by the means for moving or conveying the objects or other work, e.g. conveyor belts
    • B05B13/0264—Overhead conveying means, i.e. the object or other work being suspended from the conveying means; Details thereof, e.g. hanging hooks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C9/00—Apparatus or plant for applying liquid or other fluent material to surfaces by means not covered by any preceding group, or in which the means of applying the liquid or other fluent material is not important
    • B05C9/08—Apparatus or plant for applying liquid or other fluent material to surfaces by means not covered by any preceding group, or in which the means of applying the liquid or other fluent material is not important for applying liquid or other fluent material and performing an auxiliary operation
    • B05C9/14—Apparatus or plant for applying liquid or other fluent material to surfaces by means not covered by any preceding group, or in which the means of applying the liquid or other fluent material is not important for applying liquid or other fluent material and performing an auxiliary operation the auxiliary operation involving heating or cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B16/00—Spray booths
    • B05B16/20—Arrangements for spraying in combination with other operations, e.g. drying; Arrangements enabling a combination of spraying operations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B16/00—Spray booths
    • B05B16/40—Construction elements specially adapted therefor, e.g. floors, walls or ceilings
    • B05B16/405—Partly or totally cylindrical walls; Round floors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B5/00—Electrostatic spraying apparatus; Spraying apparatus with means for charging the spray electrically; Apparatus for spraying liquids or other fluent materials by other electric means
    • B05B5/08—Plant for applying liquids or other fluent materials to objects
    • B05B5/082—Plant for applying liquids or other fluent materials to objects characterised by means for supporting, holding or conveying the objects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/02—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
    • B05D3/0254—After-treatment
    • B05D3/0281—After-treatment with induction heating
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F26—DRYING
    • F26B—DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
    • F26B15/00—Machines or apparatus for drying objects with progressive movement; Machines or apparatus with progressive movement for drying batches of material in compact form
    • F26B15/02—Machines or apparatus for drying objects with progressive movement; Machines or apparatus with progressive movement for drying batches of material in compact form with movement in the whole or part of a circle
    • F26B15/04—Machines or apparatus for drying objects with progressive movement; Machines or apparatus with progressive movement for drying batches of material in compact form with movement in the whole or part of a circle in a horizontal plane
    • F26B15/06—Machines or apparatus for drying objects with progressive movement; Machines or apparatus with progressive movement for drying batches of material in compact form with movement in the whole or part of a circle in a horizontal plane involving several planes, one above the other
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F26—DRYING
    • F26B—DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
    • F26B3/00—Drying solid materials or objects by processes involving the application of heat
    • F26B3/28—Drying solid materials or objects by processes involving the application of heat by radiation, e.g. from the sun
    • F26B3/30—Drying solid materials or objects by processes involving the application of heat by radiation, e.g. from the sun from infrared-emitting elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F26—DRYING
    • F26B—DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
    • F26B3/00—Drying solid materials or objects by processes involving the application of heat
    • F26B3/32—Drying solid materials or objects by processes involving the application of heat by development of heat within the materials or objects to be dried, e.g. by fermentation or other microbiological action
    • F26B3/34—Drying solid materials or objects by processes involving the application of heat by development of heat within the materials or objects to be dried, e.g. by fermentation or other microbiological action by using electrical effects
    • F26B3/347—Electromagnetic heating, e.g. induction heating or heating using microwave energy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B14/00—Arrangements for collecting, re-using or eliminating excess spraying material
    • B05B14/40—Arrangements for collecting, re-using or eliminating excess spraying material for use in spray booths
    • B05B14/48—Arrangements for collecting, re-using or eliminating excess spraying material for use in spray booths specially adapted for particulate material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
    • B05D1/04—Processes for applying liquids or other fluent materials performed by spraying involving the use of an electrostatic field
    • B05D1/06—Applying particulate materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2401/00—Form of the coating product, e.g. solution, water dispersion, powders or the like
    • B05D2401/30—Form of the coating product, e.g. solution, water dispersion, powders or the like the coating being applied in other forms than involving eliminable solvent, diluent or dispersant
    • B05D2401/32—Form of the coating product, e.g. solution, water dispersion, powders or the like the coating being applied in other forms than involving eliminable solvent, diluent or dispersant applied as powders

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Microbiology (AREA)
  • Electromagnetism (AREA)
  • Combustion & Propulsion (AREA)
  • Physics & Mathematics (AREA)
  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Biomedical Technology (AREA)
  • Biotechnology (AREA)
  • Molecular Biology (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Coating Apparatus (AREA)
  • Electrostatic Spraying Apparatus (AREA)
  • Spray Control Apparatus (AREA)

Abstract

Provided is an apparatus (1) for powder coating which includes a coat-applying station (9) for applying a powder coating (P) on a work (3) to be coated, and a high frequency induction heating apparatus (47) for heating the work (3) covered with the powder coating (P) under the effect of high frequency wave and baking the powder coating (P) on the work at the interface defined between the powder coating and the work. Use of the apparatus (1) provides a uniform and strong coating film without any unevenness more efficiently with the relatively compact apparatus. <IMAGE>

Description

【０００１】
【発明の属する技術分野】
本発明は、高周波誘導加熱式の粉体塗装装置に関する。詳しくは、被塗物を吊掛けるための被塗物フックが多数取り付けられたハンガーに目的の被塗物を吊掛けた状態で行う粉体塗装装置、特に、被塗物に塗布された粉体塗料の焼付け乾燥を、被塗物に対する高周波誘導加熱によって行う方式の粉体塗装装置に関するものである。
【０００２】
【従来の技術】
粉体塗装（パウダーコーティング）は、溶剤を使用せず、塗料を効率良く消費でき、塗膜を一度で厚く形成することも容易であるといった多くの利点があることから今日広く行われている。
しかしながら、従来のこの種の塗装にあっては、被塗物に塗布した粉体塗料の焼き付け乾燥を遠赤外線の照射で行うようにしていたため、塗料層の加熱乾燥が表面から進行してしまって塗膜に乾燥ムラが生じ易く、また、この方式であるがゆえに脱脂・洗浄・乾燥といった手間の掛かる前処理が不可欠であり、少量のロットには向かないといった欠点もあった。
【０００３】
この欠点に鑑みて、本発明者は、先に、粉体塗料の焼き付け乾燥は被塗物自体を高周波誘導加熱することで行う方式の塗装装置を提案した（特願２０００−３２４３９９号）。この方式によれば、被塗物に塗布された状態の粉体塗料の層は、被塗物に生じた熱で内部から先に加熱されるので、均一な加熱乾燥を短時間のうちに行うことができ、しかも、被塗物の表面にあった油脂などは被塗物自体の加熱によって気化するので、脱脂・洗浄・乾燥といった前処理を不要ならしめることもできる。
この高周波誘導加熱式の粉体塗装装置の概要を図１０に示す。
【０００４】
同図において、ａは塗料塗布部を、ｂは加熱部を、ｃは冷却部をそれぞれ示し、被塗物ｄはハンガーｅに吊掛けた状態で上記各処理部ａ〜ｃを順次移送される。塗料塗布部ａには、静電気が帯電した粉体塗料を噴射するスプレーガンｆが上下方向で往復移動するように設けられ、加熱部ｂには長円の渦形を為すコイルをＵ字形に屈曲して成る高周波誘導コイルｇが配置され、冷却部ｃには送風ファンなどが設けられている。
【０００５】
ハンガーｅは、縦長のポールｈに水平なフック取付けバーｉを多数上下方向へ取り付けると共に、このフック取付けバーｉに被塗物フックｊを多数取り付けた構造になっていて、フック取付けバーｉにはその長手方向へ多数のボルト通し孔ｋが形成されている。被塗物フックｊは帯板を横長の略Ｌ字形を為すように加工したもので、その垂直部の丈はフック取付けバーｉの縦幅とほぼ同じになっており、この垂直部に形成された孔を通したボルトｍを上記ボルト通し孔ｋのいずれかに通し、このボルトｍにフック取付けバーｉの裏側でナットｐを螺合することで、２〜３個程度フック取付けバーｉの任意の位置に取り付けられる。
被塗物フックｊの水平部の先端は矢先形に尖っており、この尖った部分を被塗物ｄのフック孔ｑに差し込むことで、被塗物フックｊに被塗物ｄを吊掛ける。
【０００６】
ハンガーｅが塗料塗布部ａに来ると、スプレーガンｆが昇降しながらハンガーｅに向かって粉体塗料ｎを噴射する。これにより、粉体塗料ｎが静電誘導作用によって被塗物ｄに塗布される。
次いで、ハンガーｅは高周波誘導コイルｇの左半部ｇ−１と右半部ｇ−２との間へと移送され、ここでハンガーｅに吊掛けられている被塗物ｄがそれ自体内部から加熱される。この加熱は、被塗物ｄの温度が概ね２５０゜Ｃ〜２８０゜Ｃになるように調節される。これにより、被塗物ｄに塗布されている粉体塗料ｎがその内側から先行して加熱され、それによって粉体塗料が焼き付け乾燥される。
【０００７】
【発明が解決しようとする課題】
ところが、この高周波誘導加熱式の粉体塗装装置にも解決すべき課題は幾つか残されていた。
先ず、高周波誘導コイルｇによる被塗物ｄの温度上昇速度が、このコイルｇに対する位置関係によって少なからずバラついてしまうという問題があった。例えば、ある被塗物について行った温度測定試験では、コイルｇの屈曲部（Ｕ字形の底部）に一番近い位置で中央寄りにある被塗物ｄが２８０゜Ｃまで上昇した時点で、コイルｇの上端部に一番近い位置で外寄りにある被塗物が２００゜Ｃ程度にとどまった。
【０００８】
当然、被塗物ｄに対する加熱は均一な温度にしなければならないので、このような温度差が生じる状態では、例えば、温度上昇の遅い位置には被塗物を掛けないで処理するか、或いは、この位置の被塗物ｄを他の被塗物ｄよりコイルｇに近づけるためにここだけ先の長い被塗物フックに取り替えるといった対策を採らざるを得ない。
【０００９】
しかしながら、温度上昇の遅い位置には被塗物ｄを置かないといった対策では処理能率が低下することになるし、長さの異なる被塗物フックに取り替えるという対策ではその取替えのために多くの手間が掛かって、結局、これも処理能率の低下を招くことになってしまう。前記したように、被塗物フックｊは、一つ一つボルトｍとナットｐで取り付けているので、たとえ数個でも、これの交換にはそれなりの時間がかかる。
この被塗物フックｊの取替えに時間がかかる問題は、焼き入れ乾燥に関することだけで無く、塗料の塗布に際し、被塗物ｄのサイズに応じて横方向での並び間隔、換言すれば並べ個数を調整するための取替えに際しても生じる。
【００１０】
また、塗装の対象になる被塗物の形状やサイズはまちまちであるから、高周波誘導コイルｇの左半部ｇ−１と右半部ｇ−２との間の距離は、より多くの種類の被塗物に対応できるようにするために、なるべく広く構えておく必要がある。ところが、そのようにすると装置の汎用性は拡がるが、被塗物のサイズが小さいほどコイルｇとの対向距離が長くなって、高周波が被塗物に作用する効率が低下するため、温度上昇に時間が掛かってしまうという問題が生じて来る。
【００１１】
一方、被塗物フックｊは、前記した形になっているため、その水平部の先端に吊掛けた被塗物ｄの少なくとも一部はフック取付けバーｉの前側に位置することになる。この結果、被塗物ｄに後側から塗料を吹き付ける場合は、フック取付けバーｉがその前側にある部分に対して影を作って塗料塗布の邪魔をすることになってしまう。このことは当然塗装ムラの原因になる。
【００１２】
更に、この種の塗装装置にあっては塗料の塗布や焼き付け乾燥等の品質を左右する制御事項、例えば、スプレーガンｆの昇降回数や、塗料の噴射量、高周波誘導コイルｇによる加熱時間等は、被塗物の種類に応じて調節する必要があり、従来は、これらの調節を一つ一つ手作業で行っていた。このため、被塗物のロットが異なるたびにラインの運転を止めて所要の調節をしては運転を再開するという非能率な処理を余儀なくされていた。
このような運転の停止は稼働率を著しく低下させることになるので、少量のロットについては、切りの良い量まで数を増やして処理し、余分な数は在庫にして次回の受注に回すといった手当てをすることも少なくない。
【００１３】
本発明は上記した問題点に鑑みて為されたものであって、被塗物フックの交換や位置変更を極く簡単に行うことができ、或いは、被塗物フックが被塗物に対する塗料の噴射を邪魔することが少なくて済む新規な高周波誘導加熱式の粉体塗装装置を提供することを目的とする。
また本発明は、高周波誘導コイルによる加熱が、ハンガーに吊掛けた全ての被塗物により均一に作用し、或いは、このコイルと被塗物との対向距離を調節することができる新規な高周波誘導加熱式の粉体塗装装置を提供することを目的とする。
更に本発明は、塗料の塗布や焼き付け乾燥など塗装の品質を左右する制御事項を、ハンガー単位で、予め設定した内容で自動制御することができて運転効率が良い新規な高周波誘導加熱式の粉体塗装装置を提供することを目的とする。
【００１４】
【課題を解決するための手段】
この目的を達成するために、請求項１の発明は、粉体塗料を被塗物に塗布する塗料塗布部とこの粉体塗料が塗布された被塗物を高周波誘導加熱することで当該粉体塗料を焼付け乾燥する加熱部とを含む複数の処理部と、水平なフック取付けバーに被塗物フックが取り付けられたハンガーと、このハンガーを上記複数の処理部に順次移送するハンガー移送手段とを備えた高周波誘導加熱式の粉体塗装装置であって、円筒状の塗装ブースの内部に前記処理部が設けられ、前記加熱部の高周波誘導コイルは、前記ハンガーの移送経路を挟んで対向する状態で２つ配置し、前記２つの各高周波誘導コイルは、それぞれ平面上で縦長の長円渦状に巻かれ、その一端どうしが渦を形成しない形の線材を介して結ばれて回路的に接続され、且つ、前記２つの高周波誘導コイルは、これらの対向方向で相対的に反対側へ移動自在なコイル支持ベースに支持されており、前記コイル支持ベースの下端部には互いに逆ねじの関係を為すナットが固定され、これらナットにスクリュウ軸が螺旋され、このスクリュウ軸はモーターにより回転されることで、前記２つの高周波誘導コイルは互いに反対側に移動でき、その間の間隔が拡縮する構成になっていることを特徴とする高周波誘導加熱式の粉体塗装装置である。
従って、高周波誘導コイルに屈曲部を作らなくて済むので、その高周波誘導の強さに部分的な違いが生じることは殆ど無く、これに正対する全ての被塗物を均一に加熱することができる。また、２つのコイルは、両コイルの端どうしを、渦を形成しない形の線材で接続することで回路的に一体な構造にしているので、コイルへの通電手段を簡素化することができる。
このようにすると、加熱部にハンガーが出入りする際は２つのコイルをこれらの間隔が広くなる位置に待機させておき、加熱を行うときは当該被塗物に最適な対向間隔となる位置へとコイルを移動させる、といった制御ができる。これにより、対応できる被塗物のサイズが広がって汎用性が高まると共に、被塗物ごとに最適な加熱条件を設定することが実現できる。
【００１６】
請求項２の発明は、請求項１に記載した高周波誘導加熱式の粉体塗装装置において、被塗物フックは逆Ｕ字形に屈曲した取付け部と該取付け部の一端から延びた腕とを有する形状にし、フック取付けバーには上記取付け部を着脱自在に係合させるための縦溝を多数横方向へ形成したことを特徴とする高周波誘導加熱式の粉体塗装装置である。
この塗装装置にあっては、被塗物フックは、フック取付けバーの任意の縦溝を選んでそこに取付け部を掛けることで当該フック取付けバーに装着され、そのように装着された位置は取付け部が縦溝に係合することで安定に保持され、また、その状態から取付け部を引っ張るだけでフック取付けバーから外すことができる。従って、フック取付けバーに対する被塗物フックの着脱はほぼ１動作で済むので、フック取付けバーに取り付ける被塗物フックの種類や、数、横方向での取付け間隔等を当該被塗物の形状やサイズに応じて交換したり、或いは高周波誘導コイルとの対向距離を調整するために一部交換したりする作業を短時間で済ませることができる。
この被塗物フックは、粉体塗料が付着しない材料、例えばリン青銅等の線材を加工して製作すると良く、取付け部をクリップ状に形成しておけば、フック取付けバーに掛けた状態ではクリップのバネ弾性が働いて、取付け位置をより安定に保持することができる。
【００１７】
請求項３の発明は、請求項１または２に記載した高周波誘導加熱式の粉体塗装装置において、被塗物フックの取付け部と腕は断面円形の線材により形成し、該腕の先端部は取付け部より低い位置まで延び、この先端部に、被塗物を吊掛けるための矢じり形のフック部を取り付けたことを特徴とする高周波誘導加熱式の粉体塗装装置である。
従って、被塗物フックの腕の高さ寸法を、これに吊掛ける被塗物のフック孔から上端までの寸法より多少でも長くしておけば、被塗物フックに吊掛けられた被塗物は前後方向から見て、その全体がフック取付けバーより下に位置するので、後側からの塗料吹き付けに対してフック取付けバーが邪魔することは無い。しかも、この被塗物フックの取付け部と腕は線材で形成されているために横幅が非常に小さいので、後側からの塗料吹き付けを邪魔することは殆ど無い。これらによって、塗料の塗布ムラを解消できる。
【００１８】
請求項４の発明は、請求項１から３いずれかに記載した高周波誘導加熱式の粉体塗装装置において、塗料塗布部のスプレーガンの移動回数と前記スプレーガンからの粉体塗料の噴射量と高周波誘導コイル間距離と前記高周波誘導コイルによる加熱時間を制御する制御回路と、ハンガーに取り付けられ、前記制御回路の制御データを記録した記録媒体とを備え、前記記録媒体に記録されたデータを読み取ってそれに対応する制御信号を前記制御回路に出力するように構成したことを特徴とする高周波誘導加熱式の粉体塗装装置である。
従って、被塗物や塗料の特性に応じて最適な加熱を実現するための制御項目の一つである高周波誘導コイルの被塗物に対する位置は、その制御データを予め記録媒体に記録しておくことで自動的に調整される。また、被塗物や塗料の特性に応じて最適な塗料塗布や加熱を実現するための制御項目であるスプレーガンの移動回数やスプレーガンからの粉体塗料の噴射量や高周波誘導コイルによる加熱時間のうちの少なくとも一つの制御は、その制御データを予め記録媒体に記録しておくことで自動的に調整される。
従って、塗料の塗布や焼き付け乾燥の品質に関わる制御項目の１つ又は複数を、被塗物やそれに使用する塗料の種類に応じて最適な条件で自動制御することができるため、被塗物のロットが異なるたびにラインの運転を止めて制御内容を変更するという非能率な処理が不要になる。特に、これらの発明では、ハンガーごとに制御データを持たせるようにしたので、少量のロットでもその都度最適な処理条件で塗装を実行することができる。
データの記録方法としては、制御データを直接記録媒体に記録する方法と、具体的な制御データは予め被塗物ごとにデータファイルに記憶させておいて記録媒体には被塗物の品番などを記録する方法が考えられるが、この記録媒体のシステムに所謂ＳＩＤ−ＴＡＧシステム等を用いる場合は、後者の方法とすれば良い。
【００２７】
【発明の実施の形態】
以下に、本発明の実施の形態に係る高周波誘導加熱式の粉体塗装装置１を図面に従って説明する。この塗装装置１は、所要の処理部を周回軌道上に配列した形態のものである。
図に示す被塗物３は鋼製のパイプジョイントであり、そのほぼ中央部に塗装用のフック孔３ａが形成されている。勿論、この被塗物３は本塗装装置１で処理できる数多くのもののほんの一例を示したものに過ぎない。
【００２８】
〔Ａ．ハンガー〕（図１〜図５、図７、図８）
先ず、被塗物３を吊掛けて搬送するハンガー５を説明する（詳細は図３〜図５を参照）。
このハンガー５は、縦長の角パイプ状をしたポール６と、上下方向へ一定間隔で配列された状態でポール６に取り付けられた多数のフック取付けバー７と、このフック取付けバー７に着脱自在に取り付けられる多数の被塗物フック８と、ポール６の上端部から左右へ水平に突出した吊り突起９と、タグ装着部１０とから構成されていて、これら各部は高周波誘導の作用を受けない材料、例えばリン青銅により形成されている。
【００２９】
フック取付けバー７は、比較的細幅な帯板状のもので、その幅方向が上下方向となる姿勢で、ポール６から水平に突出するように取り付けられており、この取付けは、フック取付けバー７の一端部を直角に曲げてボルト止めすることで行われる。
フック取付けバー７の厚み方向両側面には、縦溝７ａが横方向へ一定のピッチで多数形成されている。この縦溝７ａは、上下方向から見てほぼＶ字形をしており、一側面側の縦溝７ａの配列位相と他側面側の縦溝７ａの配列位相は互いに一致している。
このようなフック取付けバー７は、ポール６から互いに反対側へ突出する２本１組の段が上下方向へ一定間隔で配列されるように多数設けられ、全ての段の延び方向は互いに一致している。
【００３０】
被塗物フック８は、横断面円形の線材を曲げ加工した取付け部８ａ及び腕８ｂと、フック部８ｃとから成り、これらの材料にも全てリン青銅を用いている。取付け部８ａは縦に細長い逆さＵ字形を為し、その幅はフック取付けバー７の前後２つ１組の縦溝７ａ間の厚みとほぼ同じ寸法になっている。腕８ｂは取付け部８ａの一端から前下方へ向けてほぼ４分の１円弧を描くように延びていて、この腕８ｂの先端部にフック部８ｃが固定されている。フック部８ｃはほぼ二等辺三角形の矢じり形を為すように形成され、その頂角と反対側にある側面に形成された孔に腕８ｂの先端部を圧入して溶接することで腕８ｂに取り付けられる。
【００３１】
このような被塗物フック８は、フック取付けバー７に形成されている多数の縦溝７ａの中から前後２つ１組を任意に選んでそこに取付け部９を上から掛けることで着脱自在に取り付ける。従って、被塗物フック８がフック取付けバー７に取り付けられた状態は、取付け部８ａが縦溝７ａに係合することで位置決めされてしっかり保持される。
１つのフック取付けバー７に取り付ける被塗物フック８の数は、通常、２ないし３個（図１及び図２では２個取り付けた例を示し、図３では３個取り付けた例を示してある）であるが、これは、被塗物の形状やサイズに応じて随時変更する。
【００３２】
吊り突起９は、ハンガー５を後述するハンガー吊持バーに掛けるための部位であって、ポール６の上端部を、フック取付けバー７と平行な方向へ貫通するように設けられている。
タグ装着部１０（図８参照）は、後述するＳＩＤ−ＴＡＧを着脱自在に嵌めるための部分であって、短い円筒形をしており、ポール６のうち吊り突起９の稍下方の位置から水平に突出する状態で設けられている。
【００３３】
この塗装装置１で使用するハンガーとしては、図に示したハンガー５を含めて何種類か用意されるが、ポール６やフック取付けバー７のサイズは基本的に違いが無く、フック取付けバー７の段数が多少異なる程度である。また、被塗物フックはある程度多くの種類が用意される。その種類の違いは、腕８ｂの数や形状、高さ、フック部８ｃのサイズなどである。取付け部８ａの形やサイズは共通する。
【００３４】
〔Ｂ．塗装ブース〕（図１、図２、図６、図７）
２１は塗装ブースを示す。この塗装ブース２１は、上方から見て多角形の大きな筒形をしており、円筒形の外壁によってほぼ気密に囲われ、その周囲に各種所要の付属設備が配置されている。
塗装ブース２１の内部は、その中央に縦長六角筒状のメインシャフト配置室２２が設けられると共に、このメインシャフト配置室２２の回りがほぼ同じ大きさの６つの処理室に区画され、その区画を為す隔壁には縦長のハンガーゲート２３が設けられている。このハンガーゲート２３は、ハンガー５が各処理室を出入りする度に開閉される。
【００３５】
６つの処理室は、受け渡し室２４と、２つの塗料塗布室２５及び２５′と、加熱室２６と、熱均衡室２７と、冷却室２８であり、この順で、上から見た時計回り方向へ配列され、受け渡し室２４は後述する被塗物供給部に隣接している。
受け渡し室２４は、被塗物供給部との間でハンガー５の受け渡しを行う処理部であり、塗料塗布室２５及び２５′は、被塗物３に粉体塗料を塗布する処理部であり、加熱室２６は粉体塗料が塗布された被塗物３を高周波誘導加熱することで当該粉体塗料を焼付け乾燥する処理部である。熱均衡室２７は、加熱室２６で行われた加熱の均衡を図る処理部であり、冷却室２８は、加熱された被塗物３を冷却する処理部である。
２つの塗料塗布部２５、２５′は、使用する塗料の色によって使い分けられる。
【００３６】
〔Ｂ−１．ハンガー移送手段〕（図１、図２）
前記メインシャフト配置室２２には垂直なメインシャフト３１が軸回りへ回転自在に設けられており、このメインシャフト３１は回転機構３２によって中心角６０゜ピッチで間欠的に回転される。この回転方向は上から見た時計回り方向である。
メインシャフト３１の上端部は塗装ブース２１から上に突出していて、ここから水平なハンガー吊持バー３３が６本、中心角６０゜間隔で放射状に突出している。このハンガー吊持バー３３の先端部には、それぞれ、ハンガー５の前記吊り突起９が掛けられる吊り掛け部を備えた図示しないハンガー吊り掛け部材が垂直軸の軸回りへ回転自在に設けられている。このハンガー吊り掛け部材は回転機構３４によって回転される。この回転はハンガー５の向きを反転させるためのものである。
【００３７】
メインシャフト３１の間欠回転における停止位置は、ハンガー吊持バー３３が図１及び図２に示すように前記処理室２４〜２８のほぼ中央部に各別に対応するところに来た位置である。
目的の被塗物３を吊掛けられたハンガー５は、受け渡し室２４において、ハンガー吊持バー３３のハンガー吊り掛け部材にここから垂下する姿勢で吊り掛けられる。従って、メインシャフト３１が回転することによって、ハンガー５が塗装ブース２１内を円形の周回軌道を描くように移送され、この移送によって、ハンガー５に吊り掛けられている被塗物３が前記塗料塗布室２５―塗料塗布室２５′―加熱室２６―熱均衡室２７−冷却室２８をこの順で搬送され、各処理室で所定の処理を施される。
【００３８】
〔Ｂ−２．塗料塗布室〕（図１、図２、図９）
塗料塗布室２５、２５′の外側には、それぞれ、スプレーガン走行部４１とこれに隣接して塗料レシプロ機４２が配置されている。スプレーガン走行部４１には上下方向へ走行するチェーン４３（図９参照）とこれを走行させるモーター４４などが設けられ、チェーン４３に、粉体塗料を噴射するスプレーガン４５が取り付けられている。このスプレーガン４５はハンガー５の横幅より多少長い横幅の中に多数のノズルが配列された櫛歯形のもので、塗料塗布室２５、２５′の中に、移送されて来たハンガー５に正対する向きで位置している。このスプレーガン４５に接続されたパイプは塗装ブース２１の周壁に形成された縦長スリットを通してブース外に突出しチェーン４３に固定される。
【００３９】
モーター４４は所定のタイミングで回転方向を切り替えてスプレーガン４５を直線方向で昇降させる。この昇降に伴って塗料レシプロ機４２から粉体塗料がスプレーガン４５に供給されここから被塗物３に向けて噴射する。この塗料の供給系又はスプレーガン４５のノズル先端には、塗料に静電気を帯電させるための手段、例えばフリクションチューブ、コロナ放電プラグなどが設けられていて、スプレーガン４５から噴射する塗料は静電気を帯電する。
【００４０】
〔Ｂ−３．加熱室〕（図１、図２、図６、図７）
加熱室２６には、２つの高周波誘導コイル５１、５１′が設けられている。これら高周波誘導コイル５１、５１′は、平面上で縦長の概ね長円渦を巻くように加工したものであり、従って、この高周波誘導コイル５１、５１′には前記したコイルｇのような屈曲部は無い。この高周波誘導コイル５１と５１′は、それぞれハンガー５の全体の大きさとほぼ同じであり、縦長の箱形を為す２つのコイルケース５２に垂直な姿勢で各別に収納されている。
このように、高周波誘導コイル５１と５１′は渦巻き形状においては互いに独立しているが、各端どうしを銅製の撚り線５３で結ぶことで回路的には一体に接続してある。また、この高周波誘導コイル５１と５１′は、その中に冷却水を流す水路が形成されるようにするために細い銅パイプを加工してあり、それぞれの水路はフレキシブルなホース５４で接続している。
【００４１】
コイルケース５２の底面にはスライドブロック５５が取り付けられていて、このスライドブロック５５が加熱室２６の底部に配置されたガイドレール５６に摺動自在に係合している。これにより、２つの高周波誘導コイル５１と５１′は、ハンガー５の移送経路を挟んで互いに対向し且つ互いの間隔を拡縮できるように移動自在に設けられる。
そして、２つのコイルケース５２の下端部には互いに逆ねじの関係を為すナット５７が固定されており、これらナット５７に１本のスクリュウ軸５８が螺合されている。このスクリュウ軸５８はステッピングモーター５９によって回転される。従って、このステッピングモーター５９が駆動すると、２つのコイルケース５２が互いに反対側へ移動して、高周波誘導コイル５１と５１′との間の間隔が拡縮する。
【００４２】
〔Ｂ−４.熱均衡室、冷却室〕（図１）
熱均衡室２７には、数キロワット程度の出力を持つ遠赤外線ヒーター６１が多数配置されている。
冷却室２８には、送風ファン６２が配置されている。
【００４３】
〔Ｃ．被塗物供給部〕（図１）
塗装ブース２１の手前には、受け渡し室２４と接するように、被塗物供給部７１が設けられており、この被塗物供給部７１は高所で水平に無端走行する送りチェーン７３を備えている。この送りチェーン７３にはハンガー５の吊り突起９を掛けるための吊り掛け部材が一定間隔で多数取り付けられていて、その吊り掛け部材の一つが受け渡し室２４の手前に来た位置を停止ポジションとして間欠的に走行される。
【００４４】
被塗物３を吊掛けたハンガー５は、この被塗物供給部７１の所定の位置で、送りチェーン７３に吊り掛けられる。従って、このハンガー５は、送りチェーン７３によって塗装ブース２１へ向けて運ばれ、受け渡し室２４の手前の位置で、図示しない乗せ換えロボットにより前記ハンガー吊持バー３３に渡される。そして、塗装ブース２１内を一巡して受け渡し室２４に戻って来たハンガー５は、乗せ換えロボットにより送りチェーン７３に戻され、所定の位置で送りチェーン７３から外される。
【００４５】
〔Ｄ．制御系〕（図９）
塗装ブース２１で行われる処理についての制御項目、特に、スプレーガン４５の昇降回数、粉体塗料の噴射量、高周波誘導コイル５１、５１′の位置及び該コイルによる加熱時間を制御するための制御系８１を図９に示す。
８２は、スプレーガン走行用のモーター４４を制御するスプレーガン用モータ駆動回路を示す。
８３は、スプレーガン４５に接続された塗料供給系に介挿された塗料バルブを示す。この塗料バルブ８３は、電気的指令に従って開き度を変更する開き度調節機構を備えており、この開き度調節機構は塗料バルブ制御回路８４で制御される。
【００４６】
８５は、コイルケース５２を移動させるモータ５９を制御するコイル用モータ駆動回路を示し、８６は近接スイッチなどの位置センサーを示す。この位置センサー８６はコイルケース５２の移動原点である待機位置を検出するためのもので、コイルケース５２が図７に二点鎖線で示す待機位置にきたところで信号を出力する。
８７は、高周波誘導コイル５１、５１′への通電を制御するコイル駆動回路を示し、この通電時間を制御するためのタイマー８７ａを備えている。
【００４７】
８８は、データ記録媒体としてのＳＩＤ−ＴＡＧを示し、８９はデータ読取り回路を示す。これらＳＩＤ−ＴＡＧ８８及びデータ読取り回路８９と、ＳＩＤ−ＴＡＧ８８にデータを書き込むための図示しない書き込み手段等で、ＳＩＤ−ＴＡＧシステムが構成される。ＳＩＤ−ＴＡＧ８８には被塗物の品番データが記録され、このＳＩＤ−ＴＡＧ８８はハンガー５に設けられている前記タグ装着部１０に着脱自在に装着される。
ＳＩＤ−ＴＡＧ８８に書き込まれたデータは、ＳＩＤ−ＴＡＧ８８が備えているアンテナからデータ読取り回路８９のアンテナへ送信されて、該データ読取り回路８９によって読み取られる。
【００４８】
９０はシステムプログラムを示す。このシステムプログラム９０は、スプレーガン４５を昇降させる回数、塗料バルブ８３の開き度、塗色、コイル・被塗物間距離を規定するステッピングモーター５９の回転量、高周波誘導コイル５１、５１′への通電時間等の制御データが被塗物の品番ごとに書き込まれる制御データファイルと、データ読取り回路８９が読み取った品番に対応する制御データを上記制御データファイルから読み出して所定の制御信号を前記各制御回路８２、８４，８５、８７等へ出力する手順が書き込まれたプログラムファイル等を備えている。
制御データファイルの内容の一部を表１に示す。
粉体塗装装置１は以上のように構成されている。
【００４９】
【表１】

Figure 0004688353
【００５０】
〔Ｅ．使用方法と作用〕
次に、この粉体塗装装置１の使用方法と作用を説明する。
〔Ｅ−１．事前の処理〕
塗装を開始するのに先立って、ＳＩＤ−ＴＡＧシステムにより、経験的に得られている被塗物ごとの最適な制御データや必要な塗色データを被塗物の品番と関連付けて制御データファイルに書き込む。
【００５１】
ハンガー５に被塗物を吊掛けるに際しては、当該被塗物に最適な種類の被塗物フック８を選択すると共に、フック取付けバー７に装着する数を選ぶ。特に、腕８ｂの高さＨ（図５参照）が当該被塗物３のフック孔３ａから上端までの寸法Ｌより長いものを選ぶ。また、その被塗物を１箇所で支持すれば足りる場合は前記した形状の被塗物フック８を用い、２箇所で支持すべきである場合は、腕８ｂが２つある被塗物フックを用いる。被塗物のサイズが大きい場合は、１つのフック取付けバー７に２個取り付け、サイズが小さい場合は３個取り付ける。
更に、経験的に見て、高周波誘導コイル５１、５１′に対する位置の違いによって被塗物の加熱速度が異なるときは、同じ被塗物であっても、その速度が遅い場所については高周波誘導効果を他より高くするために腕８ｂが長い形の被塗物フックを用いる。
【００５２】
このようにして被塗物フックの種類や数を選んでフック取付けバー７に取り付けた後、その被塗物フックに目的の被塗物を吊掛ける。これは、図４に示すように、当該被塗物３のフック孔３ａに被塗物フック８のフック部８ｃを稍きつく差し込むことで行う。１つのハンガー５には同じ種類の被塗物だけを吊掛ける。
そして、当該ハンガー５に吊掛けた被塗物の品番をＳＩＤ−ＴＡＧ８８に書き込み、それを当該ハンガー５のタグ装着部１０に挿入する。
この状態のハンガー５を前記送りチェーン７３に掛ける。
【００５３】
〔Ｅ−２．塗装〕
被塗物３が吊掛けられたハンガー５が受け渡し室２４に近い所定の位置まで運ばれて来ると、ＳＩＤ−ＴＡＧ８８のデータをデータ読取り回路８９が受信する。システムプログラム９０は、データ読取り回路８９が受信した品番データに対応する制御データや塗色データを制御データファイルから読み出して所定の制御信号に変換して該当する制御回路への出力に備える。この出力のタイミングは、メインシャフト３１の回転を制御するタクト信号に同期したタイミングで順次行われる。
次いで、当該ハンガー５はハンガー吊持バー３３に乗り移される。このときのハンガー５の姿勢は、図１等に示すように、フック取付けバー７がハンガー吊持バー３３の回転軌跡に外接する直線と平行な姿勢で行われる。
【００５４】
このようにして塗装ブース２１内に運び込まれたハンガー５は、先ず、塗料塗布室２５へ移送され、スプレーガン４５と正対する位置で停止する。当該被塗物の塗色が塗料塗布室２５での塗色と一致しているときはここで塗料塗布が行われ、そうでないときは次の塗料塗布室２５′へ移送されたところで塗料塗布が実行される。この塗料塗布は次のように制御される。
【００５５】
システムプログラム９０からスプレーガン走行部４１や塗料レシプロ機４２へ制御信号が出力され、それによって、スプレーガン４５が所要の回数分昇降しながら当該ハンガー５に向かって粉体塗料を吹き付ける。この粉体塗料は、当該制御信号に従って制御される塗料バルブ８３の開き度に応じた量となり、帯びた静電気によってハンガー５及び被塗物３の一方の面に付着する。
両面塗装が必要な場合は、スプレーガン４５が所定回数の昇降を完了したところで、ハンガー５の向きが反転され、ここで他方の面に対する塗料塗布が開始する。この場合、被塗物３の全体はフック取付けバー７より低い位置にあるから、被塗物３に後側から吹き付けられる塗料に対してフック取付けバー７が影を作ることは無いし、被塗物フック８の腕８ｂは線材であるから、この腕８ｂが塗料の吹き付けを邪魔することも無い。
【００５６】
〔Ｅ−３．加熱等〕
このようにして塗料塗布室２５又は２５′で塗料を塗布されたハンガー５は、次に加熱室２６へと移送される。これに先立って、２つのコイルケース５２は前記した待機位置に来ていて、互いの間の距離を広くとっている。従って、ハンガー５は２つのコイルケース５２の間にスムーズに入る。
そして、ハンガー５がこの位置に来ると、システムプログラム９０からコイル用モータ駆動回路８５へ制御信号が出力され、それにより、ステッピングモータ５９が所定量回転して２つのコイルケース５２をハンガー５に対して所定位置まで前進させると共に、コイル駆動回路８９に駆動信号が出力されて、高周波誘導コイル５１、５１′に通電する。
【００５７】
このコイル５１、５１′から出る高周波電流が当該被塗物３に作用して、被塗物３自体が加熱され、この加熱によって、表面に付着していた粉体塗料が焼き付け乾燥される。ハンガー５はその全体がリン青銅によって形成されているので、高周波電流によっては加熱されない。従って、ハンガー５の各部に付着した粉体塗料は焼き付けされることは無い。
規定の加熱時間が経過すると、高周波誘導コイル５１、５１′への通電が停止すると共に、このコイル５１、５１′が待機位置に戻される。
【００５８】
次に、ハンガー５は熱均衡室２７へと移送されて熱均衡が図られるた後、冷却室２８で冷却され、受け渡し室２４に戻って送りチェーン７３に乗せられる。
尚、ハンガー５に付着した粉体塗料は、熱均衡室２７に設けられている図示しないブロアーによって払い落とされ、バキュームによって回収される。
【００５９】
以上、本発明の実施の形態を説明したが、本発明の具体的構成がこの実施の形態に限定されるものでは無く、本発明の要旨から外れない範囲での設計変更等があっても本発明に含まれる。
例えば、実施の形態では、制御データを記録する記録媒体としてＳＩＤ−ＴＡＧを用いたが、この記録媒体がそのような方式のものにかぎられることは無い。
【００６０】
【発明の効果】
以上のように、請求項１の発明によれば、高周波誘導コイルに屈曲部を作らなくて済むので、その高周波誘導の強さに部分的な違いが生じることは殆ど無く、これに正対する全ての被塗物をほぼ均一に加熱することができる。尚、実施の形態では、両コイルの端どうしを、渦を形成しない形の線材で接続することで回路的には一体の構造にしたが、このようにすることで、コイルへの通電手段を簡素化することができる。
請求項２と請求項３の発明によれば、２つのコイルどうしの間隔や、コイルと被塗物との対向間隔を調節することができるので、例えば、加熱部にハンガーが出入りする際は２つのコイルをこれらの間隔が広くなる位置に待機させておき、加熱を行うときは当該被塗物に最適な対向間隔となる位置へとコイルを移動させる、といった制御ができる。これにより、対応できる被塗物のサイズが広がって汎用性が高まると共に、被塗物ごとに最適な加熱条件を設定することが実現できる。
請求項４の発明によれば、フック取付けバーに対する被塗物フックの着脱はほぼ１動作で済むので、フック取付けバーに取り付ける被塗物フックの種類や、数、横方向での取付け間隔等を当該被塗物の形状やサイズに応じて変更する作業を短時間で済ませることができる。
請求項５の発明によれば、フック取付けバーや被塗物フックが、被塗物への後側からの塗料吹き付けを邪魔することが無いので、塗料の塗布ムラを解消できる。
請求項６の発明によれば、被塗物や塗料の特性に応じて最適な加熱を実現するための制御項目の一つである高周波誘導コイルの位置は、その制御データを予め記録媒体に記録しておくことで自動的に調整されるので、ロットが変るたびに運転を止めて高周波誘導コイルの位置を調節するといった処置が不要になる。また、被塗物や塗料の特性に応じて最適な塗料塗布や加熱を実現するための制御項目であるスプレーガンの移動回数やスプレーガンからの粉体塗料の噴射量や高周波誘導コイルによる加熱時間のうちの少なくとも一つの制御は、その制御データを予め記録媒体に記録しておくことで自動的に調整されるので、ロットが変るたびに運転を止めて様々な制御項目を調節するといった処置が不要になる。特に、ハンガー単位で制御データを持たせるようにしたので、少量のロットでもその都度最適な処理条件で塗装を実行することができる。
【図面の簡単な説明】
【図１】本発明の実施の形態に係る粉体塗装装置の全体平面図である。
【図２】図１に示す粉体塗装装置の要部斜視図である。
【図３】図１に示す粉体塗装装置のハンガーを拡大した一部省略斜視図である。
【図４】図１の粉体塗装装置において、被塗物フックに被塗物を吊掛けた状態を示す斜視図である。
【図５】図１の粉体塗装装置において、被塗物フックに被塗物を吊掛けた状態を示す側面図である。
【図６】図１の粉体塗装装置における塗装ブースの加熱部を拡大した斜視図である。
【図７】図１の粉体塗装装置における塗装ブースの加熱部を拡大した側面図である。
【図８】図１に示す粉体塗装装置におけるハンガーのタグ装着部を拡大した斜視図である。
【図９】図１に示す粉体塗装装置の制御系を示す図である。
【図１０】先に提案した高周波誘導加熱式の粉体塗装装置の概要を示す図である。
【符号の説明】
１…高周波誘導加熱式の粉体塗装装置 ３…被塗物 ５…ハンガー
７…フック取付けバー ７ａ…縦溝 ８…被塗物フック ８ａ…取付け部
８ｂ…腕 ８ｃ…フック部 １０…記録媒体装着部
２５…塗料塗布部（処理部） ２５′…塗料塗布部（処理部）
２６…加熱部（処理部） ３１、３２、３３…ハンガー移送手段
４４、８２…制御手段（スプレーガンの移動回数） ５１…高周波誘導コイル
５１′…高周波誘導コイル ５２…コイル支持ベース
５５、５６、５７、５８、５９…コイル位置制御手段（制御手段）
８３、８４…制御手段（粉体塗料の噴射量）８７、８７ａ…制御手段（加熱時間）
８８…記録媒体 ８９、９０…制御回路[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a high frequency induction heating type powder coating apparatus. Specifically, a powder coating apparatus for performing a state in which the object to be coated is hung on a hanger in which a large number of object hooks for hanging the object to be coated are attached, particularly powder applied to the object to be coated The present invention relates to a powder coating apparatus in which the paint is baked and dried by high-frequency induction heating on an object to be coated.
[0002]
[Prior art]
Powder coating (powder coating) is widely performed today because it has many advantages that it can efficiently consume a paint without using a solvent, and that it is easy to form a thick coating at once.
However, in this type of conventional coating, the powder coating applied to the object is baked and dried by irradiation with far-infrared rays, so that the coating layer is heated and dried from the surface. Unevenness of drying is likely to occur in the coating film, and because of this method, a pretreatment which requires labor such as degreasing, washing and drying is indispensable, and there is a disadvantage that it is not suitable for a small lot.
[0003]
In view of this drawback, the present inventor has previously proposed a coating apparatus in which the powder coating is baked and dried by high-frequency induction heating of the object to be coated (Japanese Patent Application No. 2000-324399). According to this method, the powder coating layer applied to the object to be coated is first heated from the inside by the heat generated on the object to be coated, so that uniform heating and drying are performed in a short time. In addition, since the oil and fat on the surface of the object to be coated is vaporized by heating the object to be coated, pretreatment such as degreasing, washing and drying can be made unnecessary.
An outline of the high frequency induction heating type powder coating apparatus is shown in FIG.
[0004]
In the figure, a indicates a paint application unit, b indicates a heating unit, c indicates a cooling unit, and an object to be coated d is sequentially transferred to the processing units a to c while being hung on a hanger e. . The paint application part a is provided with a spray gun f for injecting a powder paint charged with static electricity so as to reciprocate in the vertical direction, and the heating part b is bent in a U-shape with an elliptical spiral coil. A high-frequency induction coil g is arranged, and a cooling fan c is provided with a blower fan or the like.
[0005]
The hanger e has a structure in which a large number of horizontal hook mounting bars i are mounted on a vertically long pole h in the vertical direction and a large number of coating object hooks j are mounted on the hook mounting bar i. A number of bolt through holes k are formed in the longitudinal direction. The coating object hook j is obtained by processing a band plate so as to have a horizontally long substantially L shape, and the vertical portion has the same vertical length as the hook mounting bar i, and is formed in this vertical portion. The bolt m passed through the hole is passed through any one of the bolt through holes k, and the nut p is screwed onto the bolt m on the back side of the hook mounting bar i. It is attached to the position.
The tip of the horizontal portion of the coating object hook j is pointed in an arrow tip shape, and the coating object d is suspended from the coating object hook j by inserting this sharp portion into the hook hole q of the coating object d.
[0006]
When the hanger e arrives at the paint application part a, the spray gun f sprays the powder paint n toward the hanger e while moving up and down. Thereby, the powder coating material n is apply | coated to the to-be-coated article d by an electrostatic induction effect | action.
Next, the hanger e is transferred between the left half g-1 and the right half g-2 of the high-frequency induction coil g, and the article d to be hung on the hanger e is from inside itself. Heated. This heating is adjusted so that the temperature of the object to be coated d is approximately 250 ° C. to 280 ° C. Thereby, the powder coating material n applied to the article to be coated d is heated in advance from the inside, whereby the powder coating material is baked and dried.
[0007]
[Problems to be solved by the invention]
However, some problems to be solved still remain in this high frequency induction heating type powder coating apparatus.
First, there has been a problem that the temperature rise rate of the object d to be coated by the high-frequency induction coil g varies depending on the positional relationship with respect to the coil g. For example, in a temperature measurement test performed on a certain object to be coated, when the object d near the center at the position closest to the bent portion (U-shaped bottom) of the coil g rises to 280 ° C., the coil The outermost object to be coated at the position closest to the upper end of g remained at about 200 ° C.
[0008]
Of course, since the heating of the object to be coated d has to be a uniform temperature, in such a state where the temperature difference occurs, for example, the position where the temperature rise is slow may be processed without applying the object to be coated, or In order to bring the coating material d at this position closer to the coil g than the other coating materials d, it is necessary to take measures such as replacing the coating material hook with a longer tip.
[0009]
However, the processing efficiency decreases when the coating d is not placed at a position where the temperature rises slowly, and the processing efficiency decreases when the hook is replaced with a coating hook having a different length. After all, this also leads to a reduction in processing efficiency. As described above, since the article hooks j are attached one by one with bolts m and nuts p, even if several pieces are exchanged, it takes some time to exchange them.
The problem that it takes a long time to replace the coating object hook j is not only related to quenching and drying, but also when applying the paint, the arrangement interval in the horizontal direction according to the size of the object to be coated, in other words, the arrangement number It also occurs when a replacement is made to adjust.
[0010]
Moreover, since the shape and size of the object to be coated vary, the distance between the left half g-1 and the right half g-2 of the high-frequency induction coil g can be more various types. In order to be able to handle the object to be coated, it is necessary to keep it as wide as possible. However, the general versatility of the apparatus is expanded in such a way, but the smaller the size of the object to be coated, the longer the facing distance from the coil g and the lower the efficiency at which the high frequency acts on the object to be coated. The problem is that it takes time.
[0011]
On the other hand, since the coating object hook j has the above-described shape, at least a part of the coating object d hung on the tip of the horizontal portion is positioned on the front side of the hook mounting bar i. As a result, when the paint is sprayed onto the article d from the rear side, the hook mounting bar i creates a shadow on the part on the front side and disturbs the paint application. This naturally causes uneven coating.
[0012]
Further, in this type of coating apparatus, control matters that affect the quality of coating, baking and drying, such as the number of times the spray gun f is moved up and down, the amount of coating sprayed, the heating time by the high frequency induction coil g, etc. Therefore, it is necessary to adjust according to the type of the object to be coated. Conventionally, these adjustments are performed manually one by one. For this reason, every time the lots of the objects to be coated are different, the operation of the line is stopped and necessary adjustments are made, so that inefficient processing is restarted.
Stopping operations like this will significantly reduce the operating rate. For small lots, increase the number up to a good amount and process the excess number in stock for the next order. There are a lot of things to do.
[0013]
The present invention has been made in view of the above-described problems, and it is very easy to replace or change the position of the coating object hook, or the coating object hook can be used for coating the coating material. It is an object of the present invention to provide a novel high-frequency induction heating type powder coating apparatus that does not obstruct injection.
In addition, the present invention provides a novel high frequency induction in which heating by the high frequency induction coil acts uniformly on all the objects to be coated suspended on the hanger, or the distance between the coil and the object to be coated can be adjusted. An object is to provide a heating type powder coating apparatus.
Furthermore, the present invention is a novel high-frequency induction heating type powder that is capable of automatically controlling the control items that affect the quality of coating, such as application of paint and baking and drying, in units of hangers with preset contents, and has high operating efficiency. An object is to provide a body coating apparatus.
[0014]
[Means for Solving the Problems]
  In order to achieve this object, the invention of claim 1 is characterized in that the powder application part for applying the powder paint to the object to be coated and the object to which the powder paint is applied are heated by high frequency induction heating. A plurality of processing units including a heating unit for baking and drying the paint;Horizontal hook mounting barA high frequency induction heating type powder coating apparatus provided with a hanger to which an object hook is attached and a hanger transfer means for sequentially transferring the hanger to the plurality of processing units,The processing section is provided inside a cylindrical paint booth,The high frequency induction coil of the heating part isSaidTwo are placed facing each other across the hanger transfer path.Each of the two high-frequency induction coils is wound in the shape of a vertically long ellipse on a plane, and one end thereof is connected via a wire that does not form a vortex, and is connected in a circuit. The two high-frequency induction coils are supported by a coil support base that is movable relatively opposite to each other in the facing direction, and a nut that has a reverse screw relationship is fixed to the lower end of the coil support base, A screw shaft is spiraled by these nuts, and the screw shaft is rotated by a motor, so that the two high-frequency induction coils can move to opposite sides, and the interval therebetween is expanded or contracted.This is a high-frequency induction heating type powder coating apparatus.
  Therefore, since it is not necessary to make a bent portion in the high frequency induction coil, there is almost no difference in the strength of the high frequency induction, and all the objects to be directly opposed can be heated uniformly. .Also,The two coils,By connecting the ends of both coils with a wire that does not form a vortex, the circuit has an integrated structureBecauseThe means for energizing the coil can be simplified.
  In this way, when the hanger enters and exits the heating unit, the two coils are kept waiting at a position where the distance between them is widened, and when heating is performed, the position is set to an optimum facing distance for the object to be coated. Control such as moving the coil can be performed. As a result, the size of the object to be coated can be expanded to increase the versatility, and it is possible to realize optimum heating conditions for each object to be coated.
[0016]
  Claim2The invention of claim1In the high frequency induction heating type powder coating device described in,Mounting part bent in an inverted U shapeAnd an arm extending from one end of the mounting portion, and the hook mounting bar has a plurality of longitudinal grooves for detachably engaging the mounting portion in the transverse direction. This is a powder coating device of the type.
  In this coating apparatus, the hook to be coated is mounted on the hook mounting bar by selecting an arbitrary longitudinal groove of the hook mounting bar and hanging the mounting portion on the vertical groove, and the position where it is mounted is mounted. The portion can be stably held by engaging the longitudinal groove, and can be detached from the hook mounting bar simply by pulling the mounting portion from this state. Therefore, since the attachment / detachment of the coating object hook with respect to the hook mounting bar can be performed in almost one operation, the type, number, and mounting interval in the horizontal direction of the coating object hook to be mounted on the hook mounting bar can be changed. The work of exchanging in accordance with the size or exchanging in part in order to adjust the facing distance from the high frequency induction coil can be completed in a short time.
  The hook to be coated may be manufactured by processing a material that does not adhere powder paint, such as phosphor bronze, and if the mounting portion is formed in a clip shape, the clip will be clipped when hooked on the hook mounting bar. Therefore, the mounting position can be held more stably.
[0017]
  Claim3The invention of claim1 or 2In the high-frequency induction heating type powder coating apparatus described in 1), the attachment portion and the arm of the article hook are formed of a wire having a circular cross section, and the tip of the arm isPosition lower than the mounting partThis is a high-frequency induction heating type powder coating apparatus characterized in that an arrowhead-shaped hook portion for suspending an object to be coated is attached to the tip portion.
  Therefore, if the height of the arm of the coating object hook is set to be slightly longer than the dimension from the hook hole to the upper end of the coating object to be suspended, the coating object hung on the coating object hook Since the whole is located below the hook mounting bar as viewed from the front-rear direction, the hook mounting bar does not interfere with the spraying of paint from the rear side. In addition, since the attachment portion and the arm of the object hook are formed of wire, the lateral width is very small, so that the paint spray from the rear side is hardly disturbed. By these, the coating application unevenness can be eliminated.
[0018]
  Claim4The invention of claim 1 starts from claim 1.3In any one of the high frequency induction heating type powder coating apparatuses described above, the number of times the spray gun moves in the paint application unit, the amount of powder paint sprayed from the spray gun, the distance between the high frequency induction coils, and the heating by the high frequency induction coil A control circuit for controlling the time, and attached to the hanger;Control dataA high frequency induction heating type powder coating apparatus, characterized in that it is configured to read data recorded on the recording medium and output a corresponding control signal to the control circuit. It is.
  Therefore, the position of the high-frequency induction coil, which is one of the control items for realizing optimum heating according to the characteristics of the object to be coated and the paint,Control dataIs automatically adjusted by recording in advance on the recording medium. In addition, the number of movements of the spray gun, the amount of powder paint sprayed from the spray gun, and the heating time by the high-frequency induction coil, which are the control items for realizing optimum paint application and heating according to the characteristics of the object and paint At least one of the controlsControl dataIs automatically adjusted by recording in advance on the recording medium.
  Therefore, one or more of the control items related to the quality of coating application and baking / drying can be automatically controlled under the optimum conditions according to the type of coating object and the type of coating used. An inefficient process of changing the control content by stopping the line operation every time the lot is different is not necessary. In particular, in these inventions, each hangerControl dataThus, even with a small amount of lots, it is possible to perform coating under optimum processing conditions each time.
  As a data recording method, a method of directly recording control data on a recording medium, and specific control data are stored in advance in a data file for each object to be coated, and the recording medium is recorded on the object to be coated.Part numberA recording method is conceivable, but when using a so-called SID-TAG system or the like for this recording medium system, the latter method may be used.
[0027]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, a high frequency induction heating type powder coating apparatus 1 according to an embodiment of the present invention will be described with reference to the drawings. The coating apparatus 1 has a configuration in which required processing units are arranged on a circular track.
The object to be coated 3 shown in the drawing is a steel pipe joint, and a hook hole 3a for coating is formed at substantially the center thereof. Of course, the article 3 is merely an example of many things that can be processed by the coating apparatus 1.
[0028]
[A. (Hanger) (FIGS. 1-5, 7, 8)
First, the hanger 5 that hangs and conveys the article 3 will be described (see FIGS. 3 to 5 for details).
This hanger 5 has a vertically long square pipe-shaped pole 6, a number of hook mounting bars 7 attached to the pole 6 in a state of being arranged at regular intervals in the vertical direction, and the hook mounting bar 7 is detachable. It is composed of a large number of article hooks 8 to be attached, suspension protrusions 9 protruding horizontally from the upper end of the pole 6 to the left and right, and a tag mounting part 10. These parts are not subjected to the action of high frequency induction. For example, it is made of phosphor bronze.
[0029]
The hook mounting bar 7 is in the form of a relatively narrow strip, and is mounted so as to protrude horizontally from the pole 6 in a posture in which the width direction is the vertical direction. This is done by bending one end of 7 at a right angle and bolting.
A large number of longitudinal grooves 7a are formed on the both sides in the thickness direction of the hook mounting bar 7 at a constant pitch in the lateral direction. The vertical grooves 7a are substantially V-shaped when viewed in the vertical direction, and the arrangement phase of the vertical grooves 7a on one side and the arrangement phase of the vertical grooves 7a on the other side coincide with each other.
Such a hook mounting bar 7 is provided in a large number so that a set of two stages protruding from the pole 6 to the opposite sides is arranged at regular intervals in the vertical direction, and the extending directions of all the stages coincide with each other. ing.
[0030]
The article hook 8 includes a mounting portion 8a and an arm 8b obtained by bending a wire having a circular cross section, and a hook portion 8c, and phosphor bronze is also used for these materials. The attachment portion 8a is vertically elongated and has an inverted U shape, and the width thereof is substantially the same as the thickness between the pair of longitudinal grooves 7a on the front and rear sides of the hook attachment bar 7. The arm 8b extends from one end of the mounting portion 8a in a forward and downward direction so as to draw a quarter arc, and a hook portion 8c is fixed to the tip of the arm 8b. The hook portion 8c is formed to have an approximately isosceles triangular arrowhead shape, and is attached to the arm 8b by press-fitting the tip of the arm 8b into a hole formed on the side surface opposite to the apex angle and welding. It is done.
[0031]
Such a coating object hook 8 is detachable by arbitrarily selecting a pair of front and rear from a plurality of longitudinal grooves 7a formed on the hook mounting bar 7 and hanging the mounting portion 9 from above. Attach to. Therefore, the state in which the article hook 8 is attached to the hook attachment bar 7 is positioned and firmly held by the attachment portion 8a engaging the longitudinal groove 7a.
The number of coating object hooks 8 attached to one hook attachment bar 7 is usually 2 to 3 (in FIG. 1 and FIG. 2, an example in which two pieces are attached is shown, and in FIG. 3, an example in which three pieces are attached is shown). However, this is changed as needed according to the shape and size of the object to be coated.
[0032]
The suspension protrusion 9 is a portion for hanging the hanger 5 on a hanger suspension bar described later, and is provided so as to penetrate the upper end portion of the pole 6 in a direction parallel to the hook attachment bar 7.
The tag mounting portion 10 (see FIG. 8) is a portion for detachably fitting a SID-TAG to be described later, has a short cylindrical shape, and is horizontal from the position below the heel of the suspension protrusion 9 in the pole 6. It is provided in a state of protruding.
[0033]
There are several types of hangers to be used in the coating apparatus 1 including the hangers 5 shown in the figure, but the sizes of the pole 6 and the hook mounting bar 7 are basically the same. The number of stages is slightly different. In addition, many types of coating object hooks are prepared. The difference in the types is the number and shape of the arms 8b, the height, the size of the hook portion 8c, and the like. The shape and size of the attachment portion 8a are common.
[0034]
[B. Painting booth] (Figs. 1, 2, 6, and 7)
Reference numeral 21 denotes a painting booth. The painting booth 21 has a large polygonal tube shape when viewed from above, and is substantially hermetically surrounded by a cylindrical outer wall, and various necessary accessory facilities are arranged around it.
The interior of the painting booth 21 is provided with a main shaft arrangement chamber 22 having a vertically long hexagonal cylindrical shape at the center thereof, and the periphery of the main shaft arrangement chamber 22 is divided into six processing chambers having substantially the same size. A vertical hanger gate 23 is provided on the partition wall. The hanger gate 23 is opened and closed each time the hanger 5 enters and exits each processing chamber.
[0035]
The six processing chambers are a delivery chamber 24, two paint application chambers 25 and 25 ', a heating chamber 26, a heat balance chamber 27, and a cooling chamber 28. In this order, the clockwise direction viewed from above. The delivery chamber 24 is adjacent to an article supply unit to be described later.
The delivery chamber 24 is a processing unit that delivers the hanger 5 to and from the coating object supply unit, and the coating material coating chambers 25 and 25 ′ are processing units that apply the powder coating material to the coating material 3. The heating chamber 26 is a processing unit for baking and drying the powder coating material 3 by high-frequency induction heating the article 3 to which the powder coating material is applied. The heat balance chamber 27 is a processing unit that balances the heating performed in the heating chamber 26, and the cooling chamber 28 is a processing unit that cools the heated article 3 to be coated.
The two paint application sections 25 and 25 'are selectively used depending on the color of the paint to be used.
[0036]
[B-1. Hanger transfer means] (FIGS. 1 and 2)
A vertical main shaft 31 is rotatably provided around the shaft in the main shaft arrangement chamber 22, and the main shaft 31 is intermittently rotated by a rotation mechanism 32 at a central angle of 60 °. This direction of rotation is the clockwise direction seen from above.
The upper end portion of the main shaft 31 protrudes upward from the coating booth 21, from which six horizontal hanger suspension bars 33 protrude radially at a central angle of 60 °. A hanger hanging member (not shown) provided with a hanging portion on which the hanging protrusion 9 of the hanger 5 is hung is provided at the front end portion of the hanger hanging bar 33 so as to be rotatable around a vertical axis. . The hanger hanging member is rotated by the rotation mechanism 34. This rotation is for reversing the direction of the hanger 5.
[0037]
The stop position in the intermittent rotation of the main shaft 31 is a position where the hanger suspension bar 33 has come to correspond to each of the substantially central portions of the processing chambers 24 to 28 as shown in FIGS.
The hanger 5 on which the object 3 to be coated is hung is hung from the hanger hanging member of the hanger hanging bar 33 in the delivery chamber 24 so as to hang from here. Accordingly, when the main shaft 31 rotates, the hanger 5 is transferred in a circular orbit around the coating booth 21, and the object to be coated 3 suspended on the hanger 5 is applied with the paint by this transfer. The chamber 25, the coating material coating chamber 25 ', the heating chamber 26, the heat balance chamber 27, and the cooling chamber 28 are conveyed in this order, and predetermined processing is performed in each processing chamber.
[0038]
[B-2. Paint coating chamber] (FIGS. 1, 2, and 9)
A spray gun traveling part 41 and a paint reciprocating machine 42 are arranged adjacent to the spray gun running part 41 on the outside of the paint application chambers 25 and 25 ', respectively. The spray gun traveling portion 41 is provided with a chain 43 (see FIG. 9) that travels in the vertical direction, a motor 44 that travels the chain 43, and the like. A spray gun 45 that sprays powder paint is attached to the chain 43. The spray gun 45 is a comb-shaped type in which a number of nozzles are arranged in a width slightly longer than the width of the hanger 5 and is directly opposed to the hanger 5 that has been transferred into the paint coating chamber 25, 25 '. Located in the direction. The pipe connected to the spray gun 45 protrudes out of the booth through a longitudinal slit formed in the peripheral wall of the painting booth 21 and is fixed to the chain 43.
[0039]
The motor 44 switches the rotation direction at a predetermined timing to raise and lower the spray gun 45 in a linear direction. Along with this elevation, a powder coating material is supplied from the coating material reciprocating machine 42 to the spray gun 45 and sprayed from here to the article 3 to be coated. The paint supply system or the nozzle tip of the spray gun 45 is provided with means for charging the paint with static electricity, such as a friction tube, a corona discharge plug, etc. The paint sprayed from the spray gun 45 is charged with static electricity. To do.
[0040]
[B-3. Heating chamber] (FIGS. 1, 2, 6, and 7)
In the heating chamber 26, two high-frequency induction coils 51 and 51 'are provided. These high-frequency induction coils 51 and 51 'are processed so as to wind a vertically long, generally oval vortex on a plane. Therefore, the high-frequency induction coils 51 and 51' include bent portions such as the coil g described above. There is no. The high-frequency induction coils 51 and 51 'are substantially the same as the entire size of the hanger 5, and are stored separately in a vertical posture in two coil cases 52 each having a vertically long box shape.
Thus, although the high frequency induction coils 51 and 51 'are independent from each other in the spiral shape, the ends are connected by the copper stranded wire 53 so as to be integrally connected in terms of the circuit. The high-frequency induction coils 51 and 51 ′ are formed by processing a thin copper pipe so that a water channel for flowing cooling water is formed therein, and each water channel is connected by a flexible hose 54. Yes.
[0041]
A slide block 55 is attached to the bottom surface of the coil case 52, and this slide block 55 is slidably engaged with a guide rail 56 disposed at the bottom of the heating chamber 26. As a result, the two high-frequency induction coils 51 and 51 ′ are movably provided so as to face each other across the transfer path of the hanger 5 and to increase or decrease the distance between them.
A nut 57 having a reverse screw relationship is fixed to the lower end portions of the two coil cases 52, and one screw shaft 58 is screwed to these nuts 57. The screw shaft 58 is rotated by a stepping motor 59. Accordingly, when the stepping motor 59 is driven, the two coil cases 52 move to the opposite sides, and the interval between the high frequency induction coils 51 and 51 'is expanded or contracted.
[0042]
[B-4. Heat balance chamber, cooling chamber] (Fig. 1)
A number of far-infrared heaters 61 having an output of several kilowatts are arranged in the heat balance chamber 27.
A blower fan 62 is disposed in the cooling chamber 28.
[0043]
[C. Substrate supply section] (Fig. 1)
In front of the painting booth 21, an object supply unit 71 is provided so as to contact the delivery chamber 24. The object supply unit 71 includes a feed chain 73 that runs horizontally and endlessly at a high place. Yes. A number of hanging members for hanging the hanging protrusions 9 of the hanger 5 are attached to the feed chain 73 at regular intervals, and the position where one of the hanging members comes before the delivery chamber 24 is intermittently set as a stop position. Drive.
[0044]
The hanger 5 on which the article 3 is hung is hung on the feed chain 73 at a predetermined position of the article supply unit 71. Accordingly, the hanger 5 is conveyed toward the painting booth 21 by the feed chain 73 and is transferred to the hanger suspension bar 33 by a transfer robot (not shown) at a position in front of the delivery chamber 24. Then, the hanger 5 that has returned through the painting booth 21 and returned to the delivery chamber 24 is returned to the feed chain 73 by the transfer robot and removed from the feed chain 73 at a predetermined position.
[0045]
[D. Control system] (Fig. 9)
Control items for processing performed in the painting booth 21, particularly a control system for controlling the number of times the spray gun 45 is moved up and down, the amount of powder paint sprayed, the positions of the high frequency induction coils 51 and 51 ′, and the heating time by the coils. 81 is shown in FIG.
A spray gun motor drive circuit 82 controls the spray gun running motor 44.
Reference numeral 83 denotes a paint valve inserted in a paint supply system connected to the spray gun 45. The paint valve 83 includes an opening degree adjusting mechanism that changes the opening degree in accordance with an electrical command. The opening degree adjusting mechanism is controlled by a paint valve control circuit 84.
[0046]
Reference numeral 85 denotes a coil motor drive circuit that controls a motor 59 that moves the coil case 52, and 86 denotes a position sensor such as a proximity switch. The position sensor 86 is for detecting a standby position that is a movement origin of the coil case 52, and outputs a signal when the coil case 52 reaches a standby position indicated by a two-dot chain line in FIG.
Reference numeral 87 denotes a coil drive circuit that controls energization of the high-frequency induction coils 51 and 51 ', and includes a timer 87a for controlling the energization time.
[0047]
Reference numeral 88 denotes a SID-TAG as a data recording medium, and 89 denotes a data reading circuit. These SID-TAG 88 and data reading circuit 89 and a writing means (not shown) for writing data to the SID-TAG 88 constitute an SID-TAG system. The product number data of the article to be coated is recorded on the SID-TAG 88, and this SID-TAG 88 is detachably mounted on the tag mounting portion 10 provided on the hanger 5.
The data written in the SID-TAG 88 is transmitted from the antenna provided in the SID-TAG 88 to the antenna of the data reading circuit 89 and read by the data reading circuit 89.
[0048]
Reference numeral 90 denotes a system program. This system program 90 includes the number of times the spray gun 45 is moved up and down, the degree of opening of the paint valve 83, the coating color, the amount of rotation of the stepping motor 59 that defines the distance between the coil and the object to be coated, and the high frequency induction coils 51 and 51 '. A control data file in which control data such as energization time is written for each product number of the object to be coated, and control data corresponding to the product number read by the data reading circuit 89 are read from the control data file, and a predetermined control signal is sent to each control. A program file in which a procedure for outputting to the circuits 82, 84, 85, 87, etc. is written is provided.
A part of the contents of the control data file is shown in Table 1.
The powder coating apparatus 1 is configured as described above.
[0049]
[Table 1]
Figure 0004688353
[0050]
[E. Usage and action)
Next, the usage method and operation of the powder coating apparatus 1 will be described.
[E-1. (Pre-treatment)
Prior to starting painting, the SID-TAG system uses the control data file to associate the optimum control data and necessary paint color data obtained from experience with the part number of the work. Write.
[0051]
When suspending the object to be hung on the hanger 5, the most suitable kind of object hook 8 for the object to be coated is selected, and the number to be attached to the hook mounting bar 7 is selected. In particular, the arm 8b having a height H (see FIG. 5) longer than the dimension L from the hook hole 3a to the upper end of the article 3 is selected. Further, if it is sufficient to support the object to be coated at one place, the object hook 8 having the shape described above is used. If the object to be supported is to be supported at two places, an object hook having two arms 8b is used. Use. When the size of the object to be coated is large, two are attached to one hook mounting bar 7, and when the size is small, three are attached.
Further, from an empirical viewpoint, when the heating speed of the object to be coated varies depending on the position with respect to the high frequency induction coils 51 and 51 ′, even if the same object is to be coated, the high frequency induction effect is applied to a place where the speed is low. In order to make the height higher than the others, a workpiece hook having a long arm 8b is used.
[0052]
In this way, after selecting the type and number of coating object hooks and attaching them to the hook mounting bar 7, the target coating object is hung on the coating object hooks. This is performed by tightly inserting the hook portion 8c of the article hook 8 into the hook hole 3a of the article 3 as shown in FIG. Only one object of the same type is hung on one hanger 5.
Then, the product number of the article to be coated hung on the hanger 5 is written on the SID-TAG 88 and inserted into the tag mounting portion 10 of the hanger 5.
The hanger 5 in this state is hung on the feed chain 73.
[0053]
[E-2. Painting〕
When the hanger 5 on which the article 3 is suspended is conveyed to a predetermined position near the delivery chamber 24, the data reading circuit 89 receives the data of the SID-TAG 88. The system program 90 reads out control data and paint color data corresponding to the product number data received by the data reading circuit 89 from the control data file, converts them into predetermined control signals, and prepares for output to the corresponding control circuit. This output timing is sequentially performed at a timing synchronized with a tact signal for controlling the rotation of the main shaft 31.
Next, the hanger 5 is transferred to the hanger suspension bar 33. The posture of the hanger 5 at this time is performed in a posture parallel to the straight line that circumscribes the rotation trajectory of the hanger suspension bar 33, as shown in FIG.
[0054]
The hanger 5 thus carried into the painting booth 21 is first transferred to the paint application chamber 25 and stopped at a position facing the spray gun 45. When the paint color of the object is the same as the paint color in the paint application chamber 25, the paint application is performed here. Otherwise, the paint application is performed when the paint is transferred to the next paint application chamber 25 '. Executed. This paint application is controlled as follows.
[0055]
A control signal is output from the system program 90 to the spray gun traveling section 41 and the paint reciprocating machine 42, whereby the spray gun 45 sprays the powder paint toward the hanger 5 while moving up and down a required number of times. The amount of the powder paint is in accordance with the degree of opening of the paint valve 83 controlled in accordance with the control signal, and adheres to one surface of the hanger 5 and the article 3 due to the static electricity.
If double-sided coating is required, the direction of the hanger 5 is reversed when the spray gun 45 completes a predetermined number of times of raising and lowering, and the coating of the other surface starts. In this case, since the entire object to be coated 3 is located at a position lower than the hook mounting bar 7, the hook mounting bar 7 does not make a shadow on the paint sprayed from the rear side on the object to be coated 3, and Since the arm 8b of the object hook 8 is a wire, the arm 8b does not interfere with the spraying of the paint.
[0056]
[E-3. Heating etc.)
The hanger 5 thus applied with the paint in the paint application chamber 25 or 25 ′ is then transferred to the heating chamber 26. Prior to this, the two coil cases 52 have come to the standby position described above, and have a large distance between each other. Accordingly, the hanger 5 smoothly enters between the two coil cases 52.
When the hanger 5 comes to this position, a control signal is output from the system program 90 to the coil motor drive circuit 85, whereby the stepping motor 59 rotates by a predetermined amount to move the two coil cases 52 to the hanger 5. In addition, the driving signal is output to the coil driving circuit 89, and the high frequency induction coils 51 and 51 'are energized.
[0057]
The high frequency current generated from the coils 51 and 51 'acts on the article 3 to be coated, and the article 3 itself is heated, and by this heating, the powder coating adhering to the surface is baked and dried. Since the entire hanger 5 is formed of phosphor bronze, it is not heated by the high frequency current. Therefore, the powder coating material adhering to each part of the hanger 5 is not baked.
When the specified heating time has elapsed, energization of the high frequency induction coils 51 and 51 'is stopped and the coils 51 and 51' are returned to the standby position.
[0058]
Next, after the hanger 5 is transferred to the heat balance chamber 27 and heat balance is achieved, the hanger 5 is cooled in the cooling chamber 28, returned to the delivery chamber 24, and placed on the feed chain 73.
The powder paint adhering to the hanger 5 is removed by a blower (not shown) provided in the heat balance chamber 27 and collected by vacuum.
[0059]
Although the embodiment of the present invention has been described above, the specific configuration of the present invention is not limited to this embodiment, and even if there is a design change or the like without departing from the gist of the present invention. Included in the invention.
For example, in the embodiment, SID-TAG is used as a recording medium for recording control data. However, the recording medium is not limited to that type.
[0060]
【The invention's effect】
  As described above, according to the invention of claim 1,Since it is not necessary to make a bent portion in the high-frequency induction coil, there is almost no difference in the strength of the high-frequency induction, and all the objects to be directly opposed can be heated almost uniformly. In the embodiment, the ends of the two coils are connected to each other with a wire that does not form a vortex, so that the circuit has an integrated structure. It can be simplified.
  According to the second and third aspects of the invention, the distance between the two coils and the distance between the coils and the object to be coated can be adjusted. It is possible to control such that one coil is kept waiting at a position where these intervals are widened, and when heating is performed, the coils are moved to a position where the optimum facing interval is applied to the object to be coated. As a result, the size of the object to be coated can be expanded to increase the versatility, and it is possible to realize optimum heating conditions for each object to be coated.
According to the invention of claim 4,Since only one operation is required to attach and detach the coating object hook to and from the hook mounting bar, the type and number of coating object hooks to be mounted on the hook mounting bar, the number of mountings in the horizontal direction, etc., can be set to the shape and size of the coating object. The work to be changed can be completed in a short time.
  According to the invention of claim 5, since the hook mounting bar and the coating object hook do not disturb the spraying of the coating material from the rear side to the coating object, the coating application unevenness can be eliminated.
  According to the sixth aspect of the present invention, the position of the high frequency induction coil, which is one of the control items for realizing optimum heating in accordance with the characteristics of the object to be coated and the paint, is recorded in advance on the recording medium. Since the adjustment is automatically performed, the operation of stopping the operation and adjusting the position of the high frequency induction coil every time the lot changes is unnecessary. In addition, the number of movements of the spray gun, the amount of powder paint sprayed from the spray gun, and the heating time by the high-frequency induction coil, which are the control items for realizing optimum paint application and heating according to the characteristics of the object and paint At least one of the controls is automatically adjusted by recording the control data in a recording medium in advance, so that each time a lot changes, the operation is stopped and various control items are adjusted. It becomes unnecessary. In particular, since control data is provided in units of hangers, it is possible to perform coating under optimum processing conditions each time even with a small lot.
[Brief description of the drawings]
FIG. 1 is an overall plan view of a powder coating apparatus according to an embodiment of the present invention.
FIG. 2 is a perspective view of a main part of the powder coating apparatus shown in FIG.
FIG. 3 is a partially omitted perspective view in which a hanger of the powder coating apparatus shown in FIG. 1 is enlarged.
4 is a perspective view showing a state in which an object to be coated is suspended from an object hook in the powder coating apparatus of FIG. 1; FIG.
5 is a side view showing a state in which an object to be coated is suspended from an object hook in the powder coating apparatus of FIG. 1; FIG.
6 is an enlarged perspective view of a heating part of a coating booth in the powder coating apparatus of FIG. 1. FIG.
7 is an enlarged side view of a heating part of a coating booth in the powder coating apparatus of FIG. 1. FIG.
8 is an enlarged perspective view of a tag mounting portion of a hanger in the powder coating apparatus shown in FIG.
9 is a diagram showing a control system of the powder coating apparatus shown in FIG. 1. FIG.
FIG. 10 is a diagram showing an outline of a previously proposed high-frequency induction heating type powder coating apparatus.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ... High frequency induction heating type powder coating apparatus 3 ... Coated object 5 ... Hanger
7 ... Hook mounting bar 7a ... Vertical groove 8 ... Coating hook 8a ... Mounting part
8b ... arm 8c ... hook part 10 ... recording medium mounting part
25 ... Paint application part (processing part) 25 '... Paint application part (processing part)
26 ... heating unit (processing unit) 31, 32, 33 ... hanger transfer means
44, 82 ... Control means (number of times the spray gun moves) 51 ... High frequency induction coil
51 '... high frequency induction coil 52 ... coil support base
55, 56, 57, 58, 59 ... Coil position control means (control means)
83, 84 ... Control means (powder coating amount) 87, 87a ... Control means (heating time)
88 ... Recording medium 89, 90 ... Control circuit

Claims (4)

粉体塗料を被塗物に塗布する塗料塗布部とこの粉体塗料が塗布された被塗物を高周波誘導加熱することで当該粉体塗料を焼付け乾燥する加熱部とを含む複数の処理部と、水平なフック取付けバーに被塗物フックが取り付けられたハンガーと、このハンガーを上記複数の処理部に順次移送するハンガー移送手段とを備えた高周波誘導加熱式の粉体塗装装置であって、
円筒状の塗装ブースの内部に前記処理部が設けられ、
前記加熱部の高周波誘導コイルは、前記ハンガーの移送経路を挟んで対向する状態で２つ配置し、前記２つの各高周波誘導コイルは、それぞれ平面上で縦長の長円渦状に巻かれ、その一端どうしが渦を形成しない形の線材を介して結ばれて回路的に接続され、且つ、前記２つの高周波誘導コイルは、これらの対向方向で相対的に反対側へ移動自在なコイル支持ベースに支持されており、前記コイル支持ベースの下端部には互いに逆ねじの関係を為すナットが固定され、これらナットにスクリュウ軸が螺旋され、このスクリュウ軸はモーターにより回転されることで、前記２つの高周波誘導コイルは互いに反対側に移動でき、その間の間隔が拡縮する構成になっていることを特徴とする高周波誘導加熱式の粉体塗装装置。A plurality of processing units including a coating unit for applying the powder coating to the object to be coated and a heating unit for baking and drying the powder coating by high-frequency induction heating of the object to be coated with the powder coating; A high frequency induction heating type powder coating apparatus comprising a hanger having a hook to be coated attached to a horizontal hook mounting bar and hanger transfer means for sequentially transferring the hanger to the plurality of processing units,
The processing section is provided inside a cylindrical coating booth,
High-frequency induction coil of the heating section, the to two disposed in a state opposite to each other across the transfer path of the hanger, the two respective high frequency induction coils are respectively wound elongated oval spiral on a plane, one end The two high-frequency induction coils are connected to each other via a wire rod that does not form a vortex, and the two high-frequency induction coils are supported by a coil support base that is relatively movable in opposite directions. Nuts that are reversely screwed to each other are fixed to the lower end of the coil support base, and screw shafts are spiraled to the nuts, and the screw shafts are rotated by a motor, thereby the two high frequency components. A high frequency induction heating type powder coating apparatus characterized in that the induction coils can move to opposite sides and the interval therebetween is expanded or contracted . 請求項１に記載した高周波誘導加熱式の粉体塗装装置において、被塗物フックは逆Ｕ字形に屈曲した取付け部と該取付け部の一端から延びた腕とを有する形状にし、フック取付けバーには上記取付け部を着脱自在に係合させるための縦溝を多数横方向へ形成したことを特徴とする高周波誘導加熱式の粉体塗装装置。2. The high frequency induction heating type powder coating apparatus according to claim 1, wherein the article hook is formed into a shape having a mounting portion bent in an inverted U shape and an arm extending from one end of the mounting portion. Is a high-frequency induction heating type powder coating apparatus characterized in that a large number of longitudinal grooves for detachably engaging the attachment portion are formed in the transverse direction . 請求項１または２に記載した高周波誘導加熱式の粉体塗装装置において、被塗物フックの取付け部と腕は断面円形の線材により形成し、該腕の先端部は取付け部より低い位置まで延び、この先端部に、被塗物を吊掛けるための矢じり形のフック部を取り付けたことを特徴とする高周波誘導加熱式の粉体塗装装置。3. The high frequency induction heating type powder coating apparatus according to claim 1 or 2, wherein the attachment portion and the arm of the object hook are formed of a wire having a circular cross section, and the tip of the arm extends to a position lower than the attachment portion. A high frequency induction heating type powder coating apparatus characterized in that an arrowhead-shaped hook portion for suspending an object to be coated is attached to the tip portion . 請求項１から３のいずれかに記載した高周波誘導加熱式の粉体塗装装置において、塗料塗布部のスプレーガンの移動回数と前記スプレーガンからの粉体塗料の噴射量と高周波誘導コイル間距離と前記高周波誘導コイルによる加熱時間を制御する制御回路と、ハンガーに取り付けられ、前記制御回路の制御データを記録した記録媒体とを備え、前記記録媒体に記録されたデータを読み取ってそれに対応する制御信号を前記制御回路に出力するように構成したことを特徴とする高周波誘導加熱式の粉体塗装装置。The high frequency induction heating type powder coating apparatus according to any one of claims 1 to 3, wherein the number of movements of the spray gun in the paint application unit, the spray amount of the powder paint from the spray gun, and the distance between the high frequency induction coils, A control circuit for controlling the heating time by the high-frequency induction coil; and a recording medium attached to the hanger and recording the control data of the control circuit, and reading the data recorded on the recording medium and corresponding control signals Is output to the control circuit . A high-frequency induction heating type powder coating apparatus.
JP2001197772A 2000-10-24 2001-06-29 High frequency induction heating type powder coating equipment Expired - Lifetime JP4688353B2 (en)

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JP2001197772A JP4688353B2 (en) 2001-06-29 2001-06-29 High frequency induction heating type powder coating equipment
US10/101,722 US6797066B2 (en) 2000-10-24 2002-03-21 Apparatus and method for powder coating
CNB021082596A CN1247317C (en) 2001-06-29 2002-03-28 Device and method for coating powder
EP02252483A EP1270089B1 (en) 2001-06-29 2002-04-05 Apparatus and method for powder coating with induction heating
AT02252483T ATE277692T1 (en) 2001-06-29 2002-04-05 DEVICE AND METHOD FOR POWDER COATING WITH INDUCTIVE HEATING
DE60201380T DE60201380T2 (en) 2001-06-29 2002-04-05 Apparatus and method for powder coating with inductive heating
KR1020020020404A KR100864684B1 (en) 2001-06-29 2002-04-15 Apparatus and method for powder coating
HK03103874A HK1051663A1 (en) 2001-06-29 2003-05-30 Apparatus and method for powder coating with induction heating

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CN1393293A (en) 2003-01-29
DE60201380T2 (en) 2005-02-24
KR100864684B1 (en) 2008-10-23
EP1270089A1 (en) 2003-01-02
CN1247317C (en) 2006-03-29
EP1270089B1 (en) 2004-09-29
HK1051663A1 (en) 2003-08-15
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KR20030004018A (en) 2003-01-14
DE60201380D1 (en) 2004-11-04

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