JPH10506842A

JPH10506842A - Vehicle powder coating system

Info

Publication number: JPH10506842A
Application number: JP8512567A
Authority: JP
Inventors: シュテイク，ジェフリイ，アール．; エフ．カールソン，ジョン，; イー．ホルスタイン，トーマス，; イー．ウィリアムズ，キース，; ジェー．フエナ，アーネスト，
Original assignee: Nordson Corp
Current assignee: Nordson Corp
Priority date: 1994-10-11
Filing date: 1995-08-29
Publication date: 1998-07-07
Anticipated expiration: 2015-08-29
Also published as: SE520183C2; AU3374595A; SE9701187D0; SE9701187L; CA2200343A1; DE19581792T1; JP3708445B2; JP3429316B2; CA2200343C; JP2001293422A

Abstract

(57)【要約】自動車、トラックまたはその他の車体（３２）などの大きい物体に粉体塗装材料を塗布する装置は、車体（３２）に粉体塗装材料を塗布する制御区域を規定する粉体吹付けブース（１２）と、粉体吹付けブース（１２）から遠方の位置にある粉体キッチン（１４）と、ブース（１２）の近傍に位置して、粉体キッチン（１４）から粉体塗装材料を受け取って、それをブースに関連付けられた自動または手動操作の粉体スプレー・ガン（４２、４６）に供給する幾つかの供給ホッパー（６８、９６）とを含む。過剰に吹き付けられた粉体塗装材料は、過剰に吹き付けられた粉体を、粉体スプレー・ガン（４２、４６）へと再循環するために粉体キッチン（１４）に戻す粉体収集回収システム（１６）によって、ブース室内（１２）から除去される。 (57) [Summary] Apparatus for applying a powder coating material to a large object such as an automobile, truck or other vehicle body (32) is a powder that defines a control area for applying the powder coating material to a vehicle body (32). A spray booth (12), a powder kitchen (14) located far from the powder spray booth (12), and a powder kitchen located near the booth (12). And a number of supply hoppers (68, 96) for receiving the coating material and supplying it to an automatically or manually operated powder spray gun (42, 46) associated with the booth. Oversprayed powder coating material returns the oversprayed powder to the powder kitchen (14) for recirculation to the powder spray guns (42, 46). By (16), it is removed from the booth room (12).

Description

【発明の詳細な説明】車両粉体塗装システムこれは、１９９３年５月２５日に出願され車両粉体塗装システムと題され本発明の譲受人が所有する、Shuticその他に帰される米国特許出願第08/066,873号の一部継続出願である。発明の分野本発明は、粉体塗装システムに関し、特に粉体吹付けブース、粉体収集回収システム、および未使用の粉体塗装材料と未使用および再生または過剰吹付けの粉体塗装材料の混合物を遠方位置から吹付けブースに付随する塗装用ディスペンサに搬送する粉体供給装置を含む車両製造施設に使用する粉体塗装システムに関する。発明の背景自動車やその他の車体などの大型物体に塗装材料を塗布する作業は、従来、車体が進入する入口、塗料塗布区域、設計によっては硬化または乾燥区域、および車体が出る出口で形成された細長いトンネル状の構造を有する吹付けブースで実施されてきた。多くのシステムでは、「調整済み」の空気、つまり増湿して濾過した空気を、ブロワまたは送風ファンで吹付けブースの頂部にあるプレナム・チャンバに導入し、次にブースを通過する車両に向けて下方向に方向づける。調整済みの空気は、ブース室内の過剰吹付け塗装材料を拾い、空気で搬送されるこの過剰吹付け材料は、１個以上の排気ファンがブースの床または側面を通って下方向に排出する。フィルタを設けて、過剰に吹き付けた塗装材料を捕捉し、その結果得られた濾過済みまたは清浄な空気をブースから抜き取り、大気中に排気するか、システム内で再循環させて再利用する。自動車、トラックなどの車両に最も一般的に使用される塗装材料は、樹脂材料の霧化を容易にする液体溶剤成分の割合が比較的高い、ハイ・ソリッドの樹脂塗料材料である。過剰に吹き付けた樹脂塗料材料の回収に伴う問題については、詳細な記録があり、塗装および仕上げ産業で引き続き環境問題になっている。Cobb sに帰される米国特許第4,247,591号およびRehmanその他に帰される第4,553,701 号を参照のこと。 Shuticその他に帰され本発明の譲受人が所有する米国特許第5,078,084号で開示されているように、粉体塗装材料が、車体などの大きい物体を塗装する溶剤ベースの液体塗料材料の代替品として提案されてきた。粉体塗装の実際では、粉未状樹脂を基板に塗布してから基板と粉体とを加熱すると、粉体が溶融し、その後冷却すると、基板上に連続的な固体被膜を形成する。大抵の粉体吹付け用途では、基板に付着する粉体の量が増加し、基板への粉体の保持を助けるよう、塗布すべき接地物体に向ける吹付け用粉体に静電荷を与える。自動車またはトラックの車体に粉体材料を塗布する作業は、車体に付着しない過剰吹付け粉体を収集できる管理区域を提供する吹付けブース内で実施する。ブース内への過剰吹付け粉体の封じ込めは、ブース室内に負圧を生成して過剰に吹き付けた粉体をブースから吸い出し、粉体収集回収システムに入れる排出システムによって補助される。回収した過剰吹付け粉体は、今後の使用のために保管しておくことができ、あるいは粉体吹付けブースに関連付けられた粉体スプレー・ガンへと、即座に再循環する。粉体塗装材料で自動車およびその他の車体に塗装するには、固有の問題が幾つかある。車両製造施設の設計のため、塗装材料の供給源は、通常は吹付けブースから遠方、つまり数百フィートもの位置にある。さらに、たとえば１時間当たり３００ポンド以上などの大量の粉体塗装材料を、１秒当たり１ないし２ポンドなどの流量で、この比較的長距離を供給源から吹付けブースまで移送しなければならない。また、車体に粉体材料を適切に塗装するため、適切な密度および粒子分布で、粉体塗装材料を移送しなければならない。「密度」という用語は、粉体と空気との相対的な混合または割合を指し、「粒子分布」という用語は、粉体吹付けブースに関連付けられたスプレー・ガンに送る、空気で搬送される粉体材料の流れの中の様々なサイズの粉体粒子の分布を指す。現在利用可能な粉体塗装システムは、長い距離を大流量で大量に粉体材料を移送しながら、所望の密度および粒子分布を維持することができない、あるいは不十分にしかできないことが分かっている。上述したように、粉体吹付けブース内で放出される粉体塗装材料は、すべてがブースを通過する車体に付着するわけではない。この過剰に吹き付けた粉体材料は、たとえばShuticその他に帰される特許第5,078,084号などで開示されているようなブースの基部で、粉体収集回収システムで収集される。このタイプのシステムでは、粉体収集回収システムは、吹付けブースの床の下に並んで取り付けられた一連の粉体収集チャンバの個々に含まれたカートリッジ・フィルタの個々のグループまたはバンクを含む。１個の排気ファンまたはブロワが、ブース室内に負圧を生成し、負圧が、過剰に吹き付けられて空気で搬送される粉体材料を、個々の粉体収集チャンバに吸い込み、そこで粉体はカートリッジ・フィルタの壁上に収集され、「クリーン・エア」はそれを通過して、その後大気に放出される。逆向きのエア・ジェットを操作して、収集した粉体をカートリッジ・フィルタの壁から取り除くと、粉体は粉体収集チャンバの基部に落下し、そこで粉体吹付けブースに関連付けられたスプレー・ガンに戻すよう収集または再循環するため取り出される。自動車の車体の塗装などの大量な用途では、粉体収集回収システムの実用性、およびブース室内の均等な負圧の適用が、特に問題となる。１個の排気ファンまたはブロワ・ファンを使用してブース室内で均等な負圧を獲得するのは、場合によっては多少困難であり、そのため粉体塗装材料を収集できる効率に悪影響を及ぼし、ブースを通過する車体上にスプレー・ガンから放出される粉体塗装材料のパターンを崩壊させる可能性があることが分かっている。このタイプのシステムでは、各粉体回収チャンバ内に含まれる逆エア・ジェットバルブの実用性を改善する必要もある。上述したタイプの粉体塗装システムには、それ以外にも問題があり、それは粉体吹付けブースに関連付けられたスプレー・ガンに戻る再循環のための過剰吹付け粉体の回収に関するものである。未使用の粉体塗装材料は、粒子サイズの分布の幅が広い、つまりサイズが多種多様な粉体粒子を含む。大きい粉体粒子の方が、吹付けブース内で塗装する物体に付着しやすい傾向がある。というのは、そのサイズのために、小さい方の粒子より静電荷が高く、大きく重い粒子の方が、スプレー・ガンから塗装物体に向けて放出された時に、小さい粒子よりモーメントが大きいからである。その結果、過剰に吹き付けられ、物体に付着せずに再循環してスプレー・ガンに戻るよう収集される粉体は、未使用の粉体より小さい方の粒子の割合が大きい。大きい粒子の方が、小さい粒子より物体に付着する割合が大きいからである。粉体塗装システムの動作の安定性は、少なくとも一部は、「微粉」、たとえば約１０ミクロン未満のサイズを有する粒子の付着または蓄積をいかに回避するかにかかっている。本明細書で用いる「安定性」という用語は、過剰なレベルの微粉によって生じる問題なく、粉体塗装材料を流動化し、移送し吹き付けるシステムの能力を指す。粉体塗装材料内に過剰なレベルの微粉が存在すると、粉体の流動化の低下、衝突融合、フィルタ・カートリッジおよび篩の目詰まり、粉体吹付けブースの内面およびスプレー・ガンへの粉体の付着の増大、および塗着効率の低下をもたらすことがある。「衝突融合」という用語は、静電気の引力に対する粒子速度の結果、粉体粒子が表面に付着することを指し、「塗着効率」とは物体に向けて吹き付けられた粉体の総量に対する物体に付着した粉体材料の割合の尺度である。上述したタイプの粉体塗装システムには、過剰に吹き付けた粉体材料を、収集後にスプレー・ガンへと再循環させるときのシステムの動作安定性を確保する措置が、基本的にはない。供給用ホッパーなどから微粉を除去するために換気ユニットを使用しているが、このようなユニットは有効性に限界があり、所定の供給用ホッパー内の微粉のレベルまたは割合を所望の精度で制御するのに、これに頼ることはできない。発明の要約したがって、長い距離を比較的大流量で大量に粉体材料を搬送しながら、所望の密度および粒子分布を維持することができ、要求量に関係なくシステム内の粉体塗装材料の適量を維持し、過剰に吹き付けた大量の粉体を再循環のために効率的に収集して回収し、過剰なレベルの微粉の蓄積を回避し、保守が比較的容易な、自動車やその他の車体などの大きい物体に粉体塗装材料を塗布する粉体吹付けシステムを提供することが、本発明の目的の一部である。これらの目的は、自動車、トラックまたはその他の車体などの大きい物体に粉体塗装材料を塗布するために、車体に粉体塗装材料を塗布する制御区域を規定する粉体吹付けブースと、粉体吹付けブースから遠方の位置に配置された「粉体キッチン」と、ブースの近傍に位置して、粉体キッチンから粉体塗装材料を受け、それをブースに関連付けられ自動操作または手動操作される粉体スプレー・ガンに供給する幾つかの供給ホッパーとを含む機器内で達成される。過剰に吹き付けた粉体塗装材料は、粉体収集回収システムによってブース室内から取り出され、このシステムが、過剰に吹き付けた粉体を、粉体スプレー・ガンへと再循環するために粉体キッチン内の１個以上の混合ホッパーに戻す。本発明の一つの態様は、遠方の、つまり粉体キッチンの位置からスプレー・ブースの近傍に位置した供給ホッパーまで、粉体塗装材料を移送するための有効な手段を提供するという概念に基づいて予測される。これは、正圧ではなく真空または負圧で操作する粉体移送システムによって、本発明の機器で達成される。粉体キッチンは、粉体キッチン内の未使用粉体塗装材料の供給源に接続された、粉体受けユニットにそれぞれ結合された１個以上の１次ホッパーを含む。移送ラインは、１次ホッパーを、吹付けブースの各供給ホッパーに関連付けられた粉体受けユニットと相互接続させる。第１真空ポンプを操作して、１次ホッパーに関連付けられた粉体受けユニット内に負圧を生成し、未使用粉体材料を供給源から粉体受けユニットに吸い込んで、粉体を１次ホッパーに供給することができる。第２真空ポンプが、供給ホッパーに関連付けられた各粉体受けユニット内に負圧を与え、したがって粉体キッチン内に配置された１次ホッパーからの未使用粉体材料が、長い移送ラインを通って、吹付けブースの近傍にある供給ホッパーに関連付けられた粉体受けユニットに吸い込まれる。吹付けブースにある粉体受けユニットは、個々の供給ホッパーに粉体を充填し、粉体は粉体ポンプによって供給ホッパーから吹付けブース内の粉体スプレー・ガンに移送される。吹付けブースから過剰吹付け粉体材料を収集するのに、負圧を適用した粉体移送のこの同じ原理が用いられる。粉体キッチン内に配置された再生ホッパーは、粉体受けユニットに結合し、これは再生ラインによって、粉体吹付けブースに関連付けられた粉体収集回収システムに接続される。真空ポンプは、ブースから過剰に吹き付けた粉体を受け取る再生ホッパーに関連付けられた粉体受けユニット内に負圧を発生させ、このような過剰吹付け粉体を再生ホッパーに移送する。本発明で好ましい一つの実施形態では、再生されたこの過剰吹付け粉体を、次に別の真空ポンプによる負圧で再生ホッパーから搬送し、ブース付近に位置する供給ホッパーに接続された粉体受けユニットに、過剰吹付け粉体を供給する。次に、この供給ホッパーが、過剰吹付け粉体を、吹付けブースに関連付けられたスプレー・ガンに供給し、これは塗装される車体の他の部分に粉体を塗布するよう作動する。別の実施形態では、再生ホッパーおよび１次ホッパーが、それぞれ粉体キッチン内に配置された混合ホッパーに接続される。１次および再生ホッパー内の粉体ポンプが、選択された割合の未使用粉体と再生または過剰吹付け粉体とを混合ホッパーに移送し、このような粉体は、吹付けブースに関連付けられたスプレー・ガンに移送する準備として、ここで混合される。混合ホッパー内に含まれる粉体の粒子サイズの分布が数学的に予想される本発明の方法によると、混合ホッパーに導入される未使用粉体と再生粉体の供給は、混合ホッパーに含まれる微粉の体積百分率が、所定の最高百分率を上回らないよう制御される。これによって、ブース内の物体に再生または過剰吹付け粉体を塗布する場合に、粉体塗装システムの安定した動作が確保される。たとえば１時間に約３００ポンド以上の大量の粉体塗装材料を、上述した真空移送システムで効率的かつ効果的に搬送して、粉体塗装材料の供給源が粉体吹付けブースの遠方に配置された自動車製造施設の特定の需要を満足させられることが分かっている。正圧ではなく負圧を使用すると、空気の使用量が少なくなり、したがってシステムの全体的なエネルギー要件が少なくなると考えられる。また、粉体キッチンと吹付けブースとの間に延びる移送ラインのいずれか１本が漏れた場合、粉体材料は、正圧の粉体移送システムの場合では強制的に外側に出るが、このような移送ラインでは、真空のためにラインの内側に吸い込まれる。これによって、漏れの問題が発生した場合に、施設を粉体で汚染する危険性が少なくなる。本発明の粉体移送の態様に関する別の特徴は、塗装作業が進行するにつれ、未使用粉体塗装材料と過剰吹付け粉体材料とを自動的に監視し、補給することに関する。１次ホッパー、再生ホッパーおよび供給ホッパーはそれぞれ、プログラム可能な論理制御装置に接続されたロード・セルが担持している。このロード・セルは、個々のホッパーが空の重量でゼロ基準に設定され、システムの動作中に個々のホッパーそれぞれに入る粉体材料の重量を測定するのに効果的である。たとえば、１次ホッパーについて考えると、それに関連付けられたロード・セルは、システムの動作中にこのような１次ホッパー内の粉体の重量を示す信号を、制御装置に送信する。１次ホッパー内の粉体材料の量が、所定の最小値より下がった場合は、制御装置がロード・セルから信号を受信し、このような１次ホッパーに関連付けられた粉体受けユニットに接続された真空ポンプを作動し、その結果、追加の未使用粉体塗装材料が、供給源から粉体受けユニットに搬送され、次に１次ホッパーに搬送される。１次ホッパーが、十分なレベルの粉体塗装材料を受け取ると、それ以上の粉体の供給は停止される。再生ホッパーおよび供給ホッパーが、同様の方式で作動するので、粉体塗装作業中は、それぞれで適切なレベルの粉体塗装材料が維持される。１つの実施形態では、１次ホッパーと再生ホッパーそれぞれの間に接続ラインが設けられるので、吹付けブースの粉体収集回収システムに収集された過剰吹付け粉体材料の量が、再生ホッパー内の粉体材料の量を所望のレベルで維持するのに不十分な場合には、未使用の粉体塗装材料を１次ホッパーから再生ホッパーに供給することができる。別の実施形態では、プログラム可能な制御装置が、上述し以下で詳細に検討する方法によって決定された選択割合に従って、各１次ホッパーからの未使用の粉体塗装材料の移送と、関連のホッパーから混合ホッパーへの再生または過剰吹付け粉体の移送とを支配する。混合ホッパーは、未使用の粉体と再生した粉体との混合物を、１個以上のスプレー・ガンに供給する。本発明の別の態様は、１次ホッパー、再生ホッパーおよび供給ホッパーのそれぞれに構造によって、粉体塗装材料が所望の密度および粒子分布でシステム内を確実に移送され、スプレー・ガンに供給される措置に関する。この態様では、本発明の譲受人が所有しCrumその他に帰される米国特許第5,018,909号で開示された粉体供給ホッパーに用いられているのと同様の動作原理が、本発明の様々なホッパーに用いられている。一般に、本明細書の各ホッパーは、有孔板を含み、それが、このようなホッパーの基部の空間に配置されたバッフルを通過する空気の上方向の流れを受ける。回転式櫂または翼を含む撹拌器が、有孔板の上に配置され、これによって個々のホッパーから放出する前に、粉体材料の適切な流動化、粉体粒子の均等な分布、および適切な密度または空気対粒子の割合が確保される。本発明のさらに別の態様は、粉体吹付けブースに効率的に容易に保守可能な粉体収集回収システムを提供し、これがブース室内に均質で下向きの空気の流れを生成する、という概念に基づく。この粉体収集回収システムは、モジュール式の構造で、粉体吹付けブースの長さに沿って、その床下に並んで取り付けられる幾つかの粉体収集ユニットを含む。各粉体収集ユニットは粉体収集チャンバを含み、これは、粉体収集チャンバの基部に配置された角度のついた流動化プレートの上に、逆Ｖ字形で取り付けられた２グループすなわち２つの列のカートリッジ・フィルタを収容する。限られた数の個別粉体収集ユニットが、共通ダクトによって別個の排気ファンまたはブロワ・ユニットに接続される。各排気ファンは、関連の粉体収集ユニット内に負圧を生成し、空気で搬送される過剰吹付け粉体材料をブース室内からブースの床を通して下方向に吸い込み、次いで各粉体収集チャンバに入れるのに有効である。過剰に吹き付けられた粉体材料は、カートリッジ・フィルタの壁上に溜まり、「クリーン」な空気はそれを通過して、各粉体収集ユニットに関連付けられたクリーン・エア・チャンバに入る。パルス状の空気ジェットが、カートリッジ・フィルタの上に配置されたエア・ジェット弁からカートリッジ・フィルタの内部に定期的に導入され、フィルタの壁に溜まった粉体を追い払うと、次にこの粉体は、各粉体収集チャンバの基部にある角度の付いた流動化プレート上に落下し、除去される。各粉体収集チャンバは、共通のヘッダ・パイプに接続された出口を有し、その出口線のそれぞれにゲート弁が配置される。システム制御装置は、収集された粉体材料が、粉体キッチンに関連付けられた再生ホッパーに移送する順序で、様々な粉体収集ユニットから取り出されるように、弁を順次開閉するのに有効である。本明細書で述べる粉体収集回収システムの構造には、幾つかの利点がある。幾つかの排気またはブロワ・ユニットを使用し、それぞれが限定された数の粉体収集ユニットに関連するので、より均一でむらなく分布した下方向の空気の流れが、粉体吹付けブースの室内に、その全長に沿って生成される。これは、単一の排気ファンまたはブロワを有するシステムに対する改良点である。というのは、車体などの大きい物体を塗布するのに必要な極端な長さを有する吹付けブース内で、ブロワ・ユニット１個だけでは、均一な負圧を得ることは困難であることが証明されているからである。本明細書で述べる粉体収集回収システムの保守も、従来の設計のものよりはるかに容易である。アクセスが容易になるよう、粉体収集ユニットの頂部に逆エア・ジェット弁が配置され、オペレータ１人でカートリッジ・フィルタを粉体収集チャンバから容易に取り外せる。各粉体収集チャンバから粉体材料を除去することも、その基部にある角度をつけた流動化プレートによって容易になり、それは、チャンバから粉体を滑らかに移送するのに役立つ。また、粉体収集チャンバの壁は、空気の逆噴射が起動すると振動して粉体を有孔板上に送るのに役立つよう、十分薄くできている。図面の説明本発明の現在好ましい実施形態の構造の動作および利点は、以下の記述を添付の図面と結び付けて考察すると、より明瞭になる。図１は、粉体収集回収システムの一部および供給ホッパーを含む粉体吹付けブースの一方端部を描き、粉体キッチンの概略図を含む、本発明の１つの実施形態の部分概略図である。図２は、粉体キッチンに含まれる１次ホッパーと粉体受けユニットとの立面図である。図３は、図１に示す１次ホッパーの平面図である。図４は、おおむね図３の線４−４に沿って切り取った断面図である。図５は、本発明の供給ホッパーの１つの実施例の部分断面図の立面図である。図６は、本発明のロボット・ホッパーの概略部分切断図である。図７は、粉体収集回収システムの概略部分切断図である。図８は、粉体収集チャンバの端面図である。図９は、図８で描いた粉体収集チャンバの側面図である。図１０は、本発明の粉体塗装システムの別の実施形態を除き、図１に類似の図である。図１１は、図５に示した供給ホッパーの別の実施形態の部分断面図の立面図である。図１２は、未使用の粒状粉体塗装材料の粒子サイズ分布を体積百分率で示したグラフである。図１３は、再生した粒状粉体塗装材料の粒子サイズ分布を体積百分率で示したグラフである。図１４は、所定数の再生サイクルの後に様々な百分率の未使用粉体を有する粉体塗装材料内に存在する、１０ミクロン未満の粒子サイズの粒状粉体塗装材料の百分率をグラフで示す、計算値の曲線の組である。図１５は、図１０に示した本発明の実施形態で使用する制御装置が実施する測定および制御機能を描くブロック図である。発明の詳細な説明次に、図面を参照すると、本発明の粉体塗装システム１０の１つの実施形態は、粉体吹付けブース１２、粉体キッチン１４からブース１２へ粉体塗装材料を移送する装置、およびブース１２に関連付けられた粉体収集回収システム１６を含む。これらのシステム要素について、以下で別個に述べ、それぞれの動作について検討する。粉体吹付けブース図１および２を参照すると、粉体吹付けブース１２は、天井１８、床２０、対向する側壁２２、２４、およびブース入口２６およびブース出口２８を規定する対向する端壁を含む。図７も参照のこと。この吹付けブース１２の構造は、吹付けブース１２の縦方向に延びる中心部３６を、コンベヤ３４によって移動する車体３２などの物体に、粉体塗装材料を塗布する制御区域を形成する室内３０を規定する。車体３２に付着しない過剰吹付け粉体材料は、吹付けブース１２の床２０に沿って配置された格子３８を通過し、以下で詳述する粉体収集回収システム１６に入る。粉体吹付けブース１２は、縦方向にかなりの距離延び、ブース室内３０を通過する過程で車体３２の全域に粉体塗装材料が塗布されるよう、これに沿った様々な位置に多様な粉体スプレー・ガンを配置することができる。図示のために、スプレー・ガン４２を担持するロボット４０は、吹付けブース１２の片側に描かれ、頭上ガン・マニピュレータ４４は、車体３２の上の位置でスプレー・ガン４７を担持するよう図示されている。車体３２のサイズ、塗布される粉体塗装材料のタイプ、車体３２上の所望の被覆領域およびその他の要素に応じて、粉体塗装材料で車体３２を被覆するために、自動または手動で操作する、基本的にいかなる数のスプレー・ガンも、吹付けブース１２の長さに沿って設けることができる。このようなスプレー・ガンの特定の位置および動作は、それ自体は本発明の一部を形成しないので、本明細書では検討しない。本発明の好ましい実施の形態では、車体３２をコンベヤ３４によって接地電位に維持し、スプレー・ガン４２および４６によって、粉体塗装材料に静電荷を与える。粉体材料に与えられた静電荷は、車体３２に付着する粉体の量を増大させ、それへの粉体の保持を助けるが、それでも比較的大量の粉体材料が「過剰吹付け」される、つまり車体３２に付着しない。この過剰吹付け粉体は、以下で述べるように、粉体塗装作業の過程で収集、回収しなければならない。図１の粉体塗装システム本発明の重要な態様は、粉体塗装材料を粉体キッチン１４から吹付けブース１２に移送するシステム１０の構造に関する。多くの車両製造施設で、粉体キッチン１４は吹付けブース１２から遠方の、たとえば数百フィートの位置に配置され、大量の粉体塗装材料は、その間を迅速に移送しなければならない。１秒当たり１〜２ポンドの粉体流量、および１時間当たり３００ポンド以上の総要求量が珍しくない。このようなパラメータを効率的かつ経済的に満足することができる本発明の粉体移送システムの全体的な構成について最初に説明し、その後、このような移送システムを構成する様々な別個の要素について、詳細に検討する。図１の実施の形態では、粉体キッチン１４は、基本的に閉じた筐体（図示せず）で、従来通りの設計のエア・ハウス（図示せず）から供給される「調整済み」の空気、つまり濾過して増湿した空気が与えられる。粉体キッチン１４内には、未使用の粉体塗装材料を収容する供給源５４があり、これは、以下で詳述する第１粉体受けユニット５８に、ライン５６によって接続される。粉体受けユニット５８は、１次ホッパー６０に接続されて、吸込みホース６１によって第１真空ポンプ６２にも接続され、これは両方とも粉体キッチン内１４に収容される。１次ホッパー６０は、第１供給ホッパー６８に結合した第２粉体受け６６に、移送ライン６４によって接続される。この移送ライン６４は、第１ゲート弁７０を担持し、第１補給空気弁７２に接続され、これは両方とも１次ホッパー６０の下流で、粉体キッチン１４内に位置する。補給空気弁７２は、図１に概略的に描かれた加圧空気供給源７３に接続される。図１の頂部で図示するように、第２粉体受け６６および第１供給ホッパー６８は、粉体吹付けブース１２の近傍に位置するが、１次ホッパー６０と第２粉体受け６６とを相互接続する移送ライン６４は、数百フィートの長さでよい。供給ホッパー６８は、ライン６７によって、粉体キッチン１４に収容される第３真空ポンプ６９に接続され、粉体ポンプ７４を担持し（図５を参照）、これはライン７６によってロボット・ホッパー７８に接続される。ロボット・ホッパー７８は、ライン７９によって、ロボット４０に関連付けられたスプレー・ガン４２に接続される。図１で図示するように、粉体キッチン１４の右側部分は、１次ホッパー６０に関して上述したのと同様の構造を含む。粉体キッチン１４のこの部分は、容器５４から未使用の粉体塗装材料を受ける代わりに、主に、粉体吹付けブース１２の収集回収システム１６から、収集された過剰吹付け粉体が供給される。本発明の好ましい実施形態では、粉体キッチン１４は、受けユニット５８および６６と同じタイプの第３粉体受けユニット８２に結合された再生ホッパー８０を収容する。第３粉体受けユニット８２は、ライン８３によって、粉体キッチン１４内に配置された第３真空ポンプ８４に接続し、以下で検討するように、再生吸込みライン８６によって、粉体収集回収システム１６に接合される。第２移送ライン８８は、空気供給源７３に接続された補給空気弁９２およびゲート弁９０を担持し、再生ホッパー８０を第４粉体受けユニット９４と相互接続させる。この第４粉体受けユニット９４は、粉体吹付けブース１２の近傍に位置する第２供給ホッパー９６に結合される。図１および５で概略的に図示するように、第２供給ホッパー９６は、頭上ガン・マニピュレータ４４に関連付けられたスプレー・ガン４６へと、ライン１００を通して粉体材料を供給する正圧粉体ポンプ９８を含む。第４粉体受けユニット９４は、粉体キッチン１４内に位置する第４真空ポンプ１０２と、ライン１０４によって接続される。本発明の好ましい実施形態では、１次ホッパー６０、第１供給ホッパー６８、ロボット・ホッパー７８、再生ホッパー８０および第２供給ホッパー９６はそれぞれ、ハーディインスツルメンツカンパニー（Hardy Instruments Company ）が型番FLB-3672-1KおよびH1242 PS-C500で市販しているタイプの個別のロード・セル１１６Ａ〜Ｅに担持される。ロード・セル１０６Ａ〜Ｅは、関連する各ホッパーに粉体塗装材料がない場合のゼロ重量を反映するよう、「ゼロ化」つまり調節される。以下で検討するように、各ロード・セル１０６Ａ〜Ｅは、関連するホッパーに蓄積した粉体塗装材料の重量または量を測定し、このような重量読取値を表す信号を生成するよう作動する。その信号は、プログラム可能論理制御装置１０８(ＰＬＣ)に送信され、それはオハイオ州クリーブランドのAllen Bradle yが型番PLC-5で市販しているタイプであることが好ましい。制御装置１０８は、ロード・セル１０６Ａ〜Ｅからの信号に応じて、真空ポンプ６２、７１、８４および１０２、さらに弁７０、７２、９０および９２をそれぞれ操作する。図１に図示した粉体塗装システムの動作粉体塗装システム１０の個別要素それぞれの構造および動作について、以下で詳細に検討するが、その１つの実施形態の全体的な動作は、図１の概略図を参照して述べることができる。多くの先行システムと異なり、本発明の粉体塗装システム１０は、負圧を用いて、粉体塗装材料を粉体キッチン１４から粉体吹付けブース１２へと搬送する。また、粉体の供給と移送とは、粉体塗装作業の進行につれて、基本的に自動的に実行される。最初に粉体キッチン１４の左側部分を参照すると、制御装置１０８が第１真空ポンプ６２を起動すると、未使用の粉体塗装材料が供給源５４から移送される。第１真空ポンプ６２が第１粉体受け５８内に負圧を生成し、これによって未使用の粉体塗装材料が、ライン５６を通って供給源５４から第１粉体受け５８へ吸い込まれる。以下で述べるように、第１粉体受け５８は粉体塗装材料を１次ホッパー６０内に放出し、このような粉体塗装材料を受け取る量は、１次ホッパー６０に関連付けられたロード・セル１０６Ａで監視される。所定のレベルまたは量の粉体塗装材料が１次ホッパー６０内にあると、ロード・セル１０６Ａは、この状態を表す信号を制御装置１０８へ送信し、これが第１真空ポンプ６２を停止する。粉体塗装材料を１次ホッパー６０から第１供給ホッパー６８へ移送する作業は、負圧の適用によっても実施される。制御装置１０８が、第２真空ポンプ６９を起動して、第１供給ホッパー６８に関連付けられた第２粉体受け６６内に負圧を生成する。この負圧が、粉体塗装材料を１次ホッパー６０から移送ライン６４へ吸い込み、制御装置１０８によって第２真空ポンプ６９の起動と同時に開放されるゲート弁７０を通過させる。１次ホッパー６０からの粉体の移送は、そのロード・セル１１６Ａによって監視され、これは所定量または重量の粉体が１次ホッパー６０から放出されると、制御装置１０８に信号を送信する。制御装置１０８は、移送ライン６４内のゲート弁７０を閉じて、それを通過する粉体の流れを停止し、第２真空ポンプ６９のスイッチを切る。第１供給ホッパー６８に１次ホッパー６０からの粉体を充填する作業は、それに関連するロード・セル１０６Ｂが粉体の重量または量をモニタすることによって実行される。第１供給ホッパー６８内の粉体の量が、所定のレベルより下がると、そのロード・セル１０６Ｂが制御装置１０８に信号を送信し、以下で詳細に検討するように、第２粉体受け６６に含まれる計量装置を起動する。次に、１次ホッパー６０から第２粉体受け６６に移送された粉体は、第１供給ホッパー６８に向けられ、所定の重量が得られると、ロード・セル１０６Ｂから制御装置１０８への信号によって、第２粉体受け６６内の計量装置が動作を中止する。図１の頂部で概略的に示すように、第１供給ホッパー６８内の粉体塗装材料は、正圧をかけて粉体ポンプ７４により除去され（図５も参照）、ライン７６を介して、独自のロード・セル１０６Ｃに担持されたロボット・ホッパー７８に搬送する。ロボット・ホッパー７８が十分な量の粉体塗装材料を受け取ると、ロード・セル１０６Ｃが監視し、制御装置１０８が粉体ポンプ７４を停止して、第２粉体ポンプ７７が、ライン７９を介して粉体塗装材料をロボット・ホッパー７８からロボット４０に関連付けられたスプレー・ガン４２に移送し、車体３２に塗布する。ロード・セル１０６Ａ〜Ｅの目的は、システムを移送される粉体塗装材料の流量および総量が、所定数の車体３２が粉体吹付けブース１２を通過するときの要求に合致するよう、システム１０を基本的に自動操作することである。それぞれ１次ホッパー６０、第１供給ホッパー６８およびロボット・ホッパー７８に関連付けられたロード・セル１０６Ａ〜Ｃは、それぞれ粉体塗装材料の量または重量をモニタし、粉体の量が所定レベルより下がったら制御装置１０８に信号を提供するよう作動する。制御装置１０８がこのような信号を受信すると、適切な真空ポンプまたは計量装置が起動して、供給された塗装材料が尽きたホッパーに粉体塗装材料が移送される。この方法で、ホッパー６０、６８および７８はすべて、粉体塗装材料を連続的に十分供給する。移送ライン６４の極端な長さのために、第２真空ポンプ６９が止まって１次ホッパー６０から第２粉体受け６６への粉体塗装材料の流れを停止した時に、移送ライン６４内に残留粉体塗装材料が存在しないよう、粉体キッチン１４は弁動作の配置構成を含む。上述したように、１次ホッパー６０から第２粉体受け６６を通る移送動作の間、制御装置１０８は移送ライン６４内のゲート弁７０を開く。１次ホッパー６０に関連付けられたロード・セル１０６Ａが、１次ホッパーから所定の量が放出されたことを表示すると、制御装置１０８は、粉体キッチン１４内の第２真空ポンプ６９を停止し、ゲート弁７０を閉じて補給空気弁７２を開く。次に、空気供給源７３からの加圧空気が、補給空気弁７２を通過して移送ライン６４に入り、移送ライン６４の上流に残っている塗装材料を粉体キッチン１４から第２粉体受け６６へと「追い立てる」、つまり積極的に強制移送する。これによって、移送ライン６４内への粉体塗装材料の蓄積がほぼ防止されるので、その後の１次ホッパー６０から第１供給ホッパー６８への粉体の移送作業を、迅速かつ効率的に実行することができる。粉体キッチン１４の右側部分および図１の右上部分を参照すると、粉体塗装材料をスプレー・ガン４６に供給する粉体移送システムの構成部品が描かれている。上記で検討したように、このような要素は、粉体キッチン１４内の再生ホッパー８０、第３粉体受け８２および第３および第４真空ポンプ８４、１０２、および粉体吹付けブース１２の近傍に位置する第４粉体受け９４、第２供給ホッパー９６および第３粉体ポンプ９８を含む。これらの要素の構造および動作は、図１の左側部分にある対応要素と基本的に等しいが、粉体キッチン１４から未使用の粉体塗装材料だけを吹付けブース１２に搬送するのではなく、このような要素は、主に、収集回収システム１６から受けた収集済みの過剰吹付け粉体塗装材料を搬送する。再生ホッパー８０に過剰吹付け粉体材料を充填するために、制御装置１０８が第３真空ポンプ８４を起動し、第３粉体受け８２内に負圧を生成して、再生ライン８４を介して収集回収システム１６から第３粉体受け８２へと粉体塗装材料を吸い込む。以下で詳細に検討する方法で、第３粉体受け８２は過剰吹付け粉体材料を再生ホッパー８０に入れる。再生ホッパー８０に入る粉体の量は、それに関連付けられたロード・セル１０６Ｄで監視される。制御装置１０８が第４真空ポンプ１０２を起動すると、粉体材料は、再生ホッパー８０から第４粉体受け９４および第２供給ホッパー９６に移送される。第４粉体受け９４内に生成された負圧が、粉体を再生ホッパー８０から、制御装置１０８によって開かれたゲート弁９０を通って第２移送ライン８８へと吸い込み、第４粉体受け９４の中に入れる。第２供給ホッパー９６は、このような粉体を第４粉体受け９４から受け取り、その量は、それに関連付けられたロード・セル１０６Ｅに監視され、正圧粉体ポンプ９８が、その後、粉体を第２供給ホッパー９６からライン１００を介して、マニピュレータ４４が担持するスプレー・ガン４６に移送する。真空ポンプ８４および１０２、および第４粉体受け９４に関連付けられた計量装置の動作は、上記で検討したのと同じ方法、つまりそれぞれ再生ホッパー８０および第２供給ホッパー９６に関連付けられたロードセル１０６Ｄおよび１０６Ｅからの信号に応じて、制御装置１０８によって支配される。正圧粉体ポンプ９８の動作も、粉体吹付けブース１２内に車体３２が存在するか否かに応じて、制御装置１０８に支配される。粉体キッチン１４内の弁９０および９２は、上述した弁７０および７２と同じ方法で機能する。粉体移送システムに関連付けられた個々の要素について、それぞれ詳細に検討する前に、粉体移送システムのさらに別の特徴２つについて、述べておいたほうがよい。用途によっては、再生ホッパー８０に要求される粉体塗装材料の総量が、収集回収システム１６から供給される過剰吹付け粉体塗装材料の量を上回ることがある。常に再生ホッパー８０内に十分な量の粉体塗装材料が確実に存在するために、未使用の粉体塗装材料を含む１次ホッパー６０は、再生ホッパー８０によって担持されるミニサイクロン１１４にライン１１２によって接続される粉体ポンプ１１０を含む。このミニサイクロン１１４は、オハイオ州アムハーストのノードソンコーポレーションが型番PC-4-2で市販している。再生ホッパー８０に関連付けられたロード・セル１０６Ｄによって、再生ホッパー８０内の粉体材料が必要重量を下回り、粉体を収集回収システム１６から十分に供給できないことが感知されたら、制御装置１０８が粉体ポンプ１１０を起動して、未使用の粉体塗装材料を、ライン１１２およびミニサイクロン１１４を介して再生ホッパー８０に移送し、その粉体の総量を補充する。このような移送が必要な場合は、未使用の粉体塗装材料と過剰に吹き付けられて収集されたブース１２からの粉体塗装材料との両方を、再生ホッパー８０内で混合し、その後、上述した方法でスプレー・ガン４６に供給する。図１に示した粉体移送システムのさらに別の態様は、粉体キッチン１４内に位置し、ライン１１８によって１次ホッパー６０の頂部にある通気孔１２０に接続される通気ユーティリティ・コレクタ１１６を使用する。同様に、これも粉体キッチン１４に含まれる第２通気ユーティリティ・コレクタ１２２は、ライン１２４によって再生ホッパー８０の通気孔１２６に接続される。通気ユーティリティ・コレクタ１１６、１２２はそれぞれ、１次および再生ホッパー６０、８２の内部を通気し、このようなホッパー６０、８２の内部上方から「微粉」を除去する。本明細書では、「微粉」という用語は、通常は粉体供給ホッパーの上方部分付近に集中し、スプレー・ガン４２および４６などのスプレー・ガンから放出されたときに、静電気を帯電せず、塗布すべき物体に到達するのに十分なモーメントも持たない、１０μ未満の非常に小さい直径の粉体材料の粒子を指す。このように小さい粒子は、通常は塗布すべき物体の表面に引き付けられず、したがってシステム内に溜まる傾向があり、塗着効率、つまり塗布すべき物体に付着する粒子の割合が下がる。したがって、これらの小さい粒子つまり微粉は、粉体キッチン１４内の通気ユーティリティ・コレクタ１１６および１１２で除去して、その後処分すると有利である。図１０の粉体塗装システムおよび操作方法図１０を参照すると、本発明による粉体塗装システム５００の別の実施形態が、概略的に図示されている。粉体塗装システム５００は、図１に示して上述した要素を幾つか含むので、図１と共通の構造を特定するために、図１０では同じ参照番号を使用する。図１０のシステム５００と図１のシステム１０との区別は、主に、様々なタイプの未使用の粉体塗装材料を使用する特定の吹付け用途では、「微粉」の過剰な蓄積を回避するために注意する必要がある、という認識に基づく。「微粉」という用語は、サイズが約１０ミクロン未満の粉体粒子を指す。上述したように、微粉が過剰に蓄積すると、ホッパー６０、６８内での流動化の低下、塗装すべき部品上での衝突融合、フィルタ・カートリッジおよび篩の目詰まり、吹付けブース１２および様々な塗装用ディスペンサ４２、４６の粉体の蓄積の増加、および塗着効率の低下という問題を生じることが分かっている。多くのタイプの粉体塗装材料で、粉体塗装材料の総量の約３０％以上の微粉が蓄積すると、上で挙げた問題が１つ以上発生するが、粉体塗装材料のタイプによって、用途で問題を生じる微粉の割合は異なる。スプレー・ガン４２、４６に供給される粉体塗装材料内への過剰な量の微粉の蓄積に関する懸念に加えて、粒子を粉体状にした塗装材料の塗装時には、完成品の外観も考慮すべき要素である。たとえば、比較的大きい、または粗い粒子の割合が増加するにつれ、表面の仕上げは劣化する傾向がある。たとえば、約７０ミクロンより大きい粒子は、約１０ミクロンの粒子と同程度には、塗装すべき部品の表面上を流れず、したがって表面仕上げが粗くなる。これに対して、粒子が小さい方が表面の仕上げは良好であるが、このような小さい粒子の相対的割合が所定のレベルを超えると、上記の問題が優勢になる。過剰な微粉の蓄積を抑制しながら許容可能な表面仕上げを保持するという問題に対処するため、図１０に示すシステム５００は、１対の供給ライン５０４、５０５によって、未使用粒子粉体材料を含む１次ホッパー６０に接続された混合ホッパー５０２と接続し、１対の供給ライン５０６、５０７によって、上述のようにブース１２から過剰吹付け粉体を受け取る再生ホッパー８０と接続する。ゲート弁５０８が、１次ホッパー６０から混合ホッパー５０２へと延びる供給ライン５０４、５０５のそれぞれに配置され、再生ホッパー８０と混合ホッパー５０２との間の各ライン５０６、５０７には、ゲート弁５０９が取り付けられる。混合ホッパー５０２は、移送ライン５１２によって第４粉体受けユニット９４に接続され、これは図１の実施形態では、ライン８８によって再生ホッパー８０に接続されていた。上記以外に、図１に図示した塗装システム１０とシステム５００とのその他の構造的な違いは、ライン５１６によって各粉体受け６６および９４に接続された単一の真空ポンプ５１４を使用することである。上述したように、図１の実施形態では、２個の真空ポンプ６９および１０２を使用して、塗装材料をそれぞれ粉体受け６６、９４に移送する負圧を提供していた。また、図１０では、図１に描いた２個の通気ユーティリティ・コレクタ１１６、１２２の代わりに、１個の通気ユーティリティ・コネクタ５１８を使用する。通気ユーティリティ・コネクタ５１８は、上述したものより容量が大きく、図１０の粉体キッチン１４の右側部分に示すように、ライン５２０によってフィルタ・ユニット５２２に接続される。フィルタ・ユニット５２２は、ダクト５２４によってファン５２６に接続される。通気ユーティリティ・コレクタ５１８は、ライン５１９によって１次ホッパー６０に、ライン５２１によって再生ホッパー８０に、ライン５２３によって混合ホッパー５０２に接続される。図１の通気ユーティリティ・コレクタ１１６、１２２の検討に関連して上述したように、通気ユーティリティ・コレクタ５１８の目的は、１次ホッパー６０、再生ホッパー８０および混合ホッパー５０２内に存在する微粉の少なくとも一部を除去して、過剰な微粉の蓄積を回避し、上述したのと同じ付随の問題を回避することである。にもかかわらず、通気ユーティリティ・コレクタ１１６、１１２や５１８は、それ自体では、スプレー・ガンの少なくとも一部に供給される未使用の粉体塗装材料と再生粉体塗装材料との全体的な混合物における微粉の相対的体積百分率を、適切に制御するには十分ではない。図１０の粉体塗装システム５００は、図１に関連して上述したのと同じ方法で作動するが、未使用の粉体塗装材料と再生または過剰吹付けの粉体塗装材料との混合物が、塗装用ディスペンサ４６に供給される。図１で図示し上述したように、過剰吹付け粉体材料を再生ホッパー８０からガン４６に直接供給するのではなく、本発明のシステム５００は、未使用の粉体塗装材料を過剰に吹き付けたか再生した粉体塗装材料と適切な体積百分率で混合し、混合ホッパー５０２内に過剰な微粉が蓄積しないこと、および塗装用ディスペンサ４６に供給されるこのような混合物で、適切な粒子サイズの分布が獲得されることを保証する操作の方法および手段を提供する。未使用粉体供給ライン５０４、５０５に関連付けられたゲート弁５０８、および再生粉体供給ライン５０６、５０７に関連付けられたゲート弁５０９は、制御装置１０８内でソフトウェアが実行する数学モデルに従い、制御装置１０８が操作する。数学モデルの目的は、定常運転における混合ホッパー５０２内の粒子サイズの分布を予想することであり、これを用いると、「安定した」運転をする、つまり過剰な微粉がなく、容易に流動化して塗装すべき部品にポンプで送り、吹き付けることができる粉体混合物が得られるよう、再生ホッパー８０からホッパー５０２に供給される再生または過剰吹付け粉体と組み合わせるため、供給ホッパー６０から混合ホッパー５０２に未使用の粉体塗装材料をどの程度加えねばならないか、決定することができる。まず図１２および１３を参照すると、粉体塗装材料内の粒子サイズ分布が、グラフで描かれている。「粒子サイズ分布」という用語は、所定の粉体塗装材料サンプルの特定のサイズ範囲における粉体粒子の体積百分率を指す。図１２は、オハイオ州クリーブランドのFerro製でNo.158E114として販売されている、未使用の粉体塗装材料の粒子サイズ分布を示す。この未使用の粉体塗装材料は、粒子サイズの中央値が２２ミクロンで、グラフで示すデータ点は、このタイプの未使用粉体塗装材料内の１６の粒子サイズ範囲の合計の体積百分率を、マサチューセッツ州サウスボローのマルバーンインスツルメンツインコーポレーテッド（Ma lvern Instruments，Inc.）が市販しているMalvern PSD分析器などのレーザ回折粒子サイズ分析器で物理的に測定し、表したものである。１６の粒子サイズの範囲は、たとえば０．５〜１．９μ、１．９〜２．４μなどで、容易に図示できるよう選択した範囲であり、本発明の方法に関する以下の記述においては、様々な他の粒子サイズ範囲を用いることができると考えられる。図１３は、図１２と同様のグラフであるが、ブース１２内で所定の車体３２に未使用の粉体塗装材料を塗布した後に、粉体吹付けブース１２から再生または収集した粒子状粉体塗装材料内の粒子サイズ分布を表すものである。つまり、図１３は、図１２で示した未使用の粉体塗装材料で１回吹付け作業をした後、吹付けブース１２内で車体３２に付着しなかった粉体塗装材料の粒子サイズ分布を示す。図１３に示す粉体の粒子サイズ分布も、MalvernのPSD分析器で測定し、図示のように、図１３の１パス後の過剰吹付け粉体サンプルには、図１２の未使用の粉体塗装材料より、小さめの粒子の割合が大きい。これは、おおむね、大きい粉体粒子の方が、物体上に付着する前に塗装用ディスペンサ４２または４６によって容易かつ効率的に静電気を帯電し、このように大きい粒子のほうが質量が大きいので、吹付けブース１２内の車体３２に流れるためのモーメントが大きいからである。本発明の数学モデルの目的は、システム５００の定常運転の間、１次ホッパー６０からの十分な量の未使用粉体塗装材料を、連続的に混合ホッパー５０２に導入して過剰な微粉の蓄積を回避し、許容可能な全体的粒子サイズ分布を維持できるよう、システム内に残る、つまりブース１２内の車体３２に付着しない粉体の粒子サイズ分布を数学的に予測することである。時間の経過に伴う粒子サイズ分布の変化を計算するためには、粒子がシステム内に残る確率を決定しなければならない。分布のサイズ範囲ごとの確率係数を求める方法について、以下で簡単に述べ、その後、数学的に詳述する。その目的は、未使用の粒子サイズ分布をかけると過剰に吹き付けた粒子のサイズ分布が得られる数字の組（確率係数）を見いだすことである。 (ｉ)まず、サイズの範囲ごとに、再生粒子のサイズ分布に対する未使用粒子のサイズ分布の割合を得る。この割合は、様々な粒子サイズが部品に引き付けられる相対的傾向の尺度である。１以上の割合を有する粒子サイズは、割合が１未満の粒子サイズより、部品に引き付けられやすい。この後者の粒子は、システム内に残る傾向がある。 (ii)次に、パラグラフ(ｉ)からのデータの累積合計を１．００まで正規化し、確率分布が依然として全粒子の１００％を反映していることを保証する。 (iii)粉体がシステム内に残る確率を、「１」の値から各粒子サイズの上記の確率分布を引き、正規化して計算する。しかし、この数学的操作でも、まだ必要な確率分布は得られない。求めているのは、未使用粒子のサイズ分布をかけると過剰に吹き付けた粒子のサイズ分布が得られる数字の組である。 (iv)この粒子サイズ分布の計算値と過剰に吹き付けた粉体の粒子サイズ分布との良好な整合を得るため、上記のパラグラフ(iii)の分布に、各粒子サイズの適切な乗数を使用する。この新しい数字の組も正規化すると、その結果得られる値は、システムを通る各サイクルの粒子サイズ分布に確率係数をかけた値である。上記で概略した方法の最初のステップは、上述したMalvernのＰＳＤ分析器を使用して、所定の塗装用途に使用する未使用粉体塗装材料の粒子サイズ分布Ｆv を、物理的に測定する。次に、塗装すべき特定の車体３２が存在する所定の構成の吹付けブース１２中にこの材料を吹き付けてから、過剰吹付けまたは再生粉体塗装材料を収集する。本明細書の検討では、このような過剰に吹き付けた粉体材料を「１パス再生」、つまり１回「パス」または吹付け作業の後に再生された粉体を指す。次に、１パス再生の粒子サイズ分布を物理的に測定して、Ｆrを求める。図１２および１３で分かるように、粒子サイズ「分布」とは、０．５ミクロンから１８８ミクロンの１６の別個の粒子サイズ範囲を合計した体積百分率を指す。したがって、用語ＦvおよびＦrは、次のように表現される。Ｆv＝Ｆv₁〜₁₆ （１）＝Ｆv₁ Ｆv₂・・・・Ｆv₁〜₁₆ ここで、Ｆv₁＝サイズが０．５〜１．９μの未使用粉体塗装材料の粒子の体積百分率、Ｆv₂＝サイズが１．９〜２．４μの未使用粉体塗装材料の粒子の体積百分率、・・・・である。Ｆr＝Ｆr₁〜₁₆ （２）＝Ｆr₁、Ｆr₂、・・・・Ｆr₁〜₁₆ ここで、Ｆr₁＝０．５〜１．９μの１パス再生粉体塗装材料の粒子の体積百分率、Ｆr₂＝１．９〜２．４μの１パス再生粉体塗装材料の粒子の体積百分率、・・・・である。測定した粒子サイズ分布ＦvおよびＦrを、制御装置１０８に入力し、これは以下のように粒子サイズ分布の商を計算することができる。上述の式（３）から得られた商を、次に下記の関係に従って正規化する。これは、２段階のプロセスで達成されるが、まずＦv／Ｆr₁の商、つまりＳを求める。その後、図１２および１３のグラフで示した１６の粒子サイズ範囲のそれぞれについて、様々な商を「正規化した」値を、次のように計算する。制御装置１０８のソフトウェアが実行する計算の次のシーケンスによって、たとえば各粒子サイズ範囲のＰ₁〜₁₆などの、確率係数Ｐの解が得られる。確率係数Ｐ₁〜₁₆は、図１２および１３に示した１６のサイズ範囲のそれぞれで、粒子がシステム５００内に残る、つまりブース１２内の車体３２に引き寄せられず、したがって過剰吹付け粉体として再生される確率を表す。この情報が重要なのは、上述したように、システムの安定性が、混合ホッパー５０２内の微粉の体積百分率を、３０％などの所定レベルより下に維持することにかかっているからである。確率係数Ｐ₁〜₁₆を求めるのに用いる式は、以下のように与えられる。ここでＦ_A＝調整係数ｘ＝整数１〜１６Ｐ＝確率係数Ｐ₁、Ｐ₂・・・Ｐ₁₆ 式（７）のＦ_A項より後の部分は、次の２段階の計算で求める。まず、係数Ｚを次のように計算する。次に、式（８）に基づく計算から得られた商を、１に正規化する。式（９）に基づく計算から得られた商はそれぞれ、図１２および１３のグラフの１６の粒子サイズ範囲それぞれについて、正規化した値を表す。次に、この値を式（７）に用いて、各粒子サイズ範囲の確率係数Ｐ、つまり各サイズ範囲が特定の塗装作業の後にシステム内に残る（部品に付着しない）確率を表す。たとえば、式（７）を書いて、０．５〜１．９ミクロンという第１グループの粒子のサイズを有する粉体粒子について、次のように、確率係数Ｐ₁を求めることができる。１６グループの粒子サイズのそれぞれについて、試行錯誤によって経験的に「調整係数」Ｆ_Aを求めることができるので、次の式は、未使用粒子および１パス再生粒子の実際の測定値より正確である。Ｆr₁≒Ｆv₁・Ｐ₁ （１１）Ｆr₂≒Ｆv₂・Ｐ₂ （１２）Ｆr₁₆≒Ｆv₁₆・Ｐ₁₆ （１３）つまり、式（１）および（２）で述べたように、レーザ回折粒子サイズ分析器で最初に得た粒子サイズ分布ＦvおよびＦrの実際の測定値を用いて、適切な調整値Ｆ_Aを導き、Ｆr₁₆の最終的な数学的計算値が可能な限り正確になることを保証する。上述した粉体塗装材料のタイプが与えられたとすると、０．５〜１．９μから８７．２〜１８８μに増加する粒子サイズ範囲の実際の調整係数Ｆ_A1〜₁₆は、それぞれ１．０、０．９５、０．９０・・・０．２５であることが好ましい。上記のように確率係数Ｐ₁〜₁₆がそれぞれ計算されたら、この値も、上記と同じ方法で１．０に正規化しなければならない。これで、その結果得られたＰ₁〜₁ ₆ の正規化した値を、たとえば未使用粉体の粒子サイズ分布にかけるなど、乗数として用いて、装置１０を通る各サイクルの過剰吹付け粒子サイズ分布を数学的に予測することができる。以上の検討は、単純に言うと、システムにこれ以外の未使用粉体材料が追加されず、元の量の粉体材料が連続的な塗装作業中にリサイクルされる、ということを前提とした数学的モデルに基づくものであった。粉体塗装材料は、通常の運転状態では、ブース１２内の車体３２などの物体に付着し、絶えず交換しなければならないので、システム５００の実際の動作を近似するには、所定の分率の未使用粉体材料がシステムに追加されるという数学的モデルが必要である。上記で、式（１）〜（１３）で与えられた計算を繰り返さず、以下の関係式を用いて、式（１１）〜（１３）から１パス再生の粒子サイズ分布を表す。Ｆr＝Ｆv・Ｐ（１４）したがって、項Ｆrは、式（１）〜（１３）の数学的モデルを用いて計算したように、第１パス再生粉体内の粒子サイズ分布を表す。式（１４）で１．０に正規化して、第１パスまたは塗装運転の後に再生粉体に追加される新しい未使用粉体の体積分率ｙの追加を考慮すると、次の関係式が導かれる。Ｆr_iy＝（１−ｙ）Ｆr_i＋ｙＦv （１５）ここで、ｙ＝１パス再生粉体の収集後にシステムに追加される未使用粉体塗装材料の体積分率、Ｆr_iy＝分率ｙの未使用粉体塗装材料を含む１パス再生粉体の粒子サイズ分布、ｉ＝未使用粉体塗装材料から始まるパス数の指数、である。Ｆr_iyの値を計算すると、その後の「パス」または塗装作業の粒子分布を、次のように表現することができる。Ｆr_i+1＝Ｆr_iy・Ｐ（１６）式（１６）を１．０に正規化してから、次の計算を実行する。Ｆr_i+1y＝（１−ｙ）・Ｆr_i+1＋ｙＦv （１７）項Ｆr_i+1yは、分率ｙの未使用粉体を含む第２パス再生粉体（ｉ＋１）内の粒子分布を表す。図１４のグラフに描かれたタイプの曲線を生成できるよう、この同じ計算のシリーズを、サイクル数だけ繰り返す。図１４は、未使用粉体の分率または体積百分率を変化させて、Ferro 158E 114粉体塗装材料を吹き付けたときに存在する微粉の体積百分率を表す。図１４のグラフの各曲線は、再生粉体中の未使用粉体ｙの様々な体積百分率を表し、粉体の体積百分率がサイクル数または連続的な塗装作業とともに変化する様子を描く。式（１５）および（１７）からの計算、および全粒子サイズ（ｉ＋１６）に関するこれの逐次反復法に基づき、１６の粒子サイズ範囲の全範囲にわたる粒子サイズ分布の計算値が得られる。制御装置１０８のソフトウェアが作動して、１６のサイズ範囲のそれぞれにおいて、１０ミクロン以下の全粒子の体積百分率の計算値を合計し、連続的サイクルまたは塗装作業のそれぞれについて、図１４のグラフの縦座標上の値が得られる。微粉の体積百分率が、連続するサイクルとともに変化し、再生粉体に対する未使用粉体の分率の変化とともに変化する様子を示すため、例証として、幾つかの異なつたｙの値の計算値を、図１４に含めた。図１４の曲線は、粒子サイズの中央値が約２２ミクロンのFerro 158E114未使用粉体塗装材料を使用して、上記の式から数学的に導かれた。このタイプの材料の場合、上記の過剰な微粉の蓄積という問題を回避するため、微粉の体積百分率を約３０％未満に維持するとよいことが分かっている。図１４のグラフから、３０％未満という微粉の体積百分率を維持するためには、定常運転中に、システム５００に６５％を超える、あるいは約７０％のオーダーの分率ｙの未使用粉体を追加するとよいことが観察される。これは、制御装置１０８の操作によって実行され、これは、１次ホッパー６０から混合ホッパー５０２への各ライン５０４、５０５のゲート弁５０８、および再生ホッパー８０と混合ホッパー５０２との間に延びる各ライン５０６、５０７のゲート弁５０９を選択的に開閉する。上述したように、本明細書で用いる数学的モデルは、様々な体積百分率の未使用粉体を含む粉体塗装材料について、混合ホッパー５０２内の微粉の百分率を示すのに有用である。こうすると、システム５００の定常運転中、混合ホッパー５０２内に過剰な微粉が蓄積しないよう、適切な体積分率の未使用粉体を混合ホッパー５０２に追加することができる。安全対策として、本発明のシステム５００は、混合ホッパー５０２内の粒子サイズ分布を監視して、混合チャンバ５０２内の実際の微粉の百分率を数学的モデルで予想された値と確実に一致させるソフトウェアも、制御装置１０８内に含まれている。図１５を参照すると、上記のモニタ機能を実行する操作のシーケンスを図によって示した流れ図がある。最初に、サンプルを手動で混合ホッパー５０２から抜き取り、ブロック５２８で概略的に描いているように、上記と同じレーザ回折粒子サイズ分析器を使用して、混合ホッパー５０２内の実際の粒子サイズ分布Ｆ_M を測定する。粒子サイズ分布の情報を、手作業または電子的にブロック５２８からライン５３０を介して制御装置１０８に入力する。その後、図１５に描かれた作業はすべて、制御装置１０８のソフトウェアが電子的に実行する。制御装置１０８が作動して、混合ホッパー５０２に含まれる、たとえば約１０ミクロン未満の粒子などの微粉の体積百分率を計算する。ブロック５３２を参照のこと。このような体積百分率の計算値を代表する１つの値を、ライン５３４によってブロック５３６に入力し、ここで、システム５００が塗布する特定タイプの粉体塗装材料について、微粉の体積百分率の計算値と所定の最大体積百分率とを比較する。図１５に示した例証的な実施形態では、ブロック５３６に３０％という所望の最大体積百分率が名目上示されているが、他のタイプの塗装材料では、他の最小体積百分率の微粉の方が適切な場合もあることが理解される。微粉の百分率の計算値が３０％以下の場合は、ライン５３８によってブロック５２８に「ＮＯ」の信号が送り返され、次のモニタ期間が開始するまで、たとえば１日、１週間または他の所望の期間、モニタ・シーケンスは終了している。ブロック５３６で、微粉の百分率の計算値が、混合チャンバ５０２内の粉体を重量で３０％上回っていると判断されると、ライン５４０を通ってブロック５３からブロック５４２に信号が送られる。ブロック５４２で示すように制御装置１０８が実行する計算は、重量分率Ｗ、つまり２０％、３０％などの分率を経験的に選択する。次に、制御装置１０８は、選択した重量分率Ｗを用いて、次の式を解く。Ｆf＝Ｗ・Ｆv＋（１−Ｗ）・Ｆm （１８）ここで、Ｆf＝混合ホッパー内の微粉の所望の体積百分率で、たとえば＜３０％、Ｗ＝未使用粉体の重量分率、Ｆm＝混合ホッパー内の粉体の粒子サイズ分布、Ｆv＝未使用粉体の粒子サイズ分布、である。選択した重量分率Ｗで、Ｆfの値が３０％より大きくなった場合は、別の、これより大きい重量分率Ｗを選択し、式（１８）を用いた計算を繰り返す。図１５に示したモニタ・シーケンスの次のステップは、図１に関連して上述したタイプのロード・セル１０６を使用して、混合ホッパー５０２内の粉体を計量することである。ボックス５４４を参照のこと。次に、ブロック５４６で概略的に示すように、混合ホッパー５０２内の粉体の実際の重量を、混合ホッパー５０２の総重量容量と比較し、その計算を表す信号を、ライン５４８を介してブロック５５０に入力する。ブロック５５０で示すように、混合ホッパー５０２内の粉体のレベルが１−Ｗ以下の場合は、制御装置１０２が作動して、未使用粉体塗装材料を混合ホッパー５０２に入れる（ブロック５５２）。混合ホッパー５０２が満杯で、微粉の体積分率を所望のレベル、つまり＞（１−Ｗ）に下げるのに必要な体積分率Ｗの未使用粉体塗装材料を受け取れない場合は、制御装置１０８は、ブロック５５４で示すように混合ホッパー５０２から十分な量の粉体を放出してから、未使用粉体塗装材料を加える。未使用の粒子状粉体塗装材料を加えるための余地をとるよう、混合ホッパー５０２から放出または除去しなければならない粉体の量は、次の関係式から求めることができる。ここで、Ｑ_D＝混合ホッパーから放出される粉体の分率、ＭＨw＝混合ホッパーの重量測定値、ＭＨc＝混合ホッパーの容量、である。したがって、上記の一連の重量計算は、混合ホッパー５０２内には新しい未使用粉体塗装材料を受け入れるだけ十分な容量があり、したがって混合ホッパー５０２が溢れることなく、微粉の全体的な体積分率が下がるのを保証することである。未使用粉体塗装材料を追加した後（ブロック５５２）、次のモニタ期間までモニタ操作は終了している。したがって、混合ホッパー５０２内で再生粉体塗装材料と未使用粉体塗装材料との所望の割合を維持する上記の方法は、塗装作業が進行するにつれて、混合ホッパー５０２内の重量損失を測定することに依存する。あるいは、重量測定値ではなく流量測定値に基づいて、混合ホッパー５０２に適切な量の再生および未使用粉体塗装材料を供給できる、と考えられる。この実施の形態では、混合ホッパー５０２から放出される粉体塗装材料の流量を、時間の経過とともに監視し、スクリュー供給装置（図示せず）などの流量制御装置を使用して、それぞれ再生ホッパー８０および１次ホッパー６０から、所定の量の再生粉体塗装材料および未使用粉体塗装材料の両方を、混合ホッパー５０２に追加する。１次ホッパー６０に関連付けられたスクリュー供給装置または同様の装置、および再生ホッパー８０に関連付けられた別個のスクリュー供給装置は、混合ホッパー５０２からの信号に応じて、または追加の未使用粉体塗装材料と再生粉体塗装材料とを混合ホッパー５０２に導入する所定の作業期間の後、あるいはその両方で、制御装置１０８によって起動されることが好ましい。粉体受け図２を参照すると、図１のシステム１０の検討に関連して上述した粉体受け５８が、詳細に図示されている。その他の粉体受け６６、８２および９４はそれぞれ、構造的にも機能的にも粉体受け５８に等しく、したがって本明細書では粉体受けのうち１個のみを詳細に検討することを理解されたい。また、粉体受け６００の代替実施形態については、図１１に関連して以下で開示する。粉体受け５８は、板１３４でカートリッジ・フィルタ１３２を取り付けた中空の内部１３０を有するコレクタ筐体１２８を含む。コレクタ筐体１２８の一方側に沿って、掛け金１３８により開放可能な状態でアクセス・パネル１３６が固定されているので、カートリッジ・フィルタ１３２にアクセスすることができる。コレクタ筐体１２８の内部１３０は、通気孔１４０によって通気され、その上端は、掛け金１４４によって固定されたキャップ１４３で閉じている。キャップ１４２は、板１３４に接続したカートリッジ・フィルタ１３２の開放端と整列した逆エア・ジェット弁１４６を搭載する。逆エア・ジェット弁１４６は、ライン１４８によってアキュムレータ１５０に接続され、それは図２で概略的に示す加圧空気の供給源７３に接続される。キャップ１４２は、第１真空ポンプ６２からの吸込みホースまたはライン６１に接続された取付具１５４を担持する。コレクタ筐体１２８の下部は、未使用粉体塗装材料を担持する容器からのライン５６に接続された粉体入口１５８を含む。コレクタ筐体１２８は、図２で示すように、粉体入口１５８から下方向に放射状内側に先細りになり、外部フランジ１６２を含む先細りの基部１６０を形成する。上記で検討したように、１次ホッパー６０に関連付けられたロード・セル１０６Ａが適切に機能するためには、１次ホッパー６０に完全に粉体塗装材料がない状態で、これを「ゼロ設定」つまり重量の読取値をゼロに設定しなければならない。この方法により、ロード・セル１０６Ａは、実際に１次ホッパー６０に入る粉体塗装材料のみを計量する。１次ホッパー６０内で確実に粉体の重量を正確に読み取るために、第１粉体受けユニット５８に関連付けられたすべての要素を、１次ホッパー６０とは独立して、図２に示す枠１６４上で支持する。この枠１６４は、垂直の脚１６８上に支持された上板１６６、上板１６６と垂直脚１６８との間に延びる傾斜した筋交い１７０、および垂直脚１６８間の中間位置にある１個以上の水平支持体１７２を含む。コレクタ筐体１２８は、コレクタ筐体１２８の外部フランジ１６２と上板１６６との間に延びるボルト１７４によって、枠１６４の上板１６６に取り付けられる。コレクタ筐体１２８の先細りの基部１６０から下方向に延びるのは、コレクタ筐体１２８を、カンザス州サリーナのプライマーニューマティックスインコーポレーテッド（Premier Pneumatics，Inc.）が型番MDR-F-G-76-10NH-2-RT-C HE-T3で市販しているタイプの回転エア・ロック計量装置１７８に連結するフレキシブル・スリーブ１７６である。計量装置１７８は、１本の垂直脚１６８に接続した支持板１８４上に担持されたモータ１８２の出力部に、ベルト（図示せず）によって駆動接続される。モータ１８２が作動して、計量装置１７８内の一連の内部翼１８６を回転させ、計量した量の粉体塗装材料を、コレクタ筐体１２８の先細りの基部１６０から水平支持体１７２上に取り付けられた回転式篩１９６に移送する。回転式篩１９６は、ドイツのAzo Incorpor atedが型式Ｅ−２４０で製造販売しているタイプの市販の商品である。回転式篩１９６は、粉体塗装材料を、第２フレキシブル・スリーブ１９８を通って１次ホッパー６０の粉体入口２００に移送する。これについては、図３でさらに詳細に図示し、以下で述べる。運転時には、第１真空ポンプ６２が、制御装置１０８によって起動され、吸込みホースまたはライン６１に沿って真空を生成し、コレクタ筐体１２８の中空の内部１３０に負圧を生成する。これによって、未使用粉体塗装材料が、供給用容器５４からライン５６および粉体入口１５８を通って、コレクタ筐体１２８の中空の内部１３０に引き込まれる。粉体塗装材料の一部が、重力によってコレクタ筐体１２８の先細りの基部１６０に落下し、粉体塗装材料のある一部は、カートリッジ・フィルタ１３２の壁に溜まる。アキュムレータ１６０から定期的に供給された加圧空気が、カートリッジ・フィルタ１３２と整列した逆エア・ジェット弁１４７を通って、パルス状に搬送される。この空気のジェットによって、フィルタ１３２の壁に溜まった粉体塗装材料が離れ、コレクタ筐体１２８の先細りの基部１６０へと下方向に落下することができる。粉体塗装材料は、モータ１８２の動作に応じて、エア・ロック計量装置１７８によってコレクタ筐体１２８から移送されるので、計量された量の粉体塗装材料が、回転式篩１９６に入る。粉体塗装材料は、回転式篩１９６を通過した後、重力によってフレキシブル・スリーブ１９８を通過し、１次ホッパー６０の粉体入口２００へと落下する。所定量の粉体塗装材料が１次ホッパー６０内に溜まったら、それに関連付けられたロード・セル１０６Ａが制御装置１０８に信号を送信し、これが第１真空ポンプ６２の操作を停止する。上述したように、図１の粉体移送システムのその他の粉体受けユニット６６、８２および９４はすべて、構造的にも機能的にも同一である。図１１を参照すると、粉体受け６００の別の実施形態が、詳細に図示されている。粉体受け６００は、図２の検討に関連して上述した粉体受け５８、６６、８２および９４と部分的に類似し、図１１では、図２と共通の構造を特定するために同じ参照番号を使用する。粉体受け６００と粉体受け５８との１つの違いは、粉体塗装材料をコレクタ筐体１２８から１次ホッパー６０に移送するための構造である。特定のタイプの粉体材料を用いる用途では、粉体受け５８の先細りの基部１６０の領域で塗装材料がアーチ状またはブリッジ状になるので、中間で流れが停止することがあるのが分かっている。先細りの基部１６０が閉塞すると、粉体塗装材料は、エアロック計量装置１７８を通って図２で図示した構造の回転式篩１９６に入ることができない。また、図１１の粉体受け６００は、篩１９６を含まないが、ホッパー６０の上に配置して、ホッパー６０に導入する前に粒子状の粉体塗装材料を篩にかけることができると考えられる。少なくとも、たとえば受け５８および８２などの、システムに粉体塗装材料を最初に導入する箇所で、篩１９６を使用することが好ましい。図１を参照のこと。図１１の粉体受け６００は、基本的に図２の粉体受け６８の上部で構成され、下部はコレクタ筐体１２８に向かう粉体塗装材料を流動化する構造を含むので、１次ホッパー６０に滑らかに移送することができる。コレクタ筐体１２８の底部は、流動床６０２を含む内部を規定し、これはキャップ１４２と、コレクタ筐体１２８の側壁から外側に延びて側壁にブラケット（図示せず）で支持された有孔板６０４との間に延びる。コレクタ筐体１２８の基部内の第２区域は、コレクタ筐体１２８の側壁１２９に取り付けられたブラケットによって担持された円形の取付板６１０と有孔板６０４との間に延びるエア・プレナム６０８である。コレクタ筐体内部の基部内の第３区域は、コレクタ筐体１２８の底壁６１４と取付板６１０との間に延びるモータ・チャンバ６１２である。以下で明白になる目的のために、粉体受け６００全体を、支持スタンド６１５の頂部に、１次ホッパー６０またはその他のホッパーの垂直方向上部の位置に取り付けることが好ましい。供給ホッパー６００の基部には撹拌器６１６が設けられ、これは取付板６１０に接続されたモータ・マウントによってモータ・チャンバ６１２内に担持されたモータ６１８を含む。モータ６１８の出力は、軸受６２４内に回転可能な方法で担持された軸６２２に駆動接続される。軸受６２４は、軸受マウントによって取付板６１０に取り付けられ、エア・プレナム６０８を通って有孔板６０４のすぐ受けの箇所まで、垂直上方向に延びる。軸受６２４を通って延びる軸６２２の頂部には、ロック・ナット６３０によって少なくとも２本のエントレインメント・アーム６２８が固定されるので、モータ６１８の動作に応じて、エントレインメント・アーム６２８が有孔板６０４に対して、その上の位置で回転する。モータ・チャンバ６１２の片側に入る空気供給ライン６３６に、少なくとも２個の空気入口６３２が、管によって図示していない方法で接続される。この空気供給ラインは、加圧空気の供給源７３に接続される。上方向に向く空気の流れが、空気入口６３２を通ってエア・プレナム６０８に入り、ここで空気は、軸受け６２４に取り付けられたバッフル６３８によって偏向する。このバッフルの目的は、本発明の譲受人の所有する米国特許第5,018,909 号で詳細に開示され、その開示を、参照によって本明細書にそっくりそのまま組み込む。移送管６４０は、一方端が、有孔板６０４の上かつ流動床６０２の内部で、コレクタ筐体１２８に接続される。移送管６４０の他方端は、１次ホッパー６０の入口６４２に取り付けられる。回転式エア・ロック１７８は、モータ１８２によって駆動され、いずれも粉体受け５８の検討に関連して上述したのと同じタイプであるが、移送管６４０内で接続される。図１１で概略的に示すように、モータ１８２の動作は制御装置１０８によって制御され、従って回転式エア・ロック１７８の動作もこれに制御される。粉体受け６００内の流動床６０２からの粉体塗装材料は、回転式エア・ロック１７８の動作に応じて、重力によって下方向に流れ、移送管６４０を通過してから１次ホッパー６０の内部に入る。モータ１８２が停止して、所望通りに回転式エア・ロック１７８の動作を停止し、移送管６４０を通る粉体塗装材料の流れを留める。粉体受け６００のこの構成が、１次ホッパー６０への粉体の滑らかな移送を提供し、このような粉体受け６００は、図１および１０双方の実施形態の代替品として利用できると考えられる。その他では、粉体受け６００は上述した粉体受け５８と同じ方法で機能し、そのような動作についての検討を、ここで繰り返すことはしない。１次および再生ホッパー１次ホッパー６０および再生ホッパー８０は、基本的に相互に等しく、検討するためには、１次ホッパー６０についてのみ図示し、詳細に述べる。図３および４を参照すると、１次ホッパー６０は、おおむね「８の字」の形状の内壁２０４を有する筐体２０２を含む。したがって、内壁２０４は、２つの円形部２０６および２０８を含み、これはそれぞれが筐体２０２の片側に接続された対向する三角形のバッフル２１２および２１４によって規定され、筐体２０２の中心にある直径減少区域２１０で合う。バッフル２１２、２１４はそれぞれ、筐体２０２の壁から内側に延びて合い、筐体内部２０３の中心に向かって頂部２２０を形成する１対のサイド・パネル２１６、２１８を有する。図４で最もよく分かるように、有孔板２２２は、筐体２０２の基部付近のマウント２２４によって担持され、筐体内部２０３を、有孔板２２２と筐体２０２の上壁２２９との間にある流動床２２６と、有孔板２２２と筐体２０２の底壁２３２との間に位置するエア・プレナム２３０とに分離する。エア・プレナム２３０は、幾つかのバッフル２７０およびおおむねＵ字形の有孔空気管２７２を含む。底壁２３２は、本発明の粉体移送システムに関連して上記で検討したロード・セル１０６Ａの頂部に配置される。筐体２０２の上壁２２８は、第１撹拌器２３４と、第２撹拌器２３６と、ハンドル２４０および掛け金機構２４２を有して上壁２２８の開口部２４４に蝶番２４３によって取り付けられるアクセス・カバー２３８とを支持する。この開口部２４４は、１次ホッパー６０の粉体入口２００からずれるので、保守などのために、粉体入口２００と干渉することなく、筐体内部２０３にアクセスすることができる。第１撹拌器２３４は、軸２４８によってギア・ボックス２５０に接続されるモータ２４６を含む。ギア・ボックス２５０の出力は、管２５４内に収納された軸２５２に駆動接続される。軸２５２の下端には、少なくとも２個の撹拌器の櫂２５６が取り付けられ、これは内壁２０４によって形成された筐体内部２０３の円形部２０６の内部で、有孔板２２２の垂直上方の位置で回転する。第２撹拌器２３６は、第１撹拌器２３４と同様の構造を有する。第２撹拌器２３６は、ギア・ボックス２６２に接続された軸２６０を有するモータ２５８を含み、ギア・ボックスの出力は、管２６６内に収納された軸２６４に駆動接続される。２個以上の櫂２６８が、内壁２０４によって形成された筐体内部２０３の他方の円形部２０８内で、軸２６４の基部に取り付けられる。図４で示すように、第２撹拌器２４６に関連付けられた軸２６４および管２６６は、第１撹拌器２３４のそれよりわずかに長いので、第２撹拌器２３６の櫂２６８は、第１撹拌器２３４より有孔板２２２に近い位置にある。櫂２５６、２６８は重なるが、垂直方向にずれているので、互いに干渉することはない。上述したように、本発明の一つの態様は、たとえば１時間当たり３００ポンド以上などの大量の粉体塗装材料を、１秒当たり１ないし２ポンドなどの流量で移送しながら、粉体塗装材料の流れで所望の密度および粒子分布を維持することである。上述したように、「密度」という用語は、粉体と空気との相対的な混合または割合を指し、「粒子分布」という用語は、粉体塗装材料の流れの中の様々なサイズの粉体粒子の分布を指す。１次ホッパー６０および再生ホッパー８０は、粉体塗装材料の高いスループットにおいて、所望の密度および粒子分布の要件を満たすよう設計されている。運転時には、エア・プレナム２３０内の有孔空気管２７２に加圧空気が導入されて、空気の上向きの流れを生成し、これがバッフル２７０によって有孔板２２２の底部全体にむらなく分布する。粉体塗装材料は、粉体入口２０を通って筐体内部２０３に導入され、流動化用の上向きの空気の流れによって、および第１および第２撹拌器２３４、２３６の動作によって、有孔板２２２に沿って分布する。撹拌器の櫂２５６、２６８が、有孔板２２２に対して動くにつれ、内壁２０４によって規定された筐体内部２０３の「８の字」形によって、内部の「死点」がほぼなくなるので、粉体塗装材料は有孔板２２２の表面全域に沿ってむらなく分布し、粉体材料の凝集または蓄積がほぼなくなる。これによって、流動床２２６内に粉体がむらなく均一に分布し、所望の粒子分布および密度になる。第２真空ポンプ６９が起動すると、空気に混入した粉体塗装材料が、１次ホッパー６０の筐体２０２から吸い出され、筐体内部２０３に挿入された吸込み管２７４を通り、筐体内部は、上述した移送ライン６４に接続されている。供給ホッパー第１および第２供給ホッパー６８および９６は、基本的に構造が等しいので、ここでは第１供給ホッパー６８についてのみ詳細に検討する。図５を参照すると、供給ホッパー６８は、カバー２７９で閉じられた開口部を付けて形成された上壁２７８と、ほぼ円筒形の側壁２８０と、ロード・セル１０６Ｂに担持された底壁２８２とを備える。筐体２７６は、基本的に３つの別個の区域に分離した内部を規定する。１つの区域は、筐体の側壁２８０から外方向に延びてブラケット２８８によって側壁に支持された有孔板２８６と上壁２７８との間に延びる流動床２８４である。筐体２７６内の第２の区域は、側壁２８０に取り付けられたブラケット２９４によって担持された円形の取付板２９２と有孔板２８６との間に延びるエア・プレナム２９０である。筐体２７６の内部の第３の区域は、取付板２２９２と底壁２８２との間に延びるモータ・チャンバ２９６である。供給ホッパー６８には、取付板２９２に接続されたモータ・マウント３０２によってモータ・チャンバ２９６内に担持されたモータ３００を含む撹拌器２９８が設けられている。モータ３００の出力は、軸受３０６内に回転可能な状態で担持された軸３０４に、駆動接続される。軸受３０６は、軸受マウント３０８によって取付板２９２に取り付けられ、エア・プレナム２９０を通って垂直上方向に延び、有孔板２８６のすぐ上の箇所に至る。軸受２０６を通って延びる軸３０４に頂部には、ロック・ナット３１０によって少なくとも２つの櫂３０８が固定されているので、モータ３００の動作に応じて、櫂３０８は有孔板２８６に対し、そのすぐ上の位置で回転する。少なくとも２個の空気入口３１２が、取付板２９２に担持され、管３１４によって、モータ・チャンバ２９６の片側に入る空気供給ライン３１６に図示していない方法で接続される。この空気供給ライン３１６は、粉体受けに関して上述した加圧空気供給源７３に接続される。空気入口３１３を通ってエア・プレナム２９０に、上方向の空気の流れが提供され、ここで空気は、軸受３０６に取り付けられたバッフル３１８によって偏向する。このバッフル３１８は、粉体受け６００に使用したものと同じタイプで、上述した米国特許第5,018,909号で開示されている。運転時には、粉体塗装材料が、筐体２７６の側壁２８０に沿って取り付けられた先細りの粉体入口２７６を通って、筐体２７６の流動床２８４内に導入される。モータ３００が作動して、櫂３０８を回転するので、粉体塗装材料は死点なく有孔板２８６に沿ってむらなく分布する。粉体塗装材料は、空気供給ライン３１６および空気入口３１２からの上方向の空気の流れによって、有孔板２８６に沿って流動化される。粉体塗装材料を筐体２７６から取り出すために、ポンプ７４などの１個以上の粉体ポンプを操作し、有孔板２８６のすぐ上で筐体内部へと延びる吸込み管３２２を通って、粉体塗装材料を吸い出す。供給ホッパー６８から粉体を吸い出すために、複数の粉体ポンプ７４を使用できることを例証するため、図５に幾つかの吸込み管３２２を示す。ロボット・ホッパー図１に概略的に示したロボット・ホッパー７８を、図６にさらに詳細に示す。本発明の好ましい実施形態では、ロボット・ホッパー７８は、上端に１つ以上の櫂３３０が取り付けられている軸３２８に駆動接続されたモータ３２６を収容するモータ・チャンバとエア・プレナムとの混合３２４を形成する円筒形の基部を含む。ロボット・ホッパー７８の頂部は、エア・プレナムおよびモータ・チャンバ３２４と連絡する有孔板３３６によって形成された底壁と上壁３３４とを有する円筒形の筐体３３２を含む。円筒形の筐体３３２は、流動床３３８を規定し、その中には長方形の板またはバッフル３４０が取り付けられている。バッフル３４０は、有孔板３３６の上に垂直に間隔をおき、流動床３３８を２つの区画に分割する。バッフル３４０の一方の区画または側では、供給ホッパー６８からの粉体塗装材料が、円筒形筐体３３２の頂部に概略的に図示された粉体入口３４２に通って導入される。粉体ポンプ７９に関連付けられた吸込み管３４４が、バッフル３４０の反対側で円筒形筐体３３２に取り付けられ、この吸込み管３４４は、有孔板３３６のすぐ上で終了している。ロボット・ホッパー７８は、供給ホッパー６８に関連付けられた粉体ポンプ７４から、ライン７６を介して粉体塗装材料を受け取る。粉体塗装材料は、円筒形筐体３３２の粉体入口３４２に入り、バッフル３４０の一方側に沿って下方向に向かい、有孔板３３６に至る。モータ３２６が作動して、有孔板３３６のすぐ上の櫂３３０を回転するので、空気に混入した粉体材料の均一な流れが、吸込み管３４４を通って粉体ポンプ７９から引き出され、ロボット４０およびそれに関連付けられたスプレー・ガン４２に送られる。円筒形筐体３３２の内部にバッフル３４０があると、有孔板３３６にわたる粉体塗装材料の流動化を安定させるのに役立ち、粉体ポンプ７９によって引き出される粉体塗装材料の流れに、確実に所望の密度および粉体分布が維持される。粉体収集回収システム図１および７ないし９を参照すると、粉体収集回収システム１６が、さらに詳細に図示されている。このシステム１６は、全体としてShuticその他に帰される米国特許第5,078,084号で開示されたシステムに関係があり、その開示は、参照により本明細書にそっくりそのまま組み込む。上述したように、粉体収集回収システム１６は、粉体吹付けブース１２の床２０の下で、車体３２がコンベヤ３４によって移送されるブース１２の中心部３６のいずれかの側に位置する。図７の左側の部分で示すように、格子３８がブースの床２０を覆うので、過剰に吹き付けた空気混入の粉体塗装材料は、ブース室内３０のいかなる区域からもシステム１６内へと下方向に吸い込むことができる。粉体収集回収装置１６は、構造がモジュール式で、全体として、ブース１２の全長に沿って縦方向に延び並んで取り付けられた一連の粉体収集ユニット３４６を備える。図７の中央を参照のこと。図１および図４の右側で示すように、粉体収集ユニット３４６は、たとえば３つか４つのグループで、粉体収集ユニット３４６の下に位置する個々のファンまたはブロワ・ユニット３４８に接続される。各粉体収集ユニット３４６は、対向する側壁３５４、３５６、対向する端壁３５８、３６０、および傾斜した底壁３６２を有するコレクタ筐体３５０を含む。クリーン・エア・チャンバ３６４がコレクタ筐体３５０の頂部に位置し、内側に傾斜してそれぞれが幾つかの間隔をあけた開口部３６８を有する１対の支持板３６６、３６７、対向する側板３６９、３９０、およびそれぞれ側板３６９、３７０に蝶番で留められた１対のアクセス・ドア３７１、３７２によって形成される。クリーン・エア・チャンバ３６４は、コレクタ筐体３５０の長さにわたって延び、延長部３７３に接続するが、その目的については以下で述べる。コレクタ筐体３５０の下部は、有孔板３７６で規定された底壁および先細りの側壁を有する粉体収集チャンバ３７４を形成する。有孔板３７６は、コレクタ筐体３５０の基部３６２に、水平に対して約５度の角度で取り付けられ、その間にエア・プレナム３７７を形成する。入口（図示せず）を通って、有孔板３７６の下のエア・プレナム３７７に、上方向の空気の流れが導入されるので、粉体収集チャンバ３７４に入る粉体塗装材料は、有孔板３７６の頂部で流動化する。本発明の好ましい実施形態では、２グループすなわち２列のカートリッジ・フィルタ３７８が、粉体収集チャンバ３７４内に位置し、図８で分かるように、逆Ｖ字形に配置される。各カートリッジ・フィルタ３７８の開放された頂部は、クリーン・エア・チャンバ３６４の支持板３６６、３６７の一方によって、この板３６６、３６７の開口部３６８の上の位置に担持される。各カートリッジ・フィルタ３７８は、上端にねじ込んだ中心棒３８２を有し、棒３８２に締め付けられたマウント３８４を受けるので、支持板３６６または３６７の一方が、マウント３８４とカートリッジ・フィルタ３７８の頂部との間に挟まれる。コレクタ筐体３５０の端壁３５８、３６０間に延びるフィルタ取付板３８６のうち１枚以上が、各カートリッジ・フィルタ３７８に追加の支持を提供することが好ましい。上記で検討したようにコレクタ筐体３５０に入る粉体塗装材料を、カートリッジ・フィルタ３７８の壁から除去するために、カートリッジ・フィルタ３７８の各バンクに、１組または１グループのエア・ジェット・ノズル３９２が設けられる。１組のエア・ジェット・ノズル３９２が、クリーン・エア・チャンバ３６４内に取り付けられたノズル支持体３９４上に担持され、第２組のエア・ジェット・ノズル３９２が、クリーン・エア・チャンバ３６４内のノズル支持体３９６上に担持される。図８で示すように、各組のエア・ジェット・ノズル３９２は、１グループすなわち１列のカートリッジ・フィルタ３７８の開放された頂部に向けられている。各列のカートリッジ・フィルタ３７８に関連付けられたエア・ジェット・ノズル３９２は、空気ライン３９８によって油圧弁４００に接続され、これは加圧空気供給源７３に接続される。システム制御装置１０８からの信号に応じて、油圧弁４００が作動し、加圧空気のジェットがエア・ジェット・ノズル３９２から一方または両方の列のカートリッジ・フィルタ３７８へと放出されるよう、空気ライン３９８を通って加圧空気を選択的に方向づける。このパルス状の空気ジェットが、粉体塗装材料をカートリッジ・フィルタ３７８の壁から取り除くので、粉体塗装材料は、重力によって粉体収集チャンバ３７４へ、さらに有孔板３７６へと落下することができる。図１および７を参照すると、空気に混入した粉体塗装材料は、上述したブロワ・ユニット３４８によって生成された負圧がかかると、ブース内部３０から粉体収集ユニット３４６のそれぞれに吸い込まれる。各ブロワ・ユニット３４８は、ファンまたはブロワ４０４を収容するファン・プレナム４０２、および図１で概略的に示す幾つかの最終フィルタ４０６を含む。ファン・プレナム４０２は、幾つかの開口部４０８が形成され、その上に排気ダクト４１０が固定される。各排気ダクト４１０は、垂直上方向に延び、各粉体収集ユニット３４６に関連付けられたクリーン・エア・チャンバ３６４の１つの基部に位置する軸継手４１２と係合する。ファン・プレナム４０２内のブロワ４０４の作動に応じて、排気ダクト４１０内に負圧が生成され、各粉体収集ユニット３４６に関連付けられたクリーン・エア・チャンバ３６４内にも生成する。この負圧は、ブース室内３０に下向きの空気の流れを生じ、それに過剰に吹き付けた粉体塗装材料が混入する。空気に混入した粉体塗装材料は、吹付けブース１２の床２０にある格子３８を通過して、各粉体収集ユニット３４６に入り、ここで粉体塗装材料は、カートリッジ・フィルタ３７８の壁に沿って溜まるか、コレクタ筐体３５０の基部にある有孔板３７６上に落下する。本発明の粉体収集回収システム１６の重要な態様は、１つのブロワ・ユニット３４８が限られた数の粉体収集ユニット３４６に対応することである。たとえば、図７の右側部分に示したブロワ・ユニット３４８Ａには、それぞれが１つの粉体収集ユニット３４６に接続された排気ダクト４１０を受ける４つの開口部４０８で形成されたファン・プレナム４０２を有する。したがって、４つの粉体収集ユニット３４６に、１つのブロワ・ユニット３４８Ａが対応している。他のブロワ・ユニット３４８は、比較的小さいグループの隣接する粉体収集ユニット３４６に関連付けられ、その結果、ブース室内３０全体に均一な下向きの空気の流れが与えられる。さらに、各粉体収集ユニット３４６のクリーン・エア・チャンバ延長部３７３の構成によって、吹付けブース１２の一方側にある粉体収集ユニット３４６は、ブース１２の反対側にある粉体収集ユニット３４６に「あり継ぎ」つまり嵌合することができる。図７の中央を参照のこと。これによってスペースが節約され、ブース１２の全体的寸法が小さくなる。本発明の粉体収集回収システム１６の別の態様は、収集した過剰吹付け粉体を粉体収集ユニット３４６から回収して、粉体キッチン１４に再循環して戻すことである。上述したように、ブース室内３０からの空気に混入した粉体材料は、各粉体収集ユニット３４６に吸い込まれ、重力によって基部にある有孔板３７６上に落下するか、エア・ジェット・ノズル３９２から放出した加圧空気の定期的な噴射により、カートリッジ・フィルタ３７８の壁から取り除かれる。本発明の好ましい実施形態では、有孔板３７６への粉体の移動は、エア・ジェット・ノズル２９３から逆の加圧空気ジェットが放出されると振動するように、各粉体収集ユニットのコレクタ筐体３５０の壁３５４〜３６２を、たとえば１８〜２０ケージのＮｏ．３０４ステンレス鋼などの比較的薄手の金属で形成することによって助けられる。有孔板３７６は、水平に対して約５度の角度がついているので、その上の流動化した粉体塗装材料は、有孔板３７６の下端にあるコレクタ筐体３５０の一方側の出口４２２に向かって流れる。粉体収集ユニット３４６の各出口４２２は、分岐ライン４２４によって共通のヘッダ・パイプ４２６と接続され、これは粉体ブース１２の長さに沿って、その両側を縦方向に延びる。ヘッダ・パイプ４２６は、粉体キッチン１４内の第３粉体受け８２につながる再生ライン８６に接続される。各分岐ライン４２４内にギロチン型のゲート弁４２８を担持し、この弁が、粉体塗装材料が流れることができる開位置とこのような流れを妨げる閉位置との間で移動できることが好ましい。粉体キッチン１４内の第３真空ポンプ８４は、上述したように第３粉体受け８２および再生ホッパー８０に関連付けられるが、この起動に応じて、ヘッダ・パイプ４２６内に負圧が生成される。粉体移送システムに関連して上述したシステム制御装置１０８が作動して、各粉体収集ユニット３４６に関連付けられたゲート弁４２８を選択的に開放するので、その中の粉体はそれぞれの分岐ライン４２４を通ってヘッダ・パイプ４２６に吸い込まれる。多数の粉体収集ユニット３４６があるので、所与の時間には所定の数のゲート弁４２８しか開放されず、第３粉体受け８２および１次ホッパー８０につながる再生ライン８６に移送するためにヘッダ・パイプ４２６に入ることができる粉体材料の総量を制限する。図１を参照すると、圧力センサ４３０が、ブロワ・ユニット３４８のファン・プレナム４０２に接続されるよう、概略的に図示されている。圧力センサ４３０の目的は、ブロワ・ユニット３４８内の最終フィルタ４０６での圧力低下を感知し、それを表す信号を制御装置１０８に送信することである。所与のブロワ・ユニット３４８と関連付けられた粉体収集ユニット３４６内で１つ以上のカートリッジ・フィルタ３４８に故障またはその他の問題が生じた場合は、粉体塗装材料がクリーン・エア・チャンバ３６４を通過して、最終フィルタ４０６に至り、最終フィルタ４０６で圧力が低下する。この圧力低下は、圧力センサ４３０によって感知され、この時点で、このような圧力低下を表す信号が制御装置１０８に送信され、オペレータにこのような粉体収集ユニット３４６内に問題があることを警告する。幾つかのブロワ・ユニット３４６があるので、粉体収集回収システム１６内の故障を正確に指摘し、１つのブロワ・ユニット３４８および関連の粉体収集ユニット３４６のグループに帰することができる。これはシステムの保守を容易にし、オペレータは、このような問題が生じた時に、ブロワ・ユニット３４８のそれぞれを検査する必要がない。本発明は、好ましい実施形態に関連して述べてきたが、当業者には、本発明の範囲から逸脱することなく、その要素に様々な変更ができ、同等品で置換できることが理解される。また、本発明の基本的な範囲から逸脱することなく、本発明の教示に対して、多くの修正を特定の状態または材料に加えることができる。たとえば、本発明のシステム１０は、単一の１次ホッパー６０、単一の再生ホッパー８０、ロボット・ホッパーおよびロボット４０に関連付けられた供給ホッパー６８、および頭上ガン・マニピュレータ４４に関連付けられた供給ホッパー９６があると述べてきた。図面で示し上述したシステム１０の実施形態は、本発明の主題となる事項を例証することを目的とし、システム１０は特定の用途の要件に応じて修正できることが理解される。複数の１次ホッパー６０および再生ホッパー８０を使用することができ、様々な組合せの供給ホッパーやロボット・ホッパーで供給した自動操作および手動操作のガンを含む、様々なスプレー・ガンの構成を使用することができる。したがって、本発明は、本発明を実行すると企画される最善のモードとして、開示した特定の実施形態に限定されるものではなく、本発明は添付の請求の範囲に入るすべての実施形態を含むもとのする。DETAILED DESCRIPTION OF THE INVENTION Vehicle powder coating system This was originally filed on May 25, 1993 and titled Vehicle Powder Coating System. No. 08 / 066,873, owned by Ming assignee and attributed to Shutic et al. Partial continuation application.Field of the invention The present invention relates to a powder coating system, and particularly to a powder spray booth, a powder collection and collection system. Stem, and unused powder coating material and unused and regenerated or oversprayed powder A spray dispenser associated with a booth spraying a mixture of body coating materials from a remote location For powder coating systems used in vehicle manufacturing facilities, including You.Background of the Invention The task of applying coating materials to large objects such as automobiles and other bodywork has traditionally been Entrance to the body, paint application area, curing or drying area depending on design, and A spray booth with an elongated tunnel-like structure formed at the exit where the vehicle exits Has been given. In many systems, "conditioned" air, i.e., humidified and filtered The blown air is blown with a blower or blower fan, and the plenum Introduced to Chamber, then directed downwards towards vehicles passing through the booth. Adjustment Spent air picks up excess spray paint in the booth room and is transported by air. Over-blown material can be caused by one or more exhaust fans running down through the booth floor or sides. Discharge in the direction. Provide a filter to catch the oversprayed coating material and Extract the resulting filtered or clean air from the booth and exhaust to atmosphere Or recirculate and reuse in the system. The most commonly used coating materials for vehicles such as automobiles and trucks are resin materials High solid resin coating with a relatively high proportion of liquid solvent component to facilitate atomization of Material. For more information on the problems associated with collecting oversprayed resin paint material, see There is a fine record and the painting and finishing industry continues to be an environmental issue. Cobb U.S. Pat.No. 4,247,591 to U.S. Pat.No. 4,553,701 to Rehman et al. See issue. U.S. Pat.No. 5,078,084 to Shutic et al. And owned by the assignee of the present invention. As shown, the powder coating material is a solvent vehicle that paints large objects such as car bodies. Has been proposed as an alternative to liquid paint materials. In powder coating practice, After heating the substrate and the powder after applying the resin in shape to the substrate, the powder melts and then Upon cooling, a continuous solid film forms on the substrate. For most powder spray applications , To increase the amount of powder adhering to the substrate and to help retain the powder on the substrate. An electrostatic charge is applied to the powder for spraying toward the ground object to be grounded. Car or truck The work of applying powder material to the car body can collect excess spray powder that does not adhere to the car body. It is carried out in a spray booth providing a controlled area. Excessive powder spray into booth Containment creates a negative pressure in the booth chamber and blows out excessively sprayed powder from the booth. Assisted by a discharge system that sucks and enters the powder collection and recovery system. Times The collected oversprayed powder can be stored for future use or Immediately recirculates to the powder spray gun associated with the powder spray booth You. There are a number of inherent problems with painting powder coating materials on automobiles and other vehicle bodies. There is. Supply of coating materials for the design of vehicle manufacturing facilities The source is usually located far from the spray booth, a few hundred feet. Further A large amount of powder coating material, such as 300 pounds or more per hour, This relatively long distance can be sprayed from the source at a rate such as one or two pounds per shot. Must be transported to the source. Also, in order to properly apply powder material to the car body The powder coating material must be transported at the appropriate density and particle distribution. "Dense The term "degree" refers to the relative mixing or proportion of powder and air, The term "empty" refers to an empty gun that feeds the spray gun associated with the powder spray booth. Refers to the distribution of powder particles of various sizes in a stream of powder material conveyed by air. Present Available powder coating systems transfer large amounts of powder material over long distances with large flow rates. While maintaining the desired density and particle distribution, or insufficient I know I can only do it. As mentioned above, all powder coating material released in the powder spray booth is It does not adhere to the vehicle passing through the booth. This oversprayed powder material Are disclosed, for example, in Patent No. 5,078,084 attributed to Shutic et al. At the base of such a booth is collected by a powder collection and collection system. This type of system In the system, the powder collection and collection system is mounted side by side under the spray booth floor Of individual contained cartridge filters in a series of powder collection chambers Includes groups or banks. One exhaust fan or blower in the booth room Negative pressure is generated, and the negative pressure separates the powder material that is over-blasted and conveyed by air. Suction into the various powder collection chambers where the powder is deposited on the cartridge filter walls And the "clean air" passes through it and is subsequently released to the atmosphere. Operate the air jet in the opposite direction to remove collected powder from the cartridge filter. Once removed from the wall, the powder falls to the base of the powder collection chamber where it is sprayed Collect to recycle or recirculate back to spray gun associated with booth Be sent out. For large-scale applications such as painting the body of an automobile, the practicality of a powder collection and collection system, And the application of a uniform negative pressure in the booth chamber is particularly problematic. One exhaust fan Or using a blower fan to achieve even pressure in the booth Some difficulties, which can adversely affect the efficiency with which powder coating materials can be collected. The powder coating material released from the spray gun on the car body passing through the booth It has been found that patterns can be disrupted. This type of system Improves the practicality of the reverse air jet valve in each powder recovery chamber You also need to do it. There are other problems with powder coating systems of the type described above, Overspray for recirculation back to the spray gun associated with the body spray booth The present invention relates to the recovery of waste powder. Unused powder coating materials have a particle size distribution Include a wide variety of powder particles, that is, a wide variety of sizes. Larger powder particles Tends to adhere to objects to be painted in spray booths. Because the Due to size, the larger particles have a higher electrostatic charge than the smaller particles, Moment when ejected from a play gun toward a painted object Is large. As a result, oversprayed and recirculated without adhering to objects Powder collected to return to the spray gun is smaller than the unused powder. Large percentage of particles. Large particles are more likely to adhere to objects than small particles. Because it is big. The stability of operation of the powder coating system is at least in part due to the "fines", e.g. How to Avoid Attachment or Accumulation of Particles with a Size of Less Than about 10 microns It depends on The term "stability" as used herein refers to excessive levels of fines. A system that fluidizes, transports and blows powder coating materials without the problems caused by powder Refers to the ability of the system. If excessive levels of fines are present in the powder coating material, Reduced activation, collision coalescence, clogging of filter cartridges and sieves, powder spraying Increase the adhesion of powder to the interior of spray booths and spray guns, and May cause a decline. The term "collision fusion" refers to the As a result of particle velocity, powder particles adhere to the surface. Of the ratio of the powder material attached to the object to the total amount of powder sprayed toward Degrees. Powder coating systems of the type described above collect excessively sprayed powder material. Measures to ensure system operation stability when subsequently recirculated to the spray gun There is basically no place. Ventilation unit to remove fines from feed hopper etc. Units are used, but such units have limited effectiveness and require Rely on this to control the level or proportion of fines in the I can't do that.Summary of the Invention Therefore, while conveying a large amount of powder material over a long distance at a relatively large flow rate, The density and particle distribution of the powder in the system, regardless of demand. Efficient for maintaining the right amount of body coating material and recycling large amounts of oversprayed powder Collect and collect High levels of fines accumulation and relatively easy maintenance, such as automobiles and other bodywork Which large object can provide a powder spraying system to apply powder coating material Is part of the object of the present invention. These objects are used to break large objects such as automobiles, trucks or other bodies. Define a control area for applying powder coating material to the bodywork to apply body coating material. Powder spray booth, and a powder spray booth located far from the powder spray booth. Titchin '', located near the booth, receiving powder coating material from the powder kitchen, Automatically or manually operated powder spray gun associated with the booth And a number of feed hoppers for feeding the feed hopper. Overspray Powder coating material is taken out of the booth room by the powder collection and collection system, This system recycles the oversprayed powder to the powder spray gun Return to one or more mixing hoppers in the powder kitchen for One aspect of the present invention is a method of spraying from a remote location, i.e., a powder kitchen location. Effective for transferring powder coating material to a feed hopper located near Predicted based on the concept of providing a means. This is not a positive pressure but a vacuum. This is achieved with the device according to the invention by means of a powder transfer system operating at a negative pressure. powder The body kitchen is connected to a source of unused powder coating material in the powder kitchen, Includes one or more primary hoppers each coupled to the body receiving unit. Transfer lie The primary hopper transfers the powder hopper associated with each supply hopper in the spray booth. Interconnected with the remote control unit. Operate the first vacuum pump and related to the primary hopper Negative pressure is generated in the attached powder receiving unit, and unused powder material is powdered from the supply source. For the body receiving unit The powder can be sucked and supplied to the primary hopper. The second vacuum pump is Apply a negative pressure in each powder receiving unit associated with the feed hopper, thus Unused powder material from the primary hopper located in the powder kitchen is transferred to the long transfer line. Through the powder receiver associated with the feed hopper near the spray booth Sucked into the unit. The powder receiving unit in the spray booth is Fill the feed hopper with powder, and spray the powder from the feed hopper with the powder pump Transferred to powder spray gun in booth. Negative pressure applied powder transfer to collect excess spray powder material from spray booth This same principle of transmission is used. The regeneration hopper placed in the powder kitchen, It is connected to the powder receiving unit, which is connected to the powder spray booth by the regeneration line. Connected to the linked powder collection and collection system. The vacuum pump is Powder receiving unit associated with a regenerating hopper that receives excess sprayed powder A negative pressure is generated in the inside, and such an excessively sprayed powder is transferred to a regeneration hopper. Book In one preferred embodiment of the invention, this regenerated overblown powder is then separated Transported from the regeneration hopper with negative pressure from the vacuum pump, and supplied near the booth The excess sprayed powder is supplied to a powder receiving unit connected to a hopper. next, The feed hopper removes excess spray powder from the spray associated with the spray booth. To the gun, which operates to apply the powder to the rest of the body to be painted I do. In another embodiment, the regeneration hopper and the primary hopper are each Connected to a mixing hopper located in the container. Powder in primary and regenerating hopper The pump will use the selected percentage of unused powder And regenerated or oversprayed powder to a mixing hopper where such powder is blown. Mixing here in preparation for transfer to the spray gun associated with the booth Is done. The particle size distribution of the powder contained in the mixing hopper is mathematically predicted. According to the method of the present invention, the unused powder and the regenerated powder introduced into the mixing hopper are supplied. Feeding is performed when the volume percentage of fines contained in the mixing hopper exceeds the specified maximum percentage. Not controlled. This allows the objects in the booth to be regenerated or oversprayed When applying the body, stable operation of the powder coating system is ensured. For example, a large amount of powder coating material of about 300 pounds or more per hour is applied to the above-described vacuum. The transfer system efficiently and effectively conveys the powder coating material as the powder spray source To meet the specific demands of car manufacturing facilities located far from the booth I know. Using negative pressure instead of positive pressure reduces air usage, Thus, the overall energy requirements of the system will be reduced. Also , One of transfer lines extending between powder kitchen and spray booth leaked Powder material is forced out in the case of a positive pressure powder transfer system. In such a transfer line, it is drawn inside the line due to the vacuum. this Reduces the risk of contaminating the facility with powder in the event of a leak problem Become. Another feature of the powder transfer aspect of the present invention is that as the painting operation proceeds, Automatic monitoring and replenishment of powder coating material used and oversprayed powder material I do. The primary hopper, regeneration hopper and supply hopper are each programmed Load cells connected to possible logic controllers carry. This load section Le, the individual The hopper is set to zero reference with empty weight and individual hoppers are It is effective for measuring the weight of the powder material entering each. For example, primary e Thinking about the load cell, the load cell associated with it During the operation, a signal indicating the weight of the powder in the primary hopper is transmitted to the control device. You. If the amount of powder material in the primary hopper falls below a predetermined minimum value, control A device receives a signal from the load cell and is associated with such a primary hopper. Activate the vacuum pump connected to the powder receiving unit, resulting in additional unused The powder coating material is conveyed from the source to the powder receiving unit and then to the primary hopper Conveyed. When the primary hopper receives a sufficient level of powder coating material, it The supply of the above powder is stopped. If the regeneration hopper and supply hopper are similar It works by the formula, so during the powder coating work, the appropriate level of powder coating material in each Is maintained. In one embodiment, between each of the primary hopper and the regeneration hopper Connection line is installed in the spray booth to collect powder in the powder collection system. The amount of oversprayed powdered material that has been removed can reduce the amount of powdered material in the regeneration hopper to the desired level. Unused powder coating material from the primary hopper if it is not sufficient to maintain Can be supplied to raw hopper. In another embodiment, the programmable controller is described above and discussed in detail below. Unused powder from each primary hopper according to the selection ratio determined by the method Transfer of body coating material and regeneration or overspray from the associated hopper to the mixing hopper Control the transfer of powder. The mixing hopper mixes unused powder with regenerated powder. The mixture is fed to one or more spray guns. Another aspect of the invention is that of a primary hopper, a regeneration hopper and a feed hopper. Each structure allows the powder coating material to pass through the system at the desired density and particle distribution. For measures to be transported securely and supplied to the spray gun. In this aspect, the book No. 5,018,909, owned by the assignee of the invention and attributed to Crum et al. The same operating principle as that used in the powder supply hoppers used in the present invention is applied to various hoppers of the present invention. It is used for the upper. Generally, each hopper herein includes a perforated plate. This causes air to pass through baffles located in the space at the base of such hoppers. Receives upward flow. A stirrer containing rotating paddles or wings is placed on the perforated plate. This ensures proper fluidization of the powder material before discharging from the individual hoppers, Ensures even distribution of powder particles and proper density or air-to-particle ratio . Yet another aspect of the present invention is an efficient and easily maintainable powder spray booth. Provide a body collection and collection system that provides a uniform, downward airflow within the booth room. It is based on the concept of generating. This powder collection and recovery system is modular Structure, along the length of the powder spray booth, mounted side by side under its floor Includes several powder collection units. Each powder collection unit includes a powder collection chamber , This is an angled fluidization plate located at the base of the powder collection chamber. Above, two groups or two rows of cartridges mounted in an inverted V-shape House the filter. A limited number of individual powder collection units can be Connected to a separate exhaust fan or blower unit. Each exhaust fan is Over-blown powder material that is conveyed by air, creating a negative pressure in a series of powder collection units Down from the booth room through the booth floor, and then It is effective to put in the body collection chamber. Excessive sprayed powder material The "clean" air passes through it and accumulates on the cartridge filter walls, Enter the clean air chamber associated with each powder collection unit. pulse Air jet placed above the cartridge filter Periodically introduced from the valve into the cartridge filter and accumulates on the filter wall. Once the powder has been dispelled, the powder is then placed at an angle at the base of each powder collection chamber. Drops on the fluidized plate marked with and is removed. Each powder collection chamber is common Outlets connected to the header pipe of Be placed. The system controller controls the collection of the powdered materials in relation to the powder kitchen. Removed from various powder collection units in the order of transfer to attached regeneration hopper As described above, it is effective to sequentially open and close the valves. The structure of the powder collection and recovery system described herein has several advantages. How many Use a few exhaust or blower units, each with a limited number of powder The more uniform and evenly distributed downward air flow Is generated along the entire length of the powder spray booth room. This is a single exhaust It is an improvement over systems having air fans or blowers. Because the car In a spray booth with the extreme length needed to apply large objects such as bodies Prove that it is difficult to obtain a uniform negative pressure with only one blower unit. It is because it is disclosed. Maintenance of the powder collection and recovery system described in this specification is also It is much easier than the one of the conventional design. Powder collection for easy access A reverse air jet valve is located at the top of the unit, and a single operator can control the cartridge. The filter can be easily removed from the powder collection chamber. Each powder collection chamber Removal of powdered material from the fluidized plate at an angle to its base. And it helps to transfer the powder smoothly from the chamber. Ma In addition, the wall of the powder collection chamber vibrates when the back-injection of air starts, and the powder It's thin enough to help send it up.Description of the drawings The operation and advantages of the structure of the presently preferred embodiment of the invention are set forth in the following description. It becomes clearer when considered in connection with the drawing of FIG. FIG. 1 shows a part of a powder collection and recovery system and a powder spraying blower including a feed hopper. One embodiment of the present invention, depicting one end of a source and including a schematic view of a powder kitchen FIG. Figure 2 is an elevation view of the primary hopper and powder receiving unit included in the powder kitchen It is. FIG. 3 is a plan view of the primary hopper shown in FIG. FIG. 4 is a cross-sectional view taken generally along line 4-4 of FIG. FIG. 5 is an elevational view, partially in section, of one embodiment of the feed hopper of the present invention. FIG. 6 is a schematic partial cutaway view of the robot hopper of the present invention. FIG. 7 is a schematic partial cutaway view of the powder collection and collection system. FIG. 8 is an end view of the powder collection chamber. FIG. 9 is a side view of the powder collection chamber depicted in FIG. FIG. 10 is a view similar to FIG. 1 except for another embodiment of the powder coating system of the present invention. It is. FIG. 11 is an elevation view of a partial cross-sectional view of another embodiment of the feed hopper shown in FIG. is there. FIG. 12 shows the particle size distribution of the unused granular powder coating material in volume percentage. It is a graph. FIG. 13 shows the particle size distribution of the regenerated granular powder coating material in volume percentage. It is a graph. FIG. 14 shows a powder having various percentages of unused powder after a predetermined number of regeneration cycles. Of granular powder coating material having a particle size of less than 10 microns present in the body coating material 5 is a set of curves of calculated values showing percentages graphically. FIG. 15 shows the measurement performed by the control device used in the embodiment of the present invention shown in FIG. FIG. 4 is a block diagram illustrating a setting and control function.Detailed description of the invention Referring now to the drawings, one embodiment of the powder coating system 10 of the present invention is: , Powder coating booth 12, transfer powder coating material from powder kitchen 14 to booth 12 And a powder collection and collection system 16 associated with the booth 12. No. These system elements are described separately below and their operation is described. To consider.Powder spray booth Referring to FIGS. 1 and 2, a powder spray booth 12 includes a ceiling 18, a floor 20, Defines opposing side walls 22, 24 and booth entrance 26 and booth exit 28 Includes opposing end walls. See also FIG. The structure of this spray booth 12 is The vehicle moves along a central portion 36 of the booth 12 extending in the vertical direction by a conveyor 34. A room 30 defining a control area for applying a powder coating material to an object such as a body 32 is defined. Set I do. Excess spray powder material that does not adhere to the vehicle body 32 is deposited on the floor 20 of the spray booth 12. Powder collection and collection system 1 which passes through a grid 38 arranged along Enter 6. The powder spray booth 12 extends a considerable distance in the vertical direction and passes through the booth room 30 In order to apply the powder coating material to the entire area of the vehicle body 32 during the A variety of powder spray guns can be placed in different locations. For illustration, A robot 40 carrying a play gun 42 is depicted on one side of the spray booth 12 , The overhead gun manipulator 44 is positioned above the vehicle body 32 by a spray gun 47. Are shown. The size of the body 32, Depending on the type, the desired coverage area on the body 32 and other factors, the powder coating material Operated automatically or manually to cover the body 32 with A number of spray guns can also be provided along the length of the spray booth 12. The specific position and operation of such a spray gun is, in itself, a part of the present invention. And is not discussed here. In a preferred embodiment of the present invention, the vehicle body 32 is connected to a ground potential by a conveyor 34. And spray guns 42 and 46 impart electrostatic charge to the powder coating material. I can. The electrostatic charge applied to the powder material increases the amount of powder adhering to the vehicle body 32. , Helping to keep the powder in it, but still a relatively large amount of powder material "oversprayed" In other words, it does not adhere to the vehicle body 32. This oversprayed powder is described below. As such, they must be collected and collected during the powder coating operation.1 powder coating system An important aspect of the present invention is that the powder coating material is blown from the powder kitchen 14. The present invention relates to the structure of a system 10 for transferring to a loading booth 12. In many vehicle manufacturing facilities The powder kitchen 14 is located far from the spray booth 12, for example, several hundred feet. Large amounts of powder coating material must be quickly transported between them . Powder flow of 1-2 pounds per second and more than 300 pounds per hour Total demand is not uncommon. These parameters must be satisfied efficiently and economically. First, the overall configuration of the powder transfer system of the present invention, which can be Later, the various distinct elements that make up such a transport system are examined in detail. Argue. In the embodiment of FIG. 1, the powder kitchen 14 is basically a closed housing (not shown). ), "Adjusted" supplied from a traditionally designed air house (not shown) , Ie, filtered and humidified air is provided. In the powder kitchen 14, There is a source 54 containing unused powder coating material, which can be One powder receiving unit 58 is connected by a line 56. Powder receiving unit 58 is connected to a primary hopper 60 and is connected to a first vacuum port by a suction hose 61. Also connected to a pump 62, both of which are housed in the powder kitchen 14. Primary The hopper 60 transfers the transfer powder to the second powder receiver 66 connected to the first supply hopper 68. Connected by an in 64. This transfer line 64 carries the first gate valve 70 And connected to a first make-up air valve 72, both downstream of the primary hopper 60. , Located in the powder kitchen 14. Make-up air valve 72 is schematically depicted in FIG. Connected to a pressurized air supply 73. As shown at the top of FIG. 66 and the first supply hopper 68 are located near the powder spray booth 12 , Primary hopper 60 and second powder The transfer line 64 interconnecting with the receiver 66 may be several hundred feet long. Offering The feed hopper 68 is connected to the third true It is connected to an empty pump 69 and carries a powder pump 74 (see FIG. 5), which Connected to the robot hopper 78 by the Robot Hopper 78 Is connected to spray gun 42 associated with robot 40 by line 79 Connected. As shown in FIG. 1, the right side of the powder kitchen 14 is attached to a primary hopper 60. And the same structure as described above. This part of the powder kitchen 14 4 instead of receiving the unused powder coating material, The collection and collection system 16 supplies the collected excess sprayed powder. Of the present invention In a preferred embodiment, the powder kitchen 14 is the same as the receiving units 58 and 66. For accommodating the regeneration hopper 80 connected to the third powder receiving unit 82 of the same type. . The third powder receiving unit 82 is arranged in the powder kitchen 14 by a line 83. Connected to a third vacuum pump 84, which is located, and a regeneration suction line, as discussed below. By means of the connector 86, it is joined to the powder collecting and collecting system 16. Second transfer line 88 Carries a make-up air valve 92 and a gate valve 90 connected to the air supply 73, The regeneration hopper 80 is interconnected with the fourth powder receiving unit 94. This fourth powder The receiving unit 94 includes a second supply hopper located near the powder spray booth 12. 96. As schematically illustrated in FIGS. 1 and 5, a second feed hopper 96 to the spray gun 46 associated with the overhead gun manipulator 44 And a positive pressure powder pump 98 for supplying powder material through line 100. No. The fourth powder receiving unit 94 is connected to the fourth vacuum pump 10 located in the powder kitchen 14. 2 and line 104. In a preferred embodiment of the present invention, a primary hopper 60, a first supply hopper 68, The robot hopper 78, the regeneration hopper 80 and the second supply hopper 96 Hardy Instruments Company ) Are sold separately under the model numbers FLB-3672-1K and H1242 PS-C500 -It is carried in the cells 116A to 116E. Load cells 106A-E are associated with each associated cell. "Zeroing" means to reflect zero weight when there is no powder coating material in the upper Adjusted. As discussed below, each load cell 106A-E has an associated load cell 106A-E. Measure the weight or amount of powder coating material accumulated in the hopper and read the weight Operate to generate a signal representing a value. The signal is 108 (PLC), which is located in Allen Bradle, Cleveland, Ohio. It is preferred that y is of the type commercially available under model number PLC-5. The control device 108 In response to signals from load cells 106A-E, vacuum pumps 62, 71, 84 and And 102, and further operate valves 70, 72, 90 and 92, respectively.Operation of the powder coating system shown in FIG. The structure and operation of each of the individual elements of the powder coating system 10 will be described below. Although discussed in detail, the overall operation of one embodiment is illustrated in the schematic diagram of FIG. Can be described. Unlike many prior systems, the powder coating system of the present invention The system 10 uses a negative pressure to spray powder coating material from To the tray 12. The supply and transfer of powder are defined as the progress of powder coating. Re And it is basically performed automatically. First, referring to the left side of the powder kitchen 14, the controller 108 controls the first vacuum When the pump 62 is activated, unused powder coating material is transferred from the source 54. The first vacuum pump 62 creates a negative pressure in the first powder receiver 58, thereby allowing unused Powder coating material is drawn from the source 54 to the first powder receiver 58 through the line 56. Be included. As will be described below, the first powder receiver 58 is a powder hopper which is a primary hopper. The amount of such powder coating material that is released into the primary hopper 60. Monitored by the load cell 106A associated with. Of a given level or quantity When the powder coating material is in the primary hopper 60, the load cell 106A Sends a signal indicating the state to the control device 108, which stops the first vacuum pump 62. . The operation of transferring the powder coating material from the primary hopper 60 to the first supply hopper 68 , By applying a negative pressure. The control device 108 controls the second vacuum pump 69 Activate and create a negative pressure in the second powder receiver 66 associated with the first feed hopper 68 Generate. This negative pressure transfers the powder coating material from the primary hopper 60 to the transfer line 64. Sucked, opened by the controller 108 at the same time as the activation of the second vacuum pump 69 Through the gate valve 70. The transfer of the powder from the primary hopper 60 Monitored by the primary cell 116A, which indicates that a predetermined amount or weight of When released from par 60, it sends a signal to controller 108. Control device 108 Closes the gate valve 70 in the transfer line 64 and stops the flow of powder passing through it. Then, the second vacuum pump 69 is turned off. The primary hopper 68 is The operation of filling the powder from the par 60 is performed by the load The cell 106B is implemented by monitoring the weight or amount of the powder. First When the amount of powder in the feed hopper 68 falls below a predetermined level, the load 106B sends a signal to the controller 108, as discussed in detail below. 2. The measuring device included in the powder receiver 66 is started. Next, from the primary hopper 60 2 The powder transferred to the powder receiver 66 is directed to the first supply hopper 68, Once the weight is obtained, a signal from load cell 106B to controller 108 Then, the weighing device in the second powder receiver 66 stops operating. As shown schematically at the top of FIG. 1, the powder coating material in the first feed hopper 68 Is removed by a powder pump 74 under positive pressure (see also FIG. 5), And transferred to the robot hopper 78 carried by the original load cell 106C. I do. When the robot hopper 78 receives a sufficient amount of powder coating material, The cell 106C monitors and the control device 108 stops the powder pump 74, The body pump 77 removes the powder coating material via line 79 from the robot hopper 78 Transfer to the spray gun 42 associated with the robot 40 and apply it to the body 32 I do. The purpose of the load cells 106A-E is to provide a flow of powder coating material through the system. The amount and the total amount are required when a predetermined number of vehicle bodies 32 pass through the powder spray booth 12. To automatically operate the system 10 to meet the requirements. Each Associated with primary hopper 60, first supply hopper 68 and robot hopper 78 The attached load cells 106A-C each represent the amount or weight of powder coating material. And provides a signal to the controller 108 when the amount of powder falls below a predetermined level. It works to do. The control device 108 When a suitable signal is received, the appropriate vacuum pump or metering device is activated and the supplied The powder coating material is transferred to the hopper that has run out of the coating material. In this way, the hopper 60, 68 and 78 all provide a sufficient continuous supply of powder coating material. Due to the extreme length of the transfer line 64, the second vacuum pump 69 stops and the primary When the flow of the powder coating material from the upper 60 to the second powder receiver 66 is stopped, The powder kitchen 14 operates as a valve so that there is no residual powder coating material in the line 64. Including the arrangement configuration. As described above, the second powder receiver 66 is removed from the primary hopper 60. During the passing transfer operation, the controller 108 opens the gate valve 70 in the transfer line 64. Load cell 106A associated with primary hopper 60 is When indicating that the predetermined amount has been released, the control device 108 causes the powder kitchen 14 Stop the second vacuum pump 69 in the inside, close the gate valve 70 and open the make-up air valve 72 . Next, pressurized air from the air supply source 73 passes through the makeup air valve 72 and is transferred to the transfer line. The coating material remaining upstream of the transfer line 64 enters the powder kitchen 14. From the second powder receiver 66 to the second powder receiver 66, that is, positively forcibly transported. this This substantially prevents accumulation of the powder coating material in the transfer line 64, and The transfer operation of the powder from the primary hopper 60 to the first supply hopper 68 after the It can be executed efficiently. Referring to the right portion of the powder kitchen 14 and the upper right portion of FIG. The components of the powder transfer system that supply the feed to the spray gun 46 are depicted. . As discussed above, such an element is provided by a recycle hopper in the powder kitchen 14. -80, third powder receiver 82 and And near the third and fourth vacuum pumps 84, 102 and the powder spray booth 12. Fourth powder receiver 94, second supply hopper 96 and third powder pump 9 located beside 8 inclusive. The structure and operation of these elements are the same as the corresponding elements in the left part of FIG. Basically equal, but spraying only unused powder coating material from powder kitchen 14 Instead of being transported to the source 12, such elements are primarily 6. Convey the collected oversprayed powder coating material received from 6. In order to fill the regeneration hopper 80 with the oversprayed powder material, the controller 108 The third vacuum pump 84 is started to generate a negative pressure in the third powder receiver 82, and the regeneration line Powder coating material from the collection and collection system 16 to the third powder receiver 82 via the Inhale. In a manner to be discussed in detail below, the third powder receiver 82 is an oversprayed powder material. The charge is put into the regeneration hopper 80. The amount of powder entering the regeneration hopper 80 depends on It is monitored by the associated load cell 106D. The control device 108 controls the fourth vacuum port. When the pump 102 is activated, the powder material is transferred from the regeneration hopper 80 to the fourth powder receiver 94. And transferred to the second supply hopper 96. The negative generated in the fourth powder receiver 94 The gate valve opened by the controller 108 when the pressure regenerates the powder from the hopper 80 Sucks through 90 to the second transfer line 88 and enters into the fourth powder receiver 94 . The second supply hopper 96 receives such powder from the fourth powder receiver 94, The amount is monitored by its associated load cell 106E and the positive pressure powder po Pump 98 then transfers the powder from the second feed hopper 96 via line 100 It is transferred to a spray gun 46 carried by the manipulator 44. Vacuum pump 84 And 102, and the operation of the weighing device associated with the fourth powder pan 94, Record , The regeneration hopper 80 and the second supply hopper, respectively. In response to signals from load cells 106D and 106E associated with par 96 And is governed by the controller 108. The operation of the positive pressure powder pump 98 is also Is controlled by the control unit 108 depending on whether or not the vehicle body 32 exists in the booth 12. Is done. The valves 90 and 92 in the powder kitchen 14 correspond to the valves 70 and 72 described above. Works in the same way as. Examine the individual elements associated with the powder transfer system in detail Before proceeding, it is important to mention two additional features of the powder transfer system. Is good. Depending on the application, the total amount of powder coating material required for the recycling hopper 80 Exceed the amount of oversprayed powder coating material supplied from the collection and collection system 16. There is. There is always a sufficient amount of powder coating material in the reclaim hopper 80 Therefore, the primary hopper 60 including the unused powder coating material The powder connected by line 112 to the mini cyclone 114 thus carried It includes a pump 110. This mini cyclone 114 is located in Amherst, Ohio Sold by Nordson Corporation under model number PC-4-2. Reproduction hopper 80 The load material 106D associated with the Material is below the required weight and the powder cannot be supplied sufficiently from the collection and collection system 16. Is detected, the control device 108 activates the powder pump 110 to use the unused powder. Regenerating hopper for body coating material via line 112 and mini cyclone 114 80 and replenish the total amount of the powder. If such a transfer is required, Use powder coating materials and overspray collected from booth 12 Both the powder coating material and the powder coating material are mixed in the regeneration hopper 80, and then mixed with the above-described method. To the spray gun 46. Yet another embodiment of the powder transfer system shown in FIG. And connected to vent 120 at the top of primary hopper 60 by line 118 The ventilation utility collector 116 used is used. Similarly, this is also a powder key. The second ventilation utility collector 122 contained in the 4 connects to the vent 126 of the regeneration hopper 80. Ventilation utility The collectors 116 and 122 are respectively included in the primary and regeneration hoppers 60 and 82; Vent section to remove "fines" from above inside such hoppers 60,82 . As used herein, the term "fines" usually refers to the upper part of the powder feed hopper. Focused on and released from spray guns such as spray guns 42 and 46 When charged, has a sufficient moment to reach the object to be coated without charging static electricity. Refers to particles of a powder material of very small diameter, less than 10μ, without having like this Very small particles are not normally attracted to the surface of the object to be Particles that tend to accumulate in the stem and are deposited, that is, particles that adhere to the object to be coated Of the percentage decreases. Therefore, these small particles or fines 14 with vent utility collectors 116 and 112 and then It is advantageous to dispose.Powder coating system and operation method of FIG. Referring to FIG. 10, another embodiment of a powder coating system 500 according to the present invention is shown. , Are schematically illustrated. The powder coating system 500 is described above with reference to FIG. Since it includes several elements, it has the same structure as FIG. To identify the structure, the same reference numbers are used in FIG. The distinction between the system 500 of FIG. 10 and the system 10 of FIG. In certain spray applications that use virgin powder coating material, Based on the recognition that care must be taken to avoid accumulation. "Fine powder" The term refers to powder particles less than about 10 microns in size. As mentioned above, Excessive accumulation of powder reduces fluidization in the hoppers 60 and 68, Collision on product, clogging of filter cartridge and sieve, spray booth 12 and various powder dispensers 42, 46 to increase powder accumulation and It has been found that this causes a problem of a decrease in the wearing efficiency. Many types of powder coating If the material accumulates fine powder of about 30% or more of the total amount of powder coating material, One or more issues may occur, but depending on the type of powder coating material, may cause problems in the application The proportion of fines is different. Excess amount of fines into the powder coating material supplied to the spray guns 42, 46 In addition to concerns about accumulation, when coating coating materials with powdered particles, the finished product Is also a factor to consider. For example, relatively large or coarse particles As the coalescence increases, the surface finish tends to deteriorate. For example, about 70 Particles larger than cron are as large as particles of about 10 microns Does not flow over the surface of the surface, and therefore has a rough surface finish. In contrast, small particles Although the surface finish is better, the relative proportion of such small particles is Above a certain level, the above problems prevail. Maintains acceptable surface finish while controlling excessive fines accumulation To address this problem, the system 500 shown in FIG. Connection to the primary hopper 60 containing unused particulate powder material And a pair of supply lines 506 and 507 As described above, the contact with the regenerating hopper 80 for receiving the excessive spray powder from the booth 12 is made. Continue. Gate valve 508 extends from primary hopper 60 to mixing hopper 502 And the mixing hopper 80 and the mixing hopper 80 A gate valve 509 is attached to each line 506 and 507 between the upper Can be The mixing hopper 502 is moved by the transfer line 512 to the fourth powder receiving unit. 1 is connected to the regeneration hopper by line 88 in the embodiment of FIG. -80. In addition to the above, other aspects of the coating system 10 and system 500 shown in FIG. The structural differences were connected to each powder receiver 66 and 94 by line 516 The use of a single vacuum pump 514. As described above, the embodiment of FIG. In this state, the coating material is powdered using two vacuum pumps 69 and 102, respectively. Negative pressure was provided to the receivers 66,94. Also, in FIG. Instead of the two vent utility collectors 116, 122 A power utility connector 518 is used. Ventilation utility connector 518 has a larger capacity than that described above, and is located on the right side of the powder kitchen 14 in FIG. Connected to filter unit 522 by line 520 as shown . Filter unit 522 is connected to fan 526 by duct 524 You. Ventilation utility collector 518 is connected to line 519 To the primary hopper 60, to the regeneration hopper 80 by the line 521, and to the line 5 23 is connected to the mixing hopper 502. As described above in connection with the discussion of the ventilation utility collectors 116, 122 of FIG. As described above, the purpose of the ventilation utility collector 518 is to At least a part of the fine powder present in the regeneration hopper 80 and the mixing hopper 502 To avoid excessive fines accumulation and the same attendant problems as described above. Is Rukoto. Nevertheless, the ventilation utility collectors 116, 112 And 518, as such, are unused supplies to at least a portion of the spray gun. Of Fines in Overall Mixtures of Powder Coating Materials for Recycling and Powder Coating Materials The volume percentage is not enough to properly control. The powder coating system 500 of FIG. 10 operates in the same manner as described above in connection with FIG. Activated but unused powder coating material and recycled or oversprayed powder coating material The mixture is supplied to a coating dispenser 46. As shown in FIG. 1 and described above Instead of supplying the oversprayed powder material directly from the regenerating hopper 80 to the gun 46, In addition, the system 500 of the present invention can be used to overspray or re-use unused powder coating material. Mix the resulting powder coating material with the appropriate volume percentage and add excess in mixing hopper 502 That no fine powder accumulates and that this is supplied to the coating dispenser 46 Operating procedures to ensure that the correct particle size distribution is obtained with the correct mixture. And provide the means. Gestures associated with unused powder supply lines 504, 505 Gate valve 508 and the gates associated with the regenerated powder supply lines 506 and 507. The valve 509 is executed by software in the controller 108. The controller 108 operates according to the mathematical model. The purpose of the mathematical model is steady operation Is to predict the particle size distribution in the mixing hopper 502 at With "stable" operation, that is, without excessive fines and easy fluidization To obtain a powder mixture that can be pumped and sprayed onto the parts to be painted. Regeneration or overblowing supplied from regeneration hopper 80 to hopper 502 Unused from supply hopper 60 to mixing hopper 502 to combine with The amount of powder coating material to be used can be determined. Referring first to FIGS. 12 and 13, the particle size distribution in the powder coating material is It is drawn in rough. The term “particle size distribution” refers to a given powder coating material Refers to the volume percentage of powder particles in a particular size range of the sample. FIG. Unused, sold as No. 158E114 by Ferro, Cleveland, Ohio 3 shows the particle size distribution of the powder coating material of Example 1. This unused powder coating material has a particle size The median size is 22 microns and the data points shown in the graph indicate that this type of unused The volume percentage of the sum of the 16 particle size ranges in the powder coating material was Malvern Instruments Inc. (Southborough, MA) laser diffraction, such as a Malvern PSD analyzer available from lvern Instruments, Inc.) Physically measured and expressed by a particle size analyzer. 16 particle size range The surroundings are, for example, 0.5 to 1.9 μ, 1.9 to 2.4 μ, and can be easily illustrated. In the following description of the method of the present invention, various ranges have been selected. It is contemplated that other particle size ranges can be used. FIG. 13 is a graph similar to that of FIG. After applying the unused powder coating material, regenerate or collect from the powder spray booth 12 Fig. 3 shows the particle size distribution in the collected particulate powder coating material. That is, FIG. No. 3 shows that after the spraying operation is performed once with the unused powder coating material shown in FIG. 4 shows the particle size distribution of the powder coating material that did not adhere to the vehicle body 32 in the booth 12. . The particle size distribution of the powder shown in FIG. 13 was also measured with a Malvern PSD analyzer and As shown in FIG. 12, the excess sprayed powder sample after one pass shown in FIG. Larger percentage of smaller particles than body coating material. This is roughly a large powder The particles are deposited by the coating dispenser 42 or 46 before they are deposited on the object. Easily and efficiently charges static electricity, and these larger particles have higher mass Because the moment for flowing to the body 32 in the spray booth 12 is large, is there. The purpose of the mathematical model of the present invention is to provide a primary hopper during steady-state operation of the system 500. A sufficient amount of unused powder coating material from 60 is continuously introduced into the mixing hopper 502. To avoid excessive fines accumulation and maintain an acceptable overall particle size distribution. Powder that does not adhere to the vehicle body 32 in the booth 12 The mathematical prediction of the particle size distribution. To calculate the change in particle size distribution over time, the particles must be You must determine the probability of staying within. Find probability coefficient for each size range of distribution The method is described briefly below, and then mathematically detailed. The purpose is , Apply unused particle size distribution and get over sprayed particle size distribution Set of numbers (Probability coefficient). (i) First, for each size range, the unused particles Get the proportion of the size distribution. This percentage indicates that various particle sizes are attracted to the part It is a measure of relative tendency. Particle sizes having a proportion of 1 or more have proportions less than 1 It is more easily attracted to parts than its particle size. This latter particle is Tend to remain. (ii) Next, normalize the cumulative sum of the data from paragraph (i) to 1.00, Ensure that the probability distribution still reflects 100% of all particles. (iii) From the value of “1”, the probability of powder remaining in the system is Subtract the probability distribution, normalize and calculate. But this mathematical operation is still necessary A high probability distribution cannot be obtained. What we are looking for is the size distribution of unused particles This is a set of numbers that gives the size distribution of the oversprayed particles. (iv) The calculated value of the particle size distribution and the particle size distribution of the excessively sprayed powder In order to obtain a good match for each particle size, the distribution in paragraph (iii) above should be Use smart multipliers. If this new set of numbers is also normalized, the resulting value Is the particle size distribution of each cycle through the system multiplied by the probability factor. The first step in the method outlined above is to use the Malvern PSD analyzer described above. The particle size distribution Fv of the unused powder coating material used for a given coating application Is physically measured. Next, a predetermined configuration in which a specific vehicle body 32 to be painted exists. Spraying this material into the spray booth 12 and then overspraying or regenerating powder Collect coating materials You. In the examination of this specification, such an excessively sprayed powder material is referred to as “one-pass regeneration”. ", I.e., the powder regenerated after a single" pass "or spraying operation. next, Fr is determined by physically measuring the particle size distribution in one-pass reproduction. As can be seen in FIGS. 12 and 13, the particle size "distribution" is 0.5 micron Refers to the volume percentage sum of 16 distinct particle size ranges from to 188 microns . Therefore, the terms Fv and Fr are expressed as follows. Fv = Fv₁~₁₆ (1) = Fv₁ Fv_Two.... Fv₁~₁₆ Where Fv₁= Volume hundreds of particles of unused powder coating material with a size of 0.5-1.9μ Fraction, Fv_Two= Volume percentage of particles of unused powder coating material of size 1.9-2.4μ, ... Fr = Fr₁~₁₆ (2) = Fr₁, Fr_Two, ... ・ Fr₁~₁₆ Where Fr₁= 0.5-1.9μ volume percentage of particles of 1 pass regenerated powder coating material , Fr_Two= Volume percentage of particles of one pass regenerated powder coating material of 1.9-2.4μ, ... The measured particle size distributions Fv and Fr are input to the controller 108, which The quotient of the particle size distribution can be calculated as follows. The quotient obtained from equation (3) above is then normalized according to the following relationship: This is achieved in a two-step process, but first Fv / Fr₁Quotient, that is, S Ask. Thereafter, each of the 16 particle size ranges shown in the graphs of FIGS. , Calculate the "normalized" values of the various quotients as follows: The following sequence of calculations performed by the software of controller 108 For example, P in each particle size range₁~₁₆The solution of the probability coefficient P is obtained. Probability Number P₁~₁₆Represents the particle size in each of the 16 size ranges shown in FIGS. Remains in the system 500, that is, is not attracted to the vehicle body 32 in the booth 12, Therefore, it represents the probability of being regenerated as oversprayed powder. This information is important As described above, the stability of the system is limited by the Depends on maintaining the volume percentage of the flour below a predetermined level, such as 30%. This is because that. Probability coefficient P₁~₁₆The equation used to determine is given by It is. Where F_A= Adjustment factor x = integer 1 to 16 P = probability coefficient P₁, P_Two... P₁₆ F in equation (7)_AThe part after the term is obtained by the following two-stage calculation. First, the coefficient Z Calculate as follows: Next, the quotient obtained from the calculation based on Expression (8) is normalized to 1. The quotients obtained from the calculations based on equation (9) are the graphs of FIGS. Represents the normalized values for each of the 16 particle size ranges. Then this value Is used in equation (7) to calculate the probability coefficient P of each particle size range, Represents the probability of remaining in the system (not adhering to parts) after a certain painting operation. For example, writing equation (7), the first group of 0.5 to 1.9 microns For powder particles having a particle size, as follows: Probability coefficient P₁Can be requested. For each of the 16 groups of particle sizes, empirically "tuned" by trial and error. Integer coefficient F_A, The following equation gives the unused particles and the one-pass It is more accurate than the actual measurement of raw particles. Fr₁≒ Fv₁・ P₁ (11) Fr_Two≒ Fv_Two・ P_Two (12) Fr₁₆≒ Fv₁₆・ P₁₆ (13) That is, as described in equations (1) and (2), the laser diffraction particle size analyzer Using the actual measurements of the particle size distributions Fv and Fr obtained initially, F_ALeads to Fr₁₆Ensures that the final mathematical calculation of is as accurate as possible You. Given the type of powder coating material described above, 0.5-1.9μ The actual adjustment factor F for the particle size range increasing from 87.2 to 188 μm._A1~₁₆Is It is preferably 1.0, 0.95, 0.90... 0.25, respectively. As described above, the probability coefficient P₁~₁₆Is calculated, this value is also the same as above. Must be normalized to 1.0 in the same way. Now the resulting P₁~₁ ₆ Multiplied by the normalized value of The oversprayed particle size distribution of each cycle through apparatus 10 is mathematically used as Can be predicted. The above discussion, simply stated, suggests that any other unused powder No material is added and the original amount of powdered material is recycled during continuous painting operations It was based on a mathematical model on the assumption that Powder coating material In a normal driving state, it adheres to an object such as the vehicle body 32 in the booth 12 and constantly exchanges. To approximate the actual operation of the system 500, A mathematical model is needed that adds a fraction of unused powder material to the system. You. Above, without repeating the calculations given by equations (1) to (13), Equations (11) to (13) are used to represent the particle size distribution for one-pass reproduction. Fr = Fv · P (14) Therefore, the term Fr was calculated using the mathematical models of equations (1) to (13). Thus, the particle size distribution in the first pass regenerated powder is shown. Normalized to 1.0 by equation (14), and after the first pass or painting operation, Considering the addition of the volume fraction y of new unused powder to be added, the following relational expression is derived. I will Fr_iy = (1-y) Fr_i+ YFv (15) Here, the unused powder coating material added to the system after collecting the y = 1 pass regenerated powder Volume fraction of the charge, Fr_iy = particle size distribution of 1-pass regenerated powder containing unused powder coating material with fraction y, i = index of the number of passes starting from an unused powder coating material. Fr_iOnce the value of y has been calculated, the particle distribution for the subsequent "pass" or painting operation is Can be expressed as Fr_{i + 1}= Fr_iy ・ P (16) After normalizing equation (16) to 1.0, the following calculation is performed. Fr_{i + 1}y = (1-y) · Fr_{i + 1}+ YFv (17) Term Fr_{i + 1}y is particles in the second pass regenerated powder (i + 1) containing unused powder of fraction y Represents the distribution. This same calculation system is used to generate a curve of the type depicted in the graph of FIG. Repeat Leeds for the number of cycles. FIG. 14 shows the fraction or volume percentage of unused powder. The fines present when spraying the Ferro 158E 114 powder coating material with varying fractions. Represents the volume percentage of the powder. Each curve in the graph of FIG. 14 represents an unused powder y in the regenerated powder. Represents various volume percentages of powder, the volume percentage of powder is the number of cycles or continuous coating Draw a picture that changes as you work. Calculations from equations (15) and (17), and Based on this iterative method for the total particle size (i + 16), 16 A calculated value of the particle size distribution over the entire size range is obtained. Control device 108 Software runs, and 10 micron in each of 16 size ranges Sum the calculated volume percentages of all particles less than or equal to Are obtained on the ordinate of the graph of FIG. Volume of fine powder hundred The fraction changes with successive cycles, and the fraction of unused powder relative to recycled powder By way of illustration, several different values of y Are included in FIG. The curve in FIG. 14 shows the Ferro 158E114 unused with a median particle size of about 22 microns. Mathematically derived from the above equation using a powder coating material for industrial use. This type of material In order to avoid the above problem of accumulation of excessive fines, the volume percentage of fines Has been found to be less than about 30%. From the graph of FIG. In order to maintain a volume fraction of fines of less than 0%, during steady-state operation, the system Unused powder with a fraction y in excess of 65% or about 70% in 500 It is observed that it is good to add. This is executed by the operation of the control device 108. , Each line 504 from the primary hopper 60 to the mixing hopper 502, 505 gate valve 508 and between regeneration hopper 80 and mixing hopper 502 The gate valve 509 of each of the lines 506 and 507 extending to the side of FIG. As mentioned above, the mathematical model used herein is based on various volume percentages of unused volume. Percentage of fine powder in the mixing hopper 502 for powder coating materials including Useful for In this way, during steady operation of the system 500, the mixing hopper 5 To prevent excessive fine powder from accumulating in the powder mixture, mix unused powder with an appropriate volume fraction. Can be added to the par 502. As a safety measure, the system 500 of the present invention Monitors the particle size distribution in the mixing hopper 502 and Software to ensure that the percentage of actual fines in the product matches the value predicted by the mathematical model Wear is also included in the control device 108. Referring to FIG. 15, a sequence of operations for executing the above-described monitor function is shown in FIG. There is a flowchart shown in FIG. First, remove the sample from the mixing hopper 502 manually. The same laser diffraction grain as above, as schematically depicted in block 528 Using a particle size analyzer, the actual particle size distribution F in the mixing hopper 502_M Is measured. Particle size distribution information can be obtained manually or electronically from block 528. Are input to the controller 108 via the line 530. Then it was drawn in FIG. All work is performed electronically by software in controller 108. Control device 1 08 is activated and included in the mixing hopper 502 Calculate the volume percentage of the fines, eg, particles less than about 10 microns. See block 532. One of the representative values of the calculated volume percentage The value is entered by line 534 into block 536 where the system 500 For the specific type of powder coating material to be applied, the calculated value and Compare to a constant maximum volume percentage. In the exemplary embodiment shown in FIG. The desired maximum volume percentage of 30% is nominally shown in Other minimum volume percentage fines may be more appropriate for types of coating materials Is understood. If the calculated percentage of fines is less than or equal to 30%, follow line 538. A "NO" signal is sent back to block 528, and the next monitoring period starts. Until, for example, one day, one week, or any other desired period, the monitoring sequence ends doing. At block 536, the calculated percentage of fines determines the powder in the mixing chamber 502. If it is determined that the weight exceeds 30%, block 53 is passed through line 540. Sends a signal to the block 542. Controller 1 as indicated by block 542 08 performs the weight fraction W, ie, the empirical fraction of 20%, 30%, etc. To choose. Next, the control device 108 uses the selected weight fraction W to solve. Ff = W · Fv + (1−W) · Fm (18) Where Ff = the desired volume percentage of fines in the mixing hopper, for example <30% , W = weight fraction of unused powder, Fm = particle size distribution of the powder in the mixing hopper, Fv = particle size distribution of unused powder. If the value of Ff is greater than 30% at the selected weight fraction W, another A larger weight fraction W is selected and the calculation using equation (18) is repeated. The next step in the monitoring sequence shown in FIG. 15 is described above in connection with FIG. Of the powder in the mixing hopper 502 using a load cell 106 of a different type. It is to be. See box 544. Next, schematic at block 546 The actual weight of the powder in the mixing hopper 502 is And a signal representing the calculation compared to the total weight capacity of block 2 via line 548. 550. As indicated by block 550, the powder in the mixing hopper 502 If the level of the body is 1-W or less, the control device 102 is activated and unused powder coating is performed. The material is placed in the mixing hopper 502 (block 552). Mixing hopper 502 Full, necessary to reduce the volume fraction of fines to the desired level, ie> (1-W) When the controller 108 cannot receive an unused powder coating material having a high volume fraction W, Release a sufficient amount of powder from the mixing hopper 502 as indicated by block 554; , Add unused powder coating material. To add unused particulate powder coating material Must be released or removed from the mixing hopper 502 to make room for The amount of the powder can be obtained from the following relational expression. Where Q_D= Fraction of powder released from the mixing hopper, MHw = weight measurement of the mixing hopper, MHc = capacity of the mixing hopper. Therefore, the above series of weight calculations will result in a new unused Is sufficient to receive the powder coating material for 02 to ensure that the overall volume fraction of fines is reduced without overflow. You. After adding unused powder coating material (block 552), until the next monitoring period The monitoring operation has been completed. Therefore, the recycled powder coating material and the unused powder coating material are mixed in the mixing hopper 502. The above method of maintaining a desired ratio of It relies on measuring the weight loss in the upper 502. Or by weight measurement And based on the flow measurements, the mix hopper 502 is regenerated and It is considered that powder coating materials for industrial use can be supplied. In this embodiment, the mixing hopper -Monitor the flow rate of powder coating material released from Using a flow control device such as a screw feeder (not shown), each From the hopper 80 and the primary hopper 60, a predetermined amount of the regenerated powder coating material and Both of the powder coating materials used are added to the mixing hopper 502. Primary hopper 60 Screw feeder or similar device associated with the regenerative hopper 8 A separate screw feeder associated with the mixing hopper 502 Mix or mix additional unused powder coating material with recycled powder coating material. After a predetermined working period introduced into the par 502, or both, the control device 10 8 is preferred.Powder tray Referring to FIG. 2, the powder receiver 5 described above in connection with the study of the system 10 of FIG. 8 is shown in detail. The other powder receivers 66, 82 and 94 are each And is structurally and functionally equivalent to the powder receiver 58, and is therefore referred to herein as a powder receiver. It should be understood that only one of the receivers will be considered in detail. Also, the powder receiver 60 An alternative embodiment of zero is disclosed below in connection with FIG. The powder receiver 58 is hollow with the cartridge filter 132 attached by the plate 134. A collector housing 128 having an interior 130. One side of collector housing 128 Along the way, the access panel 136 is fixed so that it can be opened by the latch 138. The cartridge filter 132 can be accessed. The interior 130 of the collector housing 128 is ventilated by a vent 140 Is closed by a cap 143 fixed by a latch 144. Cap 1 42 is aligned with the open end of cartridge filter 132 connected to plate 134 A reverse air jet valve 146 is mounted. Reverse air jet valve 146 is connected to line 1 Connected by 48 to an accumulator 150, which is pressurized schematically shown in FIG. It is connected to a source 73 of air. The cap 142 is connected to the first vacuum pump 62 It carries a fitting 154 connected to the suction hose or line 61. collector The lower part of the housing 128 is in contact with the line 56 from the container carrying the unused powder coating material. A powder inlet 158 is included. The collector housing 128 is, as shown in FIG. It tapers radially inward downward from the body entrance 158 and includes an outer flange 162. A tapered base 160 is formed. As discussed above, the load cell 10 associated with the primary hopper 60 For 6A to function properly, the primary hopper 60 is completely free of powder coating material State, this must be `` zeroed '', i.e. the weight reading must be set to zero. No. In this manner, load cell 106A actually enters primary hopper 60. Weigh only powder coating material. Ensure accurate powder weight in the primary hopper 60 To read all elements associated with the first powder receiving unit 58, Independently of the primary hopper 60, it is supported on a frame 164 shown in FIG. This frame 16 4 is an upper plate 166 supported on the vertical leg 168, and the upper plate 166 and the vertical leg 168 A slanted brace 170 extending between and a middle position between the vertical legs 168 Including one or more horizontal supports 172. The collector housing 128 includes an outer flange 162 and an upper plate 16 of the collector housing 128. 6 is attached to the upper plate 166 of the frame 164 by bolts 174 extending between them. You. Extending downwardly from the tapered base 160 of the collector housing 128 is a collector. Housing 128 with Primer Pneumatics Inn, Salina, Kansas. Corporate (Premier Pneumatics, Inc.) is model number MDR-F-G-76-10NH-2-RT-C A frame connected to a rotating air-lock metering device 178 of the type commercially available on HE-T3 The kibble sleeve 176. The weighing device 178 is connected to one vertical leg 168. A belt (not shown) is connected to an output portion of a motor 182 carried on a supporting plate ). When the motor 182 operates, a series of The inner wing 186 is rotated to dispense a weighed amount of the powder coating material into the collector housing 128. Mounted on horizontal support 172 from tapered base 160 It is transferred to the rotatable sieve 196. The rotary sieve 196 is manufactured by Azo Incorpor of Germany. ated is a commercial product of the type manufactured and sold under the model E-240. Rotary sieve 196 passes the powder coating material through the second flexible sleeve 198 to the primary housing. It is transferred to the powder inlet 200 of the upper 60. This is described in more detail in FIG. Illustrated and described below. During operation, the first vacuum pump 62 is activated by the controller 108 to A vacuum is created along the hose or line 61 and the hollow A negative pressure is created in interior 130. As a result, unused powder coating material is From vessel 54 through line 56 and powder inlet 158 into collector housing 128 It is drawn into the empty interior 130. Part of the powder coating material is collected by gravity Dropping onto the tapered base 160 of the housing 128, some of the powder coating material is It collects on the walls of the ridge filter 132. Periodically supplied from accumulator 160 Compressed air is applied to the reverse air jet aligned with the cartridge filter 132. The pulse is conveyed through the valve 147. This jet of air causes The powder coating material collected on the wall of the filter 132 separates and the taper of the collector housing 128 It can fall down to the base 160. The powder coating material is supplied to the air lock metering device 178 according to the operation of the motor 182. Metered amount of powder coating material as it is transferred from the collector housing 128 by the Enters the rotary sieve 196. After passing through the rotary sieve 196, the powder coating material Force passes through the flexible sleeve 198 and enters the powder in the primary hopper 60. It falls to the mouth 200. A predetermined amount of powder coating material has accumulated in the primary hopper 60 The associated load cell 106A sends a signal to the controller 108 Then, this stops the operation of the first vacuum pump 62. As mentioned above, the powder of FIG. All other powder receiving units 66, 82 and 94 of the transfer system It is the same both in terms of function and function. Referring to FIG. 11, another embodiment of a powder receiver 600 is illustrated in detail. You. The powder receiver 600 includes the powder receivers 58, 66, 8 described above in connection with the discussion of FIG. 2 and 94 are partially similar, and FIG. 11 shows a structure common to FIG. Use the same reference numbers for One difference between the powder receiver 600 and the powder receiver 58 is that Structure for transferring powder coating material from collector housing 128 to primary hopper 60 It is. For applications using a particular type of powder material, the tapered base of powder receiver 58 In the area of the part 160, the coating material becomes arched or bridge-shaped, Have been known to stop. When the tapered base 160 closes, the powder The body coating material is passed through an airlock metering device 178 to a rotary type of structure shown in FIG. Cannot enter sieve 196. The powder receiver 600 shown in FIG. Not included, but placed on the hopper 60 and before introduction into the hopper 60 It is believed that this powder coating material can be sieved. At least, for example At the point where the powder coating material is first introduced into the system, such as receivers 58 and 82, Preferably, a sieve 196 is used. See FIG. The powder receiver 600 of FIG. 11 is basically constituted by the upper part of the powder receiver 68 of FIG. Since the lower portion includes a structure that fluidizes the powder coating material toward the collector housing 128, Transfer to the primary hopper 60 smoothly Can be. The bottom of the collector housing 128 defines an interior containing the fluidized bed 602; This extends outwardly from the side walls of the cap 142 and the collector housing 128 and It extends between a perforated plate 604 supported by a racket (not shown). Collector housing A second section in the base of 128 is attached to the side wall 129 of the collector housing 128 Extending between the circular mounting plate 610 and the perforated plate 604 carried by the Air Plenum 608. A third zone in the base inside the collector housing Motor chamber extending between bottom wall 614 of mounting housing 128 and mounting plate 610 612. For the purposes that will become apparent below, the entire powder receiver 600 is On top of stand 615, vertically above primary hopper 60 or other hopper It is preferable to attach to the position of the part. At the base of the feed hopper 600 is provided a stirrer 616, which is Carried in motor chamber 612 by a motor mount connected to Includes motor 618. The output of motor 618 is rotatable in bearing 624 It is drivingly connected to the carried shaft 622. Bearing 624 is secured by a bearing mount. Attached to the perforated plate 610 and immediately past the perforated plate 604 through the air plenum 608 It extends vertically upward to the receiving point. The top of shaft 622 extending through bearing 624 The part has at least two entrainment nuts with lock nuts 630. Since the arm 628 is fixed, the entrainment mechanism is operated according to the operation of the motor 618. Arm 628 rotates relative to perforated plate 604 at a position above it. Air supply line 636 entering one side of motor chamber 612 has at least two Individual air inlets 632 are not shown Connected by law. This air supply line is connected to a supply source 73 of pressurized air. Upwardly directed air flow enters air plenum 608 through air inlet 632. Where air is deflected by baffles 638 mounted on bearings 624 I do. The purpose of this baffle is to assign to the assignee of the present invention US Pat. No. 5,018,909. And the disclosure of which is incorporated herein by reference in its entirety. See in. The transfer pipe 640 has one end on the perforated plate 604 and inside the fluidized bed 602. Connected to the rectifier housing 128. The other end of the transfer pipe 640 is Attached to the entrance 642. Rotary air lock 178 is driven by motor 182. All of the same type as described above in connection with the examination of the powder receiver 58. However, they are connected in the transfer pipe 640. As schematically shown in FIG. The operation of 182 is controlled by the controller 108 and thus the rotary air lock 1 The operation of 78 is also controlled by this. Powder coating from fluidized bed 602 in powder receiver 600 The charge flows downward by gravity in response to the operation of the rotary air lock 178. After passing through the transfer pipe 640, it enters the inside of the primary hopper 60. Motor 182 Is stopped, the operation of the rotary air lock 178 is stopped as desired, and the transfer tube 64 is stopped. Stop the flow of powder coating material through zero. This configuration of the powder receiver 600 Providing a smooth transfer of the powder to the par 60, such a powder receiver 600 is shown in FIG. And alternatives to both embodiments. In others , The powder receiver 600 functions in the same manner as the powder receiver 58 described above, Is not repeated here.Primary and regeneration hopper The primary hopper 60 and the regeneration hopper 80 are basically equal to each other and will be considered. To this end, only the primary hopper 60 is shown and described in detail. FIG. 3 and Referring to FIG. 4, the primary hopper 60 includes an inner wall 204 having a generally “eight-shaped” shape. And a housing 202 having the same. Therefore, the inner wall 204 has two circular portions 206 and And 208, each of which is connected to opposing three ends connected to one side of the housing 202. Defined by rectangular baffles 212 and 214 and centered on housing 202 Fit at the reduced diameter area 210. The baffles 212 and 214 respectively Extending inward from the wall and forming a top 220 toward the center of the housing interior 203 And a pair of side panels 216, 218. As can be best seen in FIG. The housing 203 is supported by the perforated plate 222 and the housing 202. The fluidized bed 226 between the upper wall 229 and the perforated plate 222 and the bottom wall 23 of the housing 202 2 and an air plenum 230 located between them. Air plenum 230 Includes a number of baffles 270 and a generally U-shaped perforated air tube 272. Bottom wall 232 may be a load cell discussed above in connection with the powder transfer system of the present invention. Located at the top of the shell 106A. The upper wall 228 of the housing 202 includes a first stirrer 234, a second stirrer 236, and a handle. A hinge 240 is provided at the opening 244 of the upper wall 228 with the dollar 240 and the latch mechanism 242. 43 and an access cover 238 attached thereto. This opening 244 is shifted from the powder inlet 200 of the primary hopper 60, And powder The inside 203 of the housing can be accessed without interfering with the body entrance 200. . The first stirrer 234 has a motor connected to the gear box 250 by a shaft 248. Data 246. The output of the gear box 250 is the shaft housed in the tube 254. 252. At the lower end of the shaft 252, at least two stirrer paddles 2 56, which is the circle of the interior 203 of the housing formed by the inner wall 204 It rotates inside the shape part 206 at a position vertically above the perforated plate 222. Second stirrer 2 36 has the same structure as the first stirrer 234. The second stirrer 236 includes a gear A motor 258 having a shaft 260 connected to the box 262; The output of the box is drivingly connected to a shaft 264 housed in the tube 266. Two or more A paddle 268 is formed on the other circular portion 20 of the inside 203 of the housing formed by the inner wall 204. Within 8, it is attached to the base of the shaft 264. As shown in FIG. 4, the second stirrer 24 The shaft 264 and tube 266 associated with the first stirrer 234 are Since the paddle 268 of the second stirrer 236 is slightly longer than the first stirrer 234, It is located near 222. Oars 256, 268 overlap but are shifted vertically Therefore, they do not interfere with each other. As mentioned above, one aspect of the invention is, for example, 300 pounds per hour. Transfer a large amount of powder coating material such as above at a flow rate such as 1-2 pounds per second. While maintaining the desired density and particle distribution in the powder coating material stream is there. As mentioned above, the term "density" refers to the relative mixing of powder and air. Or particle distribution, the term "particle distribution" Refers to the distribution of size powder particles. Primary hopper 60 and regeneration hopper The hopper 80 can provide the desired density and granularity at high powder coating material throughput. Designed to meet child distribution requirements. During operation, pressurized air is introduced into perforated air pipe 272 in air plenum 230. To create an upward flow of air, which is baffled by the baffle 270. 2 are distributed evenly throughout the bottom. The powder coating material passes through the powder inlet 20 to the housing Introduced into the interior 203, by an upward air flow for fluidization, and And distributed along the perforated plate 222 by the operation of the second stirrers 234 and 236. . As the stirrers 256, 268 move relative to the perforated plate 222, the inner wall 204 The “dead figure” inside the housing 203 is defined by The powder coating material is distributed evenly along the entire surface of the perforated plate 222 because it is almost eliminated. Cloth and agglomeration or accumulation of powder material is almost eliminated. This allows the fluidized bed 226 The powder is evenly and uniformly distributed in the inside, and a desired particle distribution and density are obtained. Second vacuum When the pump 69 is started, the powder coating material mixed in the air It is sucked out of the housing 202 and passes through the suction pipe 274 inserted into the inside 203 of the housing. The inside of the housing is connected to the transfer line 64 described above.Supply hopper Since the first and second supply hoppers 68 and 96 are basically the same in structure, Here, only the first supply hopper 68 will be discussed in detail. Referring to FIG. The supply hopper 68 is formed with an opening closed by a cover 279. A wall 278, a generally cylindrical side wall 280, and a bottom carried by load cell 106B. And a wall 282. The housing 276 has an interior that is basically separated into three distinct areas. Is specified. One area extends outwardly from the housing side wall 280 and A fluidized bed extending between a perforated plate 286 supported on the side wall by 88 and an upper wall 278 284. A second area within housing 276 is a brassier attached to side wall 280. Extending between the circular mounting plate 292 carried by the Air Plenum 290. The third area inside the housing 276 is the mounting plate 2 A motor chamber 296 extending between 292 and bottom wall 282. The feed hopper 68 has a motor mount 302 connected to a mounting plate 292. Thus, the agitator 298 including the motor 300 carried in the motor chamber 296 Is provided. The output of motor 300 is carried in bearing 306 in a rotatable state. The driving shaft 304 is drivingly connected. The bearing 306 is connected to the bearing mount 308. To the mounting plate 292 and vertically upward through the air plenum 290 Extend to a location just above perforated plate 286. Shaft 304 extending through bearing 206 At the top, at least two paddles 308 are fixed by lock nuts 310. Therefore, depending on the operation of the motor 300, the paddle 308 moves with respect to the perforated plate 286. Rotate just above. At least two air inlets 312 are carried by mounting plate 292 and are connected by tubes 314. Thus, an air supply line 316 entering one side of the motor chamber 296 is shown. Connected in no way. This air supply line 316 is as described above for the powder receiver. Connected to the compressed air supply source 73. Air plenum 2 through air inlet 313 At 90, an upward air flow is provided where the air is attached to bearings 306. Deflection by the baffle 318 provided. The baffle 318 is No. 5,018,909, of the same type as used for ing. In operation, powder coating material is applied along the side walls 280 of the housing 276. Through the tapered powder inlet 276 and into the fluidized bed 284 of the housing 276 . The motor 300 operates to rotate the paddle 308, so that the powder coating material has no dead center. Evenly distributed along the perforated plate 286. The powder coating material is supplied through the air supply line 31 6 and perforated plate 286 due to upward airflow from air inlet 312. Fluidized. Pump 74 is used to remove the powder coating material from housing 276. Operate one or more powder pumps such as The powder coating material is sucked out through the suction pipe 322. From feed hopper 68 To illustrate that multiple powder pumps 74 can be used to aspirate powder 5, several suction tubes 322 are shown.Robot hopper The robot hopper 78 shown schematically in FIG. 1 is shown in more detail in FIG. In a preferred embodiment of the invention, the robot hopper 78 has one or more It houses a motor 326 which is drivingly connected to a shaft 328 on which a paddle 330 is mounted. The cylindrical base forming the mixing 324 of the motor chamber and air plenum Including. The top of the robot hopper 78 has an air plenum and a motor chamber. It has a bottom wall and a top wall 334 formed by a perforated plate 336 that communicates with the bus 324. A cylindrical housing 332. A cylindrical housing 332 defines a fluidized bed 338, Inside it is a rectangular plate or baffle 340 is attached. The baffle 340 is placed vertically on the perforated plate 336. Separate and divide fluidized bed 338 into two compartments. One section of baffle 340 Or, on the side, the powder coating material from the feed hopper 68 is fed to the top of the cylindrical housing 332. It is introduced through a powder inlet 342 schematically shown in the section. For powder pump 79 An associated suction tube 344 is connected to cylindrical housing 332 on the opposite side of baffle 340. And the suction tube 344 terminates just above the perforated plate 336 . Robot hopper 78 includes powder pump 7 associated with feed hopper 68. From 4, powder coating material is received via line 76. Powder coating material is cylindrical Enter the powder inlet 342 of the housing 332 and move downward along one side of the baffle 340. Ahead to the perforated plate 336. The motor 326 is operated, and immediately above the perforated plate 336 The paddle 330 is rotated so that a uniform flow of powdered material mixed with air Drawn from the powder pump 79 through 344, the robot 40 and its associated It is sent to the attached spray gun 42. Baffle inside cylindrical housing 332 The presence of 340 helps stabilize the fluidization of the powder coating material across the perforated plate 336. To ensure that the flow of powder coating material drawn by powder pump 79 is The desired density and powder distribution are maintained.Powder collection and recovery system Referring to FIGS. 1 and 7-9, the powder collection and recovery system 16 is described in further detail. This is shown in detail. This system 16 is entirely attributed to Shutic et al. Related to the system disclosed in U.S. Pat.No. 5,078,084, the disclosure of which is incorporated by reference. By the way Incorporate as is. As described above, the powder collection and collection system 16 includes The booth 1 in which the car body 32 is transferred by the conveyor 34 under the floor 20 of the base 12 2 located on either side of the central portion 36. As shown in the left part of FIG. The child 38 covers the booth floor 20 so that excessively sprayed aerated powder coating material Sucks down into system 16 from any area of booth room 30 be able to. The powder collecting and collecting device 16 has a modular structure, and A series of powder collection units 346 extending vertically along the entire length and mounted side by side Is provided. See the center of FIG. As shown on the right side of FIG. 1 and FIG. The collecting units 346 are, for example, groups of three or four, Connected to an individual fan or blower unit 348 located below 46. Each powder collection unit 346 includes opposing side walls 354, 356, and opposing end walls 35. 8, 360, and a collector housing 350 having a sloped bottom wall 362. K A lean air chamber 364 is located at the top of the collector housing 350 and leans inward. A pair of support plates 36 that are beveled and each have several spaced openings 368 6, 367, opposing side plates 369, 390, and side plates 369, 370, respectively. Formed by a pair of access doors 371, 372 hinged to the door. The clean air chamber 364 extends over the length of the collector housing 350 , Extension 373, the purpose of which is described below. Collector housing The lower part of 350 is a powder having a bottom wall and a tapered side wall defined by perforated plate 376. A body collection chamber 374 is formed. The perforated plate 376 is a base of the collector housing 350. At an angle of about 5 degrees with respect to the horizontal, the air 377 is formed. Through an inlet (not shown), an air pump under perforated plate 376 The upward flow of air is introduced into the renaming 377 so that the powder collection chamber 37 The powder coating material entering 4 fluidizes at the top of the perforated plate 376. In a preferred embodiment of the present invention, two groups or two rows of cartridges are provided. A filter 378 is located within the powder collection chamber 374 and, as seen in FIG. They are arranged in a V-shape. The open top of each cartridge filter 378 is By means of one of the support plates 366, 367 of the lean air chamber 364, this plate 366, 367 are carried above the opening 368. Each cartridge file Luter 378 has a central rod 382 threaded on the upper end and is fastened to rod 382. Receiving one of the support plates 366 or 367 384 and the top of the cartridge filter 378. Collector housing One or more of the filter mounting plates 386 extending between the end walls 358 and 360 of the 350 Preferably, additional support is provided for each cartridge filter 378. The powder coating material entering collector housing 350, as discussed above, is Of the cartridge filter 378 for removal from the wall of the filter 378. Each bank is provided with a set or group of air jet nozzles 392 You. A set of air jet nozzles 392 is provided in the clean air chamber 364. A second set of air jets carried on a nozzle support 394 mounted within The nozzle 392 supports the nozzle in the clean air chamber 364 Carried on body 396. As shown in FIG. 8, each set of air jet nozzles 3 Reference numeral 92 denotes an opened cartridge filter 378 of one group or one row. Pointed to the top. Associated with each row of cartridge filters 378 Air jet nozzle 392 connects to hydraulic valve 400 by air line 398. This is connected to a source of pressurized air 73. From the system controller 108 The hydraulic valve 400 is actuated in response to the signal of Discharge from nozzle 392 to one or both rows of cartridge filters 378 The compressed air is selectively directed through an air line 398 to exit. this A pulsed air jet applies powder coating material to the cartridge filter 378 wall. So that the powder coating material is gravity driven into the powder collection chamber 374, Further, it can drop onto the perforated plate 376. Referring to FIGS. 1 and 7, the powder coating material entrained in the air is When the negative pressure generated by the unit 348 is applied, powder Sucked into each of the collection units 346. Each blower unit 348 A fan plenum 402 that houses a fan or blower 404, and is schematically illustrated in FIG. Includes several final filters 406, shown schematically. Fan plenum 402 Several openings 408 are formed on which the exhaust duct 410 is fixed. Each exhaust The air duct 410 extends vertically upward and is associated with each powder collection unit 346. Associated with a shaft coupling 412 located at the base of one of the clean air chambers 364. Combine. Depending on the operation of the blower 404 in the fan plenum 402, the exhaust duct Negative pressure is generated in 410 and the cream associated with each powder collection unit 346 is generated. Also formed in the air chamber 364. This negative pressure is directed downward into the booth room 30. Airflow, into which excess sprayed powder coating material is entrained. air The powder coating material mixed into the spraying machine passes through a grid 38 on the floor 20 of the spray booth 12. And enters each powder collection unit 346 where the powder coating material is stored in the cartridge Perforated plate that collects along the wall of filter 378 or at the base of collector housing 350 It falls on 376. An important aspect of the powder collection and recovery system 16 of the present invention is a single blower unit. 348 corresponds to a limited number of powder collection units 346. For example The blower units 348A shown on the right side of FIG. Four openings 40 for receiving exhaust duct 410 connected to body collection unit 346 8 has a fan plenum 402. Therefore, four powder collections One blower unit 348A corresponds to the unit 346. Other bro W unit 348 is a relatively small group of adjacent powder collection units 34 6 so that a uniform downward air flow throughout the booth cabin 30 is achieved. Is given. Further, the clean air chamber of each powder collection unit 346 Due to the configuration of the extension 373, the powder collection unit on one side of the spray booth 12 346 connects to the powder collection unit 346 on the opposite side of the booth 12 That is, they can be fitted. See the center of FIG. This allows space And the overall size of the booth 12 is reduced. Another aspect of the powder collection and collection system 16 of the present invention is to remove collected oversprayed powder. Collected from the powder collection unit 346, the powder kitchen To recirculate back to 14. As described above, air from the booth room 30 The powder material mixed in is sucked into each powder collecting unit 346, Drop onto the perforated plate 376 at the base or release from the air jet nozzle 392 The periodic injection of the released pressurized air causes the cartridge filter 378 Removed. In a preferred embodiment of the invention, the movement of the powder to the perforated plate 376 is Vibrates when the opposite pressurized air jet is released from the air jet nozzle 293 So that the walls 354 to 362 of the collector housing 350 of each powder collecting unit are For example, No. 18 to 20 cages. Relatively thin metal such as 304 stainless steel Helped by forming with. The perforated plate 376 has an angle of about 5 degrees with respect to the horizontal. The fluidized powder coating material on top of the lower end of the perforated plate 376 To the outlet 422 on one side of the collector housing 350 located at Powder collection Each outlet 422 of the knit 346 is connected by a branch line 424 to a common header pie. 426, which runs vertically along the length of the powder booth 12 Extend to. The header pipe 426 is connected to the third powder receiver 82 in the powder kitchen 14. It is connected to the connected reproduction line 86. In each branch line 424, a guillotine-type And carries an open position through which the powder coating material can flow. Preferably, it can be moved between a closed position that obstructs such flow. The third vacuum pump 84 in the powder kitchen 14 is connected to the third powder receiver 8 as described above. 2 and the playback hopper 80, and in response to this activation, the header A negative pressure is created in ip 426. The system described above in connection with the powder transfer system System controller 108 is activated To selectively open the gate valve 428 associated with each powder collection unit 346 So that the powder therein passes through each branch line 424 and the header pipe 426 is sucked. Given a large number of powder collection units 346, a given time Only a predetermined number of gate valves 428 are opened, and the third powder receiver 82 and the primary To the header pipe 426 for transfer to the regeneration line 86 leading to the upper 80 Limit the total amount of powder material that can enter. Referring to FIG. 1, the pressure sensor 430 is connected to the fan sensor of the blower unit 348. Shown schematically as being connected to a plenum 402. Pressure sensor 430 The purpose is to sense a pressure drop across the final filter 406 in the blower unit 348 And transmitting a signal representing the signal to the control device 108. Given blower you One or more cartridges in the powder collection unit 346 associated with the knit 348 In the event of failure or other problems with the bridging filter 348, Passes through the clean air chamber 364 to the final filter 406, where The pressure drops at the end filter 406. This pressure drop is detected by the pressure sensor 430. At which point a signal indicating such a pressure drop is sent to the controller 108. The operator is informed that there is a problem within such a powder collection unit 346. Warning. Since there are several blower units 346, a powder collection and collection system 16, one blower unit 348 and associated powder It can be attributed to a group of collection units 346. This helps maintain the system To facilitate this, the operator will be able to use the blower unit 34 when such problems occur. There is no need to test each of the eight. Although the present invention has been described in connection with preferred embodiments, those skilled in the art will appreciate that Various changes can be made to the element without departing from the scope and can be replaced by equivalents. It is understood that. Also, without departing from the basic scope of the invention, Many modifications can be made to a particular condition or material to the teachings of the For example, the system 10 of the present invention includes a single primary hopper 60, a single regeneration hopper. Supply hopper 80, the robot hopper and the supply hopper associated with the robot 40. Par 68 and a supply hopper associated with the overhead gun manipulator 44 96 have been mentioned. The embodiment of the system 10 shown in the drawings and described above In order to illustrate the subject matter of the present disclosure, the system 10 may be used to It is understood that it can be modified according to the matter. A plurality of primary hoppers 60 and regeneration hoppers Can be used, and various combinations of feed hoppers and robot hoppers can be used. Various spray guns, including automatic and manually operated guns supplied by the hopper Can be used. Therefore, the present invention is, as the best mode designed to carry out the present invention, The invention is not limited to the specific embodiments disclosed, and the invention is not limited to the appended claims. Including all the embodiments that fall within.

───────────────────────────────────────────────────── フロントページの続き (81)指定国ＥＰ(ＡＴ，ＢＥ，ＣＨ，ＤＥ，ＤＫ，ＥＳ，ＦＲ，ＧＢ，ＧＲ，ＩＥ，ＩＴ，ＬＵ，ＭＣ，ＮＬ，ＰＴ，ＳＥ)，ＯＡ(ＢＦ，ＢＪ，ＣＦ，ＣＧ，ＣＩ，ＣＭ，ＧＡ，ＧＮ，ＭＬ，ＭＲ，ＮＥ，ＳＮ，ＴＤ，ＴＧ)，ＡＰ(ＫＥ，ＭＷ，ＳＤ，ＳＺ，ＵＧ)，ＡＭ，ＡＴ，ＡＵ，ＢＢ，ＢＧ，ＢＲ，ＢＹ，ＣＡ，ＣＨ，ＣＮ，ＣＺ，ＤＥ，ＤＫ，ＥＥ，ＥＳ，ＦＩ，ＧＢ，ＧＥ，ＨＵ，ＪＰ，ＫＥ，ＫＧ，ＫＰ，ＫＲ，ＫＺ，ＬＫ，ＬＲ，ＬＴ，ＬＵ，ＬＶ，ＭＤ，ＭＧ，ＭＮ，ＭＷ，ＭＸ，ＮＯ，ＮＺ，ＰＬ，ＰＴ，ＲＯ，ＲＵ，ＳＤ，ＳＥ，ＳＩ，ＳＫ，ＴＪ，ＴＴ，ＵＡ，ＵＺ，ＶＮ (72)発明者ホルスタイン，トーマス，イー. アメリカ合衆国．44001 オハイオ，アムハースト，フォレストヒルドライヴ 104 (72)発明者ウィリアムズ，キース，イー. アメリカ合衆国．48158 ミシガン，マンチェスター，シャロンヴァレイロード 19190 (72)発明者フエナ，アーネスト，ジェー. アメリカ合衆国．44116 オハイオ，ロッキイリヴァー，ローカストレーン 22577────────────────────────────────────────────────── ─── Continuation of front page (81) Designated countries EP (AT, BE, CH, DE, DK, ES, FR, GB, GR, IE, IT, LU, M C, NL, PT, SE), OA (BF, BJ, CF, CG , CI, CM, GA, GN, ML, MR, NE, SN, TD, TG), AP (KE, MW, SD, SZ, UG), AM, AT, AU, BB, BG, BR, BY, CA, C H, CN, CZ, DE, DK, EE, ES, FI, GB , GE, HU, JP, KE, KG, KP, KR, KZ, LK, LR, LT, LU, LV, MD, MG, MN, M W, MX, NO, NZ, PL, PT, RO, RU, SD , SE, SI, SK, TJ, TT, UA, UZ, VN (72) Inventor Holstein, Thomas, E. United States of America. 44001 Ohio, Am Hearst, Forest Hill Drive 104 (72) Inventors Williams, Keith, E. United States of America. 48158 Michigan, Man Chester, Sharon Valley Road 19190 (72) Inventors: Fuena, Ernest, J. United States of America. 44116 Ohio, Lo Key River, Locust Lane 22577

Claims

[Claims] 1. A device for supplying a powder coating material to a coating dispenser to adhere to an object conveyed through a powder spray booth, a primary hopper containing the powder coating material, a supply hopper, and a primary hopper. And a first transfer device connected between the primary hopper and the supply hopper under a negative pressure, and a powder spraying booth associated with the supply hopper. And a second transfer device for transferring the powder coating material to the dispensing device. 2. The apparatus of claim 1, wherein the primary hopper is at a location remote from the feed hopper. 3. The apparatus of claim 1, wherein the feed hopper is separated by a significant distance from the primary hopper and is located closer to a powder spray booth as compared to the primary hopper. 4. The second transfer device is a powder pump connected to the supply hopper, wherein the powder pump associates the powder coating material in the supply hopper with a powder spray booth by positive pressure. 2. The device according to claim 1, wherein the device is transferred to a discharge device. 5. The apparatus of claim 1, further comprising a third transfer device connected to the primary hopper and applying a negative pressure to transport coating material from a source of powder coating material to the primary hopper. 6. A powder receiving unit including a powder collection chamber connected to a powder coating material supply source, the third transfer device transferring the powder coating material from the supply source to the powder collection chamber under the influence of negative pressure; 6. The apparatus of claim 5, comprising: a first device for transferring a measured amount of powder coating material from the powder collection chamber to the primary hopper. 7. A powder receiving unit including a powder collection chamber connected to the primary hopper; and a powder coating material from the primary hopper to the powder collection chamber under the influence of negative pressure. 7. The apparatus according to claim 6, comprising a first apparatus for transferring and a second apparatus for transferring a metered amount of powder coating material from the powder collection chamber to the supply hopper. 8. The powder receiving unit of each of the second and third transfer devices includes a clean air chamber separated from the powder collecting chamber; and a clean air chamber located in the powder collecting chamber. 8. The apparatus of claim 7, including at least one cartridge filter in communication with said filter, and means for removing powder coating material accumulated on said cartridge filter. 9. The apparatus of claim 7, wherein the first device comprises a vacuum pump. Ten. A second device of each of the second and third transfer devices, wherein a metering air lock connected to the powder collection chamber; and a metering air lock and the primary hopper or the supply hopper. The apparatus of claim 7, comprising an attached sieve. 11． A transfer line interconnecting the primary hopper and the supply hopper; and a transfer line attached to the transfer line to turn on / off the flow of the powder coating material from the primary hopper to the supply hopper. A first valve, such that when the first valve is interrupting the flow of the powder coating material, the powder coating material remaining downstream of the first valve in the transfer line is conveyed to the supply hopper. And a second valve connected to said transfer line downstream of said first valve for introducing air into said transfer line. 12． A gun feed hopper, wherein the second transfer device is located near the powder spray booth and connected between the feed hopper and at least one powder spray device associated with the powder spray booth; And a pump connected to the supply hopper and having the effect of applying a positive pressure from the powder collection device to the gun supply hopper to convey the powder coating material. 13. In the powder spray booth, a part of the powder coating material does not adhere to the object and forms an excessive spray powder coating material, but in order to attach the powder spray booth to the conveyed object, A device for supplying powder coating material to a coating dispenser, comprising: a primary hopper and at least one secondary hopper containing unused powder coating material; and at least one secondary hopper associated with a powder spray booth. A first supply hopper adapted to supply one spraying device; a first transfer device for transferring unused powder coating material from the primary hopper to the first supply hopper under negative pressure; A second transfer device for transferring the oversprayed powder coating material collected in the body spray booth to one of the primary hopper and the at least one secondary hopper under negative pressure. . 14. The first transfer device includes a first powder receiving unit connected between a powder coating material supply source and the primary hopper, and the first powder receiving unit communicates with the primary hopper. A powder collecting chamber, and further connected to the powder collecting chamber of the powder receiving unit to generate a negative pressure therein and to supply the powder coating material from a supply source to the first powder receiving chamber. A first vacuum pump that sucks air into the first hopper, and a second powder receiving unit connected between the first hopper and the first supply hopper, wherein the second powder receiving unit communicates with the first supply hopper. A powder collecting chamber, and further connected to the powder collecting chamber of the second powder receiving unit to generate a negative pressure therein and to transfer a powder coating material from the primary hopper to the second powder receiving unit. 2 The second vacuum sucked into the powder receiver 14. The device of claim 13, comprising a pump. 15． The second at least one secondary hopper is a regenerative hopper, the regenerative hopper adapted to supply powder coating material to at least one spraying device associated with a powder spray booth. Apparatus according to claim 13, which is connected to a feed hopper. 16． The second transfer device comprises a second powder receiving unit connected between a powder spray booth and the regenerating hopper, wherein the second powder receiving unit is connected to the regenerating hopper. A powder collection chamber for contacting, further connected to the powder collection chamber of the second powder receiving unit, generating a negative pressure therein and powdering the excessively sprayed powder coating material; A second vacuum pump that sucks into the second powder receiver from a spray booth, and a third powder receiver unit connected between the regeneration hopper and the second supply hopper, wherein the third powder receiver unit Has a powder collection chamber in communication with the third supply hopper, and is further connected to the powder collection chamber of the third powder receiving unit to generate a negative pressure therein, Recycle the material The apparatus of claim 15 comprising a third vacuum pump to suck the receiving the third powder from par. 17． The at least one second hopper is a regenerating hopper, receiving excess sprayed powder material from the second transfer device, and selectively transferring unused powder material from the primary hopper to the regenerating hopper; 14. The apparatus of claim 13, wherein the supply of powder coating material is replenished. 18． A sensor operative to sense the amount of oversprayed powder coating material in the regenerating hopper and to generate a signal indicative thereof; and 18. The apparatus of claim 17, further comprising a pump for pumping unused powder coating material from said primary hopper to said reclaim hopper. 19. The sensor is a load cell that supports the regeneration hopper, and the load cell senses a change in the weight of the powder coating material corresponding to a change in the amount of the powder coating material in the regeneration hopper. 20. The apparatus of claim 19, wherein the signal can be generated when the weight of the powder coating material in the regeneration hopper falls below a predetermined level. 20. In order for some of the powder coating material to not adhere to the object, but to adhere to the object being conveyed through the powder spray booth forming an oversprayed powder coating material, the powder coating material should be at least A powder kitchen for containing at least one primary hopper containing at least one unused powder coating material and at least one secondary hopper, wherein the powder kitchen contains at least one unused powder coating material; A first supply feed adapted to be located proximate to the powder spray booth, wherein the supply hopper supplies powder coating material to a powder spray gun associated with the powder spray booth. And operating by applying a negative pressure to remove the oversprayed powder coating material from a powder spray booth from the primary hopper and the at least one of the two. A transfer device for transferring the powder coating material from one of the primary hopper and the at least one secondary hopper to the first supply hopper; twenty one. 21. The apparatus of claim 20, wherein the powder kitchen is an enclosure having an interior substantially isolated from ambient air. twenty two. 21. The reclaiming hopper wherein the at least one secondary hopper is adapted to connect to a powder spray booth, wherein the apparatus further comprises a second feed hopper connected to the regenerating hopper. The described device. twenty three. The transfer device comprises an individual powder receiving unit associated with each of the primary hopper, the regenerating hopper, and the first and second supply hoppers, wherein each of the powder receiving units is an unused powder. Receiving powder coating material from one of a source of coating material, a powder spray booth or another hopper, and delivering a metered amount of powder coating material to an associated hopper; 23. The apparatus of claim 22, comprising a vacuum device connected to each of said powder receiving units for transferring powder coating material under negative pressure to said powder receiving unit. twenty four. The powder receiving units each comprise a powder collection chamber for receiving a powder coating material, the powder collection chamber includes a cartridge filter, and a clean air chamber separated from the powder collection chamber; 24. The apparatus of claim 23, comprising an air jet device for removing powder material from the cartridge filter, and a device for transferring a metered amount of powder coating material from the powder collection chamber to an associated hopper. . twenty five. The apparatus for transferring a metered amount of powder coating material associated with each of the powder receiving units includes: a metering air lock connected to the powder collection chamber; 25. The apparatus of claim 24, comprising a sieve connected between the hopper, the regeneration hopper, or the first and second feed hoppers. 26. An apparatus for supplying powder coating material to at least one dispenser for attachment to an object transported through a powder spray booth, wherein the primary hopper receives the powder coating material and is connected to the primary hopper. And a first transfer device for transferring the powder coating material to the primary hopper; and sensing an amount of the powder coating material in the primary hopper, wherein the amount of the powder coating material is greater than a predetermined amount. If lowered, a first sensor that causes the first transfer device to transfer the powder coating material to the primary hopper; a supply hopper; and a connection between the primary hopper and the supply hopper, A second transfer device for transporting the powder coating material from the primary hopper to the supply hopper under a negative pressure; and sensing an amount of the powder coating material in the supply hopper, wherein the amount of the powder coating material is Below a certain amount If the apparatus comprising a second sensor for operating the second transfer device. 27. The first sensor is a load cell that supports the primary hopper, and the load cell is a load cell that supports a change in the amount of powder coating material in the primary hopper. A change in the weight of the coating material is sensed, and a signal is generated when the weight falls below a predetermined level, and the load cell operates the first transfer device to transfer the powder coating material to the primary material. The apparatus according to claim 27, wherein the signal is transmitted to a control device that supplies the hopper. 28. The second sensor is a load cell supporting the supply hopper, wherein the load cell is configured to load the powder coating material in the supply hopper corresponding to the change in the amount of the powder coating material in the supply hopper. It acts to sense changes in weight and generates a signal if the weight falls below a predetermined level, and the load cell operates a second transfer device to transfer powder coating material to the supply hopper. 28. The apparatus according to claim 27, wherein said signal is transmitted to a controller for supplying. 29. The first and second transfer devices each include a powder receiving unit coupled to the primary hopper or the supply hopper, wherein the powder receiving unit is separately supported by the primary hopper and the supply hopper. 29. The apparatus of claim 28, wherein the load cell associated therewith measures only the weight of the powder coating material entering the primary and feed hopper. 30. An apparatus for supplying a powder coating material, comprising: a hopper housing having an interior including an inner wall, forming a first powder fluidization area and a second powder fluidization area; A perforated plate that divides the interior into a fluidized bed located above and an air plenum below; a powder inlet for introducing powder coating material into the fluidized bed in the hopper housing; An air inlet for introducing an upward air flow into the air plenum below the plate, further comprising a first stirrer device located in the first powder fluidization zone and the second powder; Apparatus comprising a second stirrer device located in a fluidization zone, wherein the first and second stirrer devices produce a stable fluidized bed of powder in the first and second fluidization zones, respectively. . 31. 31. The apparatus of claim 30, wherein the inner wall of the hopper housing is formed substantially in the shape of Figure 8, with two generally circular portions meeting at a reduced diameter central area. 32. 32. The apparatus of claim 31, wherein the inner wall of the housing includes opposed triangular baffles forming the reduced radius central area. 33. The first and second stirrer devices each include a motorized paddle located in the one of the first and second fluidization zones on the perforated plate, one of the paddles being one of the paddles. 31. The apparatus of claim 30, wherein the paddle is positioned vertically above and over the other of the paddles. 34. A portion of the powder coating material introduced into the interior of the hopper housing includes fines, and the apparatus is further connected to a vent collector that serves to remove fines from the interior of the hopper housing. 31. The device of claim 30, wherein the device comprises a vent. 35. 31. The apparatus of claim 30, wherein the air plenum includes a baffle for directing an evenly distributed flow of air upwardly into the perforated plate. 36. A spray booth having an apparatus for applying powder coating material to an object, the spray booth having a ceiling, a floor, and opposing side walls defining a room providing a controlled area for applying the powder coating material to a passing object; A powder collecting device located immediately adjacent to the spray booth and collecting excess sprayed powder from the chamber, wherein the powder collecting device comprises: (i) approximately the length of the spray booth; A powder collection chamber that receives overblown powder from the chamber of the spray booth, further comprising: A clean air chamber associated with each of the body collection units, wherein each of the clean air chambers has an interior isolated from overblown powder entering the powder collection chamber. And (iii) located in each of the powder collection chambers, connected to the clean air chamber to collect excess sprayed powder, and introduced into the clean air chamber. Further comprising a filter device for forming a clean air to be blown, further connected to at least one powder collecting unit, and generating a negative pressure in the connected powder collecting chamber to form a powder mixed with the air. An apparatus comprising a number of exhaust units for drawing body coating material from the powder spray booth into the powder collection unit. 37. 37. The powder collection unit of claim 36, wherein each of the powder collection units is connected to a common header pipe by a connector line, the connector line carrying a valve operable between an open position and a closed position. apparatus. 38. 38. The apparatus of claim 37, further comprising: a vacuum device operative to provide a negative pressure in the common header pipe; and a device for sequentially opening and closing the valves associated with each of the powder collection units. 39. The exhaust units each include an exhaust plenum and an exhaust fan, the exhaust plenum being connected by separate ducts to the respective clean air chambers of the at least one powder collection unit, wherein the exhaust fan is 37. The apparatus of claim 36, operative to create a negative pressure in each of the at least one powder collection unit through the exhaust plenum and the duct. 40. 40. The apparatus of claim 39, wherein the exhaust plenums each include a number of final filters and a sensor operable to sense pressure drop at the final filters. 41. The powder collection chamber of each of the powder collection units includes a perforated plate mounted at an angle to a horizontal for receiving powder coating material from the spray booth; 37. The apparatus of claim 36, wherein the collection chamber is formed with an air inlet for directing the flow of air through the perforated plate to fluidize the received powder coating material. 42. 37. The device of claim 36, wherein the filter device comprises two rows of cartridge filters mounted in an inverted V-shape within the powder collection chamber of each powder collection unit. 43. Further, within the clean air chamber of each powder collection unit, there are several reverse air jet valves mounted at a position above the cartridge filter, each of the reverse air jet valves being 43. The device of claim 42, wherein the device is aligned with one of the cartridge filters. 44. An apparatus for supplying a powder coating material, comprising: a hopper housing having an interior formed by an upper wall, a side wall, and a bottom wall; and a fluidized bed supported in the hopper housing and having the interior positioned thereon. A perforated plate divided into an air plenum and a powder inlet for introducing a powder coating material into the fluidized bed in the hopper housing; and an upwardly directed air plenum below the perforated plate. An air inlet for introducing a flow of air, and further comprising a vertical baffle located in the fluidized bed between the upper wall of the hopper housing and the perforated plate, wherein the baffle is An apparatus located between the powder inlet and a powder discharge tube extending into the interior of the hopper housing. 45. 46. The apparatus of claim 44, further comprising an agitator for creating a stable zone of fluidized powder near the discharge tube. 46. The apparatus of claim 44, wherein the discharge tube in the hopper housing is connected to a robot carrying at least one powder spray gun. 47. A spray booth having an apparatus for applying powder coating material to an object, the spray booth having floors, ceilings, and opposing sidewalls defining a room providing a controlled area for applying the powder coating material to passing objects; Several powder collection units located immediately adjacent to the spray booth to collect oversprayed powder from the interior, and oversprayed powder coating material from the powder collection unit An apparatus comprising: a control device for sequentially transferring negatively-pressurized powder coating material to a common header pipe; and a device for transferring excessively sprayed powder coating material from the common header pipe to a hopper under negative pressure. 48. Each of the powder collection units is connected to the common header pipe by a connector line, and the controller is mounted within each of the connector lines to control the flow of powder coating material therethrough. 50. The apparatus of claim 47, comprising a gate valve that operates. 49. Each of the powder collection units includes a powder collection chamber, and each of the powder collection chambers is mounted at an angle to the horizontal to receive powder coating material from the spray booth. 48. The apparatus of claim 47, comprising a perforated plate, wherein each of the powder collection chambers is formed with an air inlet for directing air flow through the perforated plate to fluidize received powder coating material. . 50. A device for transferring powder coating material, comprising a source of unused powder coating material and a regenerating hopper adapted to communicate with a powder spray booth, wherein said regenerating hopper comprises From the booth, operative to receive oversprayed powder coating material that does not adhere to objects moving therethrough, and further comprising a mixing hopper connected to the source and the regeneration hopper, wherein the mixing hopper comprises: Is in communication with at least one coating dispenser associated with the powder spray booth, and further comprises a selected percentage of unused powder coating material and excess from the source and the reclaim hopper, respectively. A spray powder coating material is directed to the mixing hopper where it is mixed to feed at least one coating dispenser. Apparatus consisting of apparatus. 51. The source of virgin powder coating material includes a primary supply hopper for receiving virgin powder coating material, wherein the primary supply hopper includes at least one other coating associated with a powder spray booth. 51. The device of claim 50, wherein the device is connected to a utility dispenser. 52. The powder coating material is a granular powder coating, and the control unit is configured to measure a particle size distribution of a mixture of an unused powder coating material and a regenerated powder coating material in the mixing hopper. 51. The apparatus of claim 50, operable to accept a measurement of the distribution of. 53. The controller unit is operative to calculate a total volume percentage of the powder coating material in the mixing hopper, the particle size of which is smaller than a selected minimum size, and compare the calculated total volume percentage to a desired total volume percentage. 53. The apparatus of claim 52, wherein 54. The source of virgin powder coating material is connected to the mixing hopper by at least one line carrying a first valve, and the regeneration hopper is connected to the mixing hopper by at least one line carrying a second valve. 51. The controller of claim 50, connected to a hopper, wherein the controller unit is operative to open and close the first and second valves to control the amount of unused and reclaimed powder coating material entering the mixing hopper. Equipment. 55. A hopper housing having a chamber including an inner wall forming a first powder fluidization area and a second powder fluidization area; and a mixing hopper carried in the hopper housing, with the interior positioned thereon. A perforated plate that divides into a fluidized bed and an air plenum below, wherein the hopper housing has a powder inlet for introducing powder coating material into the fluidized bed and the air below the perforated plate. An air inlet for introducing an upward air flow into the plenum; and a first agitator located in the first powder fluidization zone and a second stirrer located in the second powder fluidization zone. 51. The apparatus of claim 50, comprising a second stirrer, wherein the first and second stirrers serve to create a stable fluidized bed of powder in the first and second fluidization zones, respectively. . 56. 56. The apparatus of claim 55, wherein the inner wall of the hopper housing is formed in the shape of substantially Figure 2 with two generally circular portions meeting at a reduced diameter central area. 57. 57. The apparatus of claim 56, wherein the inner wall of the housing includes opposed triangular baffles forming the reduced radius central area. 58. The first and second stirrers each include a motor-driven paddle positioned in the one of the first and second fluidization zones on the perforated plate, one of the paddles comprising: 56. The apparatus of claim 55, disposed vertically above and over the other of the paddles. 59. A portion of the powder coating material introduced into the interior of the hopper housing includes fines, and the apparatus further serves to remove at least a portion of the fines from the interior of the hopper housing. The apparatus of claim 55, comprising a vent connected to the vent collector. 60. 56. The apparatus of claim 55, wherein the air plenum includes a baffle for directing an evenly distributed flow of air upwardly into the perforated plate. 61. An apparatus for transferring a granular powder coating material, comprising a primary supply hopper connected to a supply source of unused powder coating material, wherein the primary supply hopper converts unused granular powder coating material into powder. A regenerating hopper in communication with at least one first coating dispenser operative to apply objects moving through the spray booth, and further in communication with a powder spray booth; A hopper serves to receive, from the powder spray booth, oversprayed granular powder coating material that does not adhere to objects moving therethrough, and further connects to the primary hopper for unused granular powder. A mixing hopper connected to said regenerating hopper for receiving the oversprayed granular powder coating material, said mixing hopper comprising an unused granular powder coating material. Contacting at least one second coating dispenser operable to apply the mixture with the oversprayed particulate powder coating material to an object moving through the powder spray booth; Supply of unused and excessively sprayed granular powder coating material to the mixing hopper such that the total volume of powder particles below the selected minimum size does not exceed a predetermined maximum percentage; A device comprising a control device operable to control the device. 62. The powder coating material is a granular powder coating, and the control unit is configured to measure a particle size distribution of a mixture of an unused powder coating material and a regenerated powder coating material in the mixing hopper. 51. The apparatus of claim 50, operable to accept a measurement of the distribution of. 63. The controller unit is operative to calculate a total volume percentage of the powder coating material in the mixing hopper, the particle size of which is smaller than a selected minimum size, and compare the calculated total volume percentage to a desired total volume percentage. 53. The apparatus of claim 52, wherein 64. The primary supply hopper is connected to the mixing hopper by at least one line carrying a first valve, and the regeneration hopper is connected to the mixing hopper by at least one line carrying a second valve; 62. The controller of claim 61, wherein the controller unit is operative to open and close the first and second valves to control the amount of unused and reclaimed powder coating material entering the mixing hopper. Equipment. 65. An apparatus for applying a powder coating material to an object, a powder spray booth having opposed side walls, a floor and a ceiling defining a control area for powder coating the object moving inside; and a powder spray booth. At least one coating dispenser operable to apply powder coating material to the object of matter; a source of unused powder coating material; and a regenerating hopper connected to the powder spray booth; The regeneration hopper is operable to receive from the powder spray booth oversprayed powder coating material that does not adhere to objects moving therethrough, and is further connected to the source and the regeneration hopper. A mixing hopper, said mixing hopper being connected to said at least one coating dispenser associated with a powder spray booth; Fresh powder coating material and oversprayed powder coating material from a source and the reclaim hopper, respectively, are directed to the mixing hopper where they are mixed for feeding to the at least one coating dispenser. A device consisting of a control device. 66. The source of virgin powder coating material includes a primary supply hopper for receiving virgin powder coating material, wherein the primary supply hopper includes at least one other coating associated with a powder spray booth. 66. The apparatus of claim 65, wherein the apparatus is connected to a dispenser for use. 67. The powder coating material is a granular powder coating, and the control unit is configured to measure a particle size distribution of a mixture of an unused powder coating material and a regenerated powder coating material in the mixing hopper. 66. The apparatus of claim 65, operable to accept a measurement of the distribution of 68. The controller unit is operative to calculate a total volume percentage of the powder coating material in the mixing hopper, the particle size of which is smaller than a selected minimum size, and compare the calculated total volume percentage to a desired total volume percentage. 68. The apparatus of claim 67, wherein 69. The source of virgin powder coating material is connected to the mixing hopper by at least one line carrying a first valve, and the regeneration hopper is connected to the mixing hopper by at least one line carrying a second valve. 66. The apparatus of claim 65, connected to a hopper, wherein the controller unit is operative to open and close the first and second valves to control the amount of unused and reclaimed powder coating material entering the mixing hopper. Equipment. 70. The source of unused powder material includes a primary feed hopper, wherein the primary feed hopper, the regenerating hopper, and the mixing hopper each include a first powder fluidization zone and a second powder fluidization zone. A hopper housing having a chamber including an inner wall to be formed; and a perforated plate carried in the hopper housing and dividing the inside into a fluidized bed positioned thereon and an air plenum below. The housing is formed with a powder inlet for introducing a powder coating material into the fluidized bed, and an air inlet for introducing an upward air flow into the air plenum below the perforated plate. A first stirrer located in the first powder fluidization section and a second stirrer located in the second powder fluidization section, wherein the first and second stirrers are respectively the first and second stirrers. And powder in the second fluidization area Serves to generate a stable fluidized bed apparatus according to claim 65. 71. 71. The apparatus of claim 70, wherein the inner wall of the hopper housing is formed in the shape of generally Figure 8 with two generally circular portions meeting at a reduced diameter central area. 72. 72. The apparatus of claim 71, wherein the inner wall of the housing includes opposed triangular baffles forming the central area of reduced diameter. 73. The first and second stirrers each include a motor-driven paddle positioned in the one of the first and second fluidization zones on the perforated plate, one of the paddles comprising: 71. The apparatus of claim 70, disposed vertically above and over the other of the paddles. 74. A portion of the powder coating material introduced into the interior of the hopper housing includes fines, and the apparatus further serves to remove at least a portion of the fines from the interior of the hopper housing. 71. The device of claim 70, comprising a vent connected to a vent collector. 75. 71. The apparatus of claim 70, wherein the air plenum includes a baffle for directing an evenly distributed flow of air upwardly into the perforated plate. 76. A device for supplying a powder coating material to a coating dispenser to adhere to objects conveyed through a powder spray booth, comprising: a primary hopper; and (i) formed by a top wall, side walls and a bottom wall. A hopper housing having an interior therein, and (ii) a perforated plate carried within the hopper housing and dividing the interior into a fluidized bed positioned thereon and an air plenum below. The housing is formed with a powder inlet for introducing a powder coating material into the fluidized bed, and an air inlet for introducing an upward air flow into the air plenum below the perforated plate. (iii) a supply hopper connected to the fluidized bed and including a transfer tube adapted to communicate with at least one coating dispenser; and a supply hopper connected between the primary hopper and the supply hover, The powder coating material is A first transfer device for transporting under negative pressure from the next hopper to the supply hopper. 77. 77. The apparatus of claim 76, wherein the hopper housing of the feed hopper is connected to a vacuum pump operable to draw powder coating material from the primary hopper into the hopper housing. 78. 77. The apparatus of claim 76, wherein said transfer tube of said feed hopper includes a valve. 79. A device for supplying a powder coating material to a coating dispenser for attachment to an object moving through a powder spray booth, comprising: a primary hopper; and (i) a top wall, side walls and a bottom wall. A hopper housing having an interior, and (ii) a perforated plate carried within the hopper housing and dividing the interior into a fluidized bed positioned thereon and an air plenum below. The body is formed with a powder inlet and an air inlet for introducing an upward air flow into the air plenum below the perforated plate, and (iii) a transfer pipe carrying a valve. And a first transfer device connected to the first supply hopper for transferring a powder coating material from a supply source of the coating material to the first supply hopper under a negative pressure. Comprising the first feed hopper A transfer pipe connected to the primary hopper, and further connected to the second supply hopper, for transferring the powder coating material from the primary hopper to the second supply hopper under a negative pressure; And wherein the transfer tube of the second supply hopper is in communication with at least one spray gun. 80. The transfer tube of the first supply hopper is moved from the first supply hopper to the first supply hopper so that the powder coating material from the first supply hopper can drop by gravity into the primary hopper through the transfer tube. 80. The apparatus of claim 79, wherein the apparatus extends substantially vertically downward to a next hopper. 81. Transferring the powder coating material under negative pressure from a primary hopper containing the powder coating material to a supply hopper by a method of applying the powder coating material to an object moving through a powder spray booth; Transferring the powder coating material from the supply hopper to at least one powder spraying device associated with the powder spray booth. 82. 82. The method of claim 81, further comprising the step of transporting the powder coating material from the source to the primary hopper under negative pressure. 83. The step of transporting the powder coating material from the source to the primary hopper under negative pressure includes transporting the powder coating material from the source to a powder collection chamber of a powder receiver associated with the primary hopper. 83. The method of claim 82, comprising transferring the next metered amount of powder coating material from the powder collection chamber to the primary hopper. 84. The means for transferring a metered amount of powder coating material operates an air lock metering device connected to the powder collection chamber to couple the metered amount of powder coating material therefrom to the primary hopper. 84. The method of claim 83, comprising transferring to a screened sieve. 85. Transporting the powder coating material from the primary hopper to the supply hopper under negative pressure, transporting the powder coating material from the primary hopper to a powder collection chamber of a powder receiver associated with the supply hopper; 82. The method of claim 81, further comprising the step of transferring a metered amount of powder coating material from the powder collection chamber to a supply hopper. 86. The step of transferring a metered amount of the powder coating material is performed by operating an air lock metering device connected to the powder collection chamber and dispensing the metered amount of the powder coating material therefrom to a supply hopper. The method of claim 85, comprising transferring to a sieve. 87. 82. The method of claim 81, wherein transferring the powder coating material from the supply hopper to the at least one powder spraying device comprises pumping the powder coating material under positive pressure into the spraying device. 88. Transporting the powder coating material from the supply hopper to at least one powder spraying device, wherein the step of moving the powder coating material to operate one or more spray devices in a powder spray booth. 84. The method of claim 81, comprising pumping under positive pressure to a robot hopper associated with the hopper. 89. A method of applying a powder coating material to an object moving through a powder spray booth comprises applying a powder coating material from a primary hopper to a first supply hopper located near the powder spray booth. Transporting under pressure and transporting the oversprayed powder coating material from a powder collection and collection system associated with a powder spray booth to one of a primary hopper and a secondary hopper under negative pressure. Transferring the excessively sprayed powder coating material from one of the primary and secondary hoppers to a second supply hopper located in the vicinity of the powder spray booth under negative pressure; Transferring the material from the first and second supply hoppers to separate powder sprayers associated with a powder spray booth. 90. The step of transporting the oversprayed powder coating material under negative pressure from a powder collection and collection system may comprise the step of: overspraying the powder oversprayed onto several individual powder collection units associated with a powder spray booth. Collecting the body coating material, transferring the collected oversprayed powder coating material sequentially from the powder collection unit to a common header pipe, and transferring the oversprayed powder coating material to the header / powder. Transferring from a pipe to one of the primary and secondary hoppers. 91. The step of sequentially transferring the collected oversprayed powder coating material comprises sequentially opening a gate valve carried in a connector line extending between each of the powder collection units and a common header pipe. 90. The method of claim 90, comprising: 92. The step of transporting the excessively sprayed powder coating material from the powder collection and recovery system under negative pressure includes the step of transporting the excessively sprayed powder coating material to a regeneration hopper separated from the primary hopper. 90. The method of claim 89 comprising. 93. The step of transporting the powder coating material from the first and second supply hoppers includes transporting the unused powder coating material supplied by the primary hopper to a powder spraying device and regenerating the second powder hopper by a regeneration hopper. 93. The method of claim 92, comprising transporting the oversprayed powder coating material supplied to the supply hopper to a powder spraying device. 94. A method in which a powder coating material is applied to an object moving through a powder spray booth. The powder coating material is applied under a negative pressure from a primary hopper to a supply hopper located near the powder spray booth. Transferring the powder coating material from the supply hopper to at least one powder spraying device associated with the powder spray booth; monitoring the powder coating material in the supply hopper; Transporting additional powder coating material from the primary hopper to the supply hopper whenever the amount of powder coating material in the supply hopper falls below a predetermined level. 95. The step of monitoring the weight of the powder coating material in the feed hopper includes monitoring a signal generated by a load cell supporting the feed hopper, the signal representing the weight of the powder coating material, and responsive to the signal, 95. The method of claim 94, comprising invoking the powder coating material under negative pressure to a feed hopper. 96. 95. The method of claim 94, further comprising transporting the powder coating material from a source to a primary hopper. 97. The step of transferring the powder coating material from the supply source comprises: a step of monitoring the weight of the powder coating material in the primary hopper; and a case in which the weight of the powder coating material in the primary hopper falls below a predetermined level. Always transporting additional powder coating material from the source to the primary hopper. 98. A method of applying a powder coating material to an object moving through a powder spray booth, in which unused powder coating material is transferred from a primary hopper to a first supply hopper located near the powder spray booth. And transferring the oversprayed powder coating material from a powder collection and collection system associated with the powder spray booth to a regeneration hopper located far from the powder spray booth. Transporting the powder coating material excessively sprayed from the regenerating hopper to a second supply hopper located near the powder spray booth under negative pressure; Conveying unused powder coating material from the supply hopper and oversprayed powder coating material from the second supply hopper to a separate powder spraying device associated with a powder spray booth. Stages and the first Monitor the weight of unused powder coating material in the hopper and, whenever the weight of unused powder coating material in the first feed hopper falls below a predetermined level, add additional unused powder coating material. Is transferred from the primary hopper to the first supply hopper, the weight of the excessively sprayed powder coating material in the second supply hopper is monitored, and the weight of the excessively sprayed powder coating material in the second supply hopper is Transferring the additional oversprayed powder coating material from the regeneration hopper to the second supply hopper whenever the weight falls below a predetermined level. 99. 100. The method of claim 98, further comprising monitoring the weight of the oversprayed powder coating material in the regeneration hopper. 100. The above step of monitoring the weight of the oversprayed powder coating material in the reclaim hopper further requires the use of unused powder coating material if sufficient overspray coating material is not available from the powder collection booth powder collection system. 100. The method of claim 99, comprising transferring the powder coating material from a primary hopper to a regenerating hopper. 101. A method of collecting and collecting excessively sprayed powder coating material from the powder spray booth, generating a negative pressure in the room of the powder spray booth, and removing the powder coating material mixed with air into the booth. Sucking from the room into several individual powder collection units located below the floor of the powder spray booth, and overspraying powder coating material from the powder collection unit onto a common header pipe And transferring the oversprayed powder coating material from the common header pipe to the hopper under negative pressure. 102. The step of creating a negative pressure in the chamber of the powder spray booth comprises activating a number of individual blower units associated with at least one powder collection unit, each blower unit having an associated blower unit. 102. The method of claim 101, operative to create a negative pressure within the powder collection unit and the booth chamber. 103. The step of sequentially transferring the collected oversprayed powder coating material from the powder collecting unit is carried in respective connector lines extending between one of the powder collecting units and a common header pipe. 102. The method of claim 101, comprising sequentially opening the gate valves. 104. A method of applying granular powder coating material to an object moving through a powder spray booth, wherein unused powder coating material is powdered from one or more coating dispensers in communication with a powder supply. Discharging to a moving object through a body spray booth, and transferring excessively sprayed particulate powder coating material that does not adhere to the object in the spray booth from the powder spray booth to a regenerating hopper. Directing the unused particulate powder material from the powder source and the oversprayed particulate powder material from the regenerating hopper to a mixing hopper; and a selected minimum size in the mixing hopper. Unused granular powder coating material introduced into the mixing hopper and excessively sprayed granular powder coating material so that the volume of the powder particles below the predetermined value does not exceed a predetermined percentage of the total volume of the granular powder coating material. And the proportion Controlling. 105. Measuring the particle size distribution of the granular powder coating material in the mixing hopper; measuring the volume percentage of powder particles smaller than the selected minimum particle size; and 105. The method of claim 104, comprising comparing the percentage to a desired percentage, and adjusting the supply of the virgin particulate powder material directed to the mixing hopper in response to the comparison. 106. The step of regulating the supply of unused granular powder coating material further comprises: (a) comparing the actual amount of granular powder coating material in the mixing hopper with the total volume of the mixing hopper; (B) comparing the available volume in the mixing hopper with the desired amount of unused particulate powder material to be added to the mixing hopper; Adding an amount of unused granular powder coating material to the mixing hopper; and (d) if the volume available in the mixing hopper is less than the desired amount of unused granular powder coating material to be added. Removing the particulate powder coating material from the mixing hopper before performing step (c). 107. Measuring the particle size distribution of the unused powder coating material by supplying a mixture of the unused powder coating material and the reclaimed powder coating material to at least one coating dispenser; Measuring the particle size distribution of the collected reclaimed powder coating material after first applying the material to a given part; and calculating a probability coefficient for each particle size range within the particle size distribution; Each of the probability coefficients represents a probability that particles in an individual particle size range are collected as a reclaimed powder material after a painting operation. Calculating the particle size distribution of the mixture with the percentage of virgin powder coating material. 108. Calculating the probability coefficient for each particle size range includes: (i) ΔFv / Fr = 1, (Iii) P = F _A Including the step of performing the following calculation: (1−normalized ΔFv / Fr) x, where Fv = measured value of particle size distribution of unused powder coating material, Fr = particles of one-pass recycled powder coating material A measure of the size distribution, P = probability coefficient, F _A 108. The method of claim 107, wherein x is an integer representing the total number of particle size ranges in the particle size distribution. 109. The step of calculating the probability coefficient for each particle size range further includes the step of calculating the product of the particle size distribution measurement value Fv of the unused powder coating material and the probability coefficient P to obtain the particle size distribution measurement value Fr of the recycled powder coating material. So that the numerical adjustment coefficient F is substantially equal to _A 109. The method of claim 108, comprising determining empirically. 110. Calculating the particle size distribution of the mixture of the reclaimed powder coating material and a selected fraction of unused powder coating material comprises: (i) Fr _{i + n} y = (1-y) Fr _{i + 1} + YFv, where y = volume fraction of the unused powder coating material added to the reclaimed powder coating material, and i = the pass starting at the unused powder coating material as a starting point. The exponent of the number, Fr _{i + n} 109. The method of claim 108, wherein y = the particle size distribution of the mixture of reclaimed and unused powder coating material after a total of i + 1 passes or painting operations.