Note: Descriptions are shown in the official language in which they were submitted.
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A HIGH SPEED ROTATING ATOMIZER ASSEMBLY
[00011 This application claims priority to the application for United States
Patent No,
7,721,976, which is a continuation in part application of the application for
United States
Patent No. 7,131,601, issued November 7, 2006, said application having been
filed on
December 17, 2003, and the application for United States Patent No. 7,036,750,
issued May
2, 2006, said application having been filed on July 22, 2002.
FIELD OF THE INVENTION
[0002] This invention relates to a bearing unit of a rotating atomizer for
driving a bell cup
coupled to the turbine device for coating a part.
BACKGROUND OF THE INVENTION
[0003] A production paint application process where paint is applied to a
substrate, such as, for
example a vehicle body moving through a paint booth, requires paint to be
transferred from a
paint reservoir to a paint applicator robot disposed in the paint booth, where
paint is applied by a
rotary atomizer as an integral part of the paint applicator robot. Typically,
the rotary atomizer
includes a turbine device disposed in a housing, a rotating bell unit having a
shaft connected to a
bell cup and disposed in and rotatable relative to the turbine device and the
housing. The bell
cup has a generally conical overflow surface between a radially inward central
axial opening and
a radially outward atomizing edge. At or near the radially outward atomizing
edge, the angle of
the overflow surface relative to the axis of the bell cup decreases sharply to
form a lip adjacent
the atomizing edge. The purpose of this lip is to generally direct the
atomized paint more axially
forward and reduce radial scatter. Typically, an air shaping ring is attached
to the turbine device
to improve distribution of the paint onto the vehicle body being painted.
[0004] The art is replete with prior art designs of an air shaping rings for a
rotary atomizer. The
United States Patent Nos. 5,775,598 to Takayama et al.; 5,727,735 to Baumann
et al.; 6,189,804
and 6,623,561 both to Vetter et al..; and the United States Patent Publication
Nos. 2005/0001077
and 2003/0010840 both to Kon et al. The United States Patent Publication No.
2005/0001077 to
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Kon et al., for example, teaches a rotary atomizer having a housing, a turbine
device disposed in
the housing, a bell unit disposed in and rotatable relative the turbine
device. An air shaping ring
is disposed about the turbine device and is connected to the housing by a
partially threaded
fastener extending to a hook to interconnect the air shaping ring with the
housing. This design is
complex and requires additional component, such as the aforementioned fastener
to interconnect
the housing with the air shaping ring.
[0005] The United States Patent No. 6,623,561 to Vetter et al., on the other
hand, teaches a
rotary atomizer having a housing, a turbine device disposed in the housing, a
bell unit disposed
in and rotatable relative the turbine device. An air shaping ring is disposed
about the turbine
device and between the turbine device and the housing. The air shaping ring of
the United
States Patent No. 6,623,561 to Vetter et al. does not require additional
components, such as, for
example, partially threaded fastener extending to a hook, taught by the United
States Patent
Publication No. 2005/0001077 to Kon et al. to interconnect the air shaping
ring with the
housing. Hence, the air shaping ring and the turbine device taught by the
United States Patent
No. 6,623,561 to Vetter et al. do not provide for constant surface to surface
contact between the
air shaping ring and the turbine device. In addition, none of the prior art
patents teaches an
improved design of the atomizer having improved rigidly stabilized connection
between the
turbine device and the housing for maintaining a fixed air gap between the
shaft and a paint pipe
or line extending through the shaft for keeping the shaft at a fixed distance
relative to the paint
line as the shaft rotates around the axis.
[0006] The goal of the invention is therefore to provide an improved design of
the turbine
device to eliminate at least one of the aforementioned problems associated
with prior art
atomizers.
SUMMARY OF THE INVENTION
[0007] An atomizer assembly of the present invention fluidly communicates with
a fluid source
to coat a part, such as, for example, a body of an automotive vehicle. The
atomizer assembly
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includes a housing having at least one fluid line, i.e. paint line connected
to the housing and
extending therethrough, a turbine device having terminal ends and surrounding
an axis and
disposed in the housing. An atomizing bell unit has a shaft and an atomizing
bell connected to
the shaft and is fluidly communicated with the paint line for applying the
paint to the body of the
automotive vehicle. The atomizing bell unit is disposed in the turbine device
surrounding the
axis and rotatable around the axis and relative the turbine device. The
atomizer bell unit
presents terminal ends with one terminal end exposed to the fluid source and
the other terminal
exposed to the body of the automotive vehicle being coated.
[0008] The turbine device includes an annular wall extending outwardly from
one of the
terminal ends of the turbine device. The annular wall circumscribes the
atomizing bell unit.
The annular wall and the terminal end of the bearing define a seat for
engaging the housing to
provide a rigidly stabilized connection between the turbine device and the
housing thereby
maintaining a fixed annular gap between the shaft and the paint line extending
through the shaft
of the atomizing bell unit at a fixed distance relative to the paint line as
the shaft rotates around
the axis. A potential member is disposed around the bearing at the atomizing
bell for
concentrating the paint particles as the paint is applied to the body of the
automotive vehicle. A
biasing device is disposed in the turbine device for interconnecting the
turbine device and the
potential member for improved path of continuity and for providing constant
surface to surface
contact between the turbine device and the potential member as the fluid is
applied to the part.
[0009] An advantage of the present invention is to provide an annular wall
that extends
outwardly from the turbine device defining a seat for engaging the housing
thereby forming a
rigidly stabilized connection between the turbine device and the housing,
which have proven to
maintain a fixed gap between the shaft of the rotational bell unit and the
paint line for keeping
the shaft at a fixed distance relative to the paint line to prevent contact
between the paint line and
the shaft.
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[0010] Another advantage of the present invention is to provide the turbine
device having an
improved surface-to-surface contacts between the potential member and the
turbine device to
improve ionization of the atomized fluid particles.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Other advantages of the present invention will be readily appreciated
as the same
becomes better understood by reference to the following detailed description
when considered in
connection with the accompanying drawings wherein:
[0012] Figure 1 illustrates a rotating atomizer on a robotic arm positioned
next to a vehicle body
in a paint shop;
[0013] Figure 2 is a cross sectional view of a turbine device installed in a
turbine housing;
[0014] Figure 3 is a perspective and exploded view of the turbine device shown
in Figure 2;
[0015] Figure 4 is a perspective and exploded view of the turbine device;
[0016] Figure 5 is a cross sectional view of a neck portion of the turbine
device;
[0017] Figure 6 is an end view of one of the ring plates of the housing of the
turbine device
illustrating a brake nozzle and at least two inlets;
100181 Figure 7 is a cross sectional and fragmental view of a biasing device
disposed in the
housing of the turbine device; and
[0019] Figure 8 is a cross sectional and fragmental view of the biasing device
of Figure 7 shown
in compressed mode and biased against an air shaping ring to provide surface-
to-surface contact.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] Referring to the Figures 1 and 2, wherein like numerals indicate like
or corresponding
parts, an inventive atomizer assembly is generally shown at 10. A paint
circulation system (not
shown) supplies paint to a paint booth 12 where the paint is applied to a
production part, such as,
for example, a vehicle body 14. In a typical automobile assembly plant the
vehicle body 14 is
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transported through the paint spray booth 12 by conveying equipment 16 where
the paint is
applied to the vehicle body 14 and subsequently cured in a paint oven (not
shown) as is known
to those skilled in the art. The paint is applied by automated application
equipment, such as a
robotic device 18 that includes the atomizer assembly 10 that is connected to
an arm 20 of the
robotic device 18. Alternatively, the atomizer assembly 10 is operably
connected to an overhead
or side reciprocator (not shown).
C00211 Referring to Figures 2 through 4, the atomizer assembly 10 includes a
housing, generally
indicated at 22 in Figure 2, having a curved configuration. The housing 22 is
defined by a
plurality of detachable components with one of these components, ie. core
member 24, as
shown in Figure 2, surrounding an axis A. The core member 24 is disposed in
the housing for
engaging at least one paint delivery line or a feed unit 26 fluidly
communicated with a paint
source (not shown). The core member 24 presents in interior surface 28 defined
between
annular side wall 30 of the core member 24. A turbine device, generally shown
at 40, is the
actual drive element of the high speed atomizer assembly 10 and is disposed in
the core member
24.
[0022] As best shown in Figure 3 and 4, the turbine device 40 include a front
plate 42, a neck
portion, generally indicated at 44, and defining a tubular body 46 and a base
plate 48 having a
diameter larger than a diameter of the tubular body 46. The turbine device 40
includes a pair of
core plates 50, 52 disposed between the front plate 42 and the neck portion
44. The core plates
50 and 52 and the base plate 48 form a chamber, partially shown at 54 in
Figure 5, An annular
intermediate chamber 56 is defined by a cavity formed in one of the plates 50
and covered by the
other plate 52 to form the annular intermediate chamber 56. A first inlet 58
is defined in the
annular intermediate chamber 56 for delivering fluid, such as, for example gas
or air, into the
annular intermediate chamber 56 from a fluid source (not shown). The turbine
device 40 defines
a proximal end 59 and a distal end 60, At least one second inlet 61 is defined
in the annular
intermediate chamber 56 for delivering fluid into the annular intermediate
chamber 56 thereby
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increasing amount of fluid in the annular intermediate chamber 56 to increase
a rotational speed
of an atomizing bell unit, generally indicated at 62 and best shown in Figures
3 and 4. The
atomizing bell unit 62 will be described in great details as the description
of the present
invention proceeds. The atomizing bell unit 62 is rotated as increased amount
of fluid is
introduced thereto through a plurality of nozzles, such as, for example
Lavalle nozzles 64, 66,
and 68 defined in the core plate 52 as best shown in Figure 6.
[0023] The nozzles 64 through 68 are exposed from the annular intermediate
chamber 56 and
are asymmetrically disposed relative the axis A. The nozzles 64 through 68 are
angularly and
vortecaly spaced relative to the axis A for rotating the atomizing bell unit
62. Preferably, one of
the nozzles 64 through 68 is defined between the first inlet 58 and the second
inlet 61 defined in
the core plate 52. The nozzles 64 through 68 drive fluid in unison from the
annular intermediate
chamber 56 for facilitating uniformed application of fluid onto the atomizing
bell unit 62.
Preferably, the nozzles 64 through 68 are oriented in the circumferential
direction over an angle
range of approximately 130 , relative to the axis A.
[0024] Alluding to the above, the first inlet 58 and the second inlet 61
discharge fluids axially
into the intermediate annular chamber 56. Preferably, the first and second
inlets 58 and 61
present a circular cross-section with a diameter of 5 mm. The first inlet 58
and the second inlet
61 are exposed to the intermediate chamber 56 to discharge fluid from the
intermediate chamber
56. As shown in Figure 6, the first and second inlets 58 and 61 are located in
the upper half of
the annular intermediate chamber 56, as best shown in Figure 6. A brake nozzle
69 is defined in
the core plate 52 for driving fluid onto the atomizer bell unit 62 in a
direction reverse to the
angular direction of fluid driven through the nozzles 64 through 68 thereby
decreasing a
rotational speed of the atomizer bell unit 62.
[0025] As best shown in Figure 4, the front plate 42 includes connections for
bearing air 80, a
connection port for breaking air 84, a pair of connection ports for turbine
air or turbine air ducts
86, 88, and a connection port for shaping air 90. The aforementioned
connection ports 80
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through 90 are independently or separately connected to the fluid source. The
turbine air ducts
86, 88, which are independent connected to another fluid source (not shown),
supply
compressed air to a turbine wheel 102 of the atomizing bell unit 62 for
driving a shaft 104
connected to the wheel 102. By using two ducts 86, 88 for the turbine air, the
performance of
the turbine device 40 is improved and more precisely controlled.
10026] The aforementioned connection ports 80 through 90 are radially spaced
around a
stabilizing member defined by an annular wall 94. The annular wall 94 extends
outwardly from
the proximal end 59 of the turbine device 40 circumscribing the atomizing bell
unit 62 to define =
a seat, generally indicated at 96 in Figure 2, for engaging the core member 24
to form a rigidly
stabilized connection between the turbine device 40 and the core member 24.
The annular wall
94 includes a plurality of air exhaust apertures 98 radially defined in the
annular wall 94 and at
least one cut-out portion 100 defined therein.
[0027] As best illustrated in Figures 3 and 4, the shaft 104 of the atomizing
bell unit 62 holds
and drives an atomizing bell or bell cup 108 disposed at one of the
extremities 112 of the shaft
104. The aforementioned turbine wheel 102 is rigidly connected to and
cireumscribes the shaft
104 at another extremity 114 of the shaft 104. A plurality of U-shaped out out
portions 115 are
defined at the extremity 114 of the shaft 104. Each U-shaped cut out portion
115 is aligned with
the cut out portion 100 defined in the annular wall 94 to receive a fastener
117 extending
through the housing 22 to prevent rotational movement of the shaft 104 during
cleaning of the
turbine device 40. The shaft 104 is hollow to receive the paint line 26 guided
therethrough and
exposed through the bell cup 108 to the body of the automotive vehicle. The
shaft 104 includes
an annular groove 109 defined therein to form an air bearing. Preferably, the
annular groove
109 is exposed to an air channel 119 defined in the neck portion 44 to receive
the bearing air and
to drive the bearing air to the annular groove 109 thereby distributing the
bearing air evenly
along the shaft 104 to improve alignment of the axial rotation of the shaft
104.
7
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[0028] The rigidly stabilized connection defined between the turbine device 40
and the core
member 24 maintains a fixed gap between the paint line 26 and the shaft 104 of
the atomizing
bell unit thereby keeping the shaft 104 at a fixed distance relative to the
paint line 26 as the shaft
104 rotates about the axis A, as best shown in Figure 2. This fixed gap
prevents contact between
the paint line 26 and the shaft 106 and reduces chances of wear and tear of
the paint line 26 by ,
the shaft 104 rotatable at a high speed. The shaft 104 is driven by the
turbine air.
[0029] A reflector disk, generally indicated at 116, is attached to the
turbine wheel 102 to
monitor the rotational speed of the bell cup 108, The speed of the bell cup
108 presents an
important parameter for atomization of the paint. The speed of the bell cup
108 is measured at
the turbine device 40 through the use of the aforementioned reflector disk
116, a fiber-optic
cable (not shown), and an opto-electronic converter (not shown), The reflector
disk 116 has four
reflective surfaces 122 through 128 and four alternating blackened surfaces
136.
This configuration provides for four light pulses being reflected back to the
fiber-optic cable
with each rotation of the shaft 104. The opto-electronic converter changes
these pulses of light
into electric signals which are processed by a speed transducer (not shown).
The speed
transducer compares the current speed of the shaft 104 with the present value
by means of the
signals and regulates the supply of the turbine air accordingly.
[0030] A plurality of blades 130 are connected to and extend outwardly and
axially from the
turbine wheel 102 to receive bearing air. Each turbine blade 130 is curved, as
shown in Figure
3. Alternatively, (not shown), each turbine blade 130 is non-curved and
radially extends from
the axis A. A second wheel 132 has a frostoconical configuration and is
connected to the shaft
104 below the turbine blades 130. The second wheel 132 includes a vortexly
shaped outer
surface 134 which produces air turbulence as the shaft 104 is rotated about
the axis,
100311
A potential member, such as, for example, an air shaping ring 140 provides
a source
of direct atomization of the atomized paint particles. The air shaping ring
140 is disposed
around one of the terminal ends 118 at the neck portion 44 of turbine device
40 about the bell
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cup 108. The air shaping ring 140 is blown to those skilled in the art and is
designed for
concentrating the paint as the paint is applied to the body 14 of the
automotive vehicle by
injecting air from annular channels 141 defined in the neck portion 44 air to
the bell cap 108
through annular apertures 143. To improve contact between the neck portion 44
and the air
shaping ring 140, a biasing device, generally indicated at 150, is disposed in
the neck portion 44
of the turbine device 40 to interconnect the turbine device 40 with the air
shaping ring 140 to
improve path of continuity and for providing constant surface to surface
contact between the
turbine device 40 and the air shaping ring 140. In alternative embodiment of
the present
invention, the potential member is defined by a source of indirect
atomization, such as, for
example, a plurality of electrostatic probes (not shown).
=
[0032] The biasing device 150 is disposed in a cavity 152 defined in the neck
portion 44. The
biasing device 150 includes a tubular housing 154, a ball 156, and a spring
158 extending from
the cavity 152 to the ball 156 for forcing the ball 156 away from the tabular
housing 154 as the
air shaping ring 140 is disposed about the neck portion 44 of the turbine
device 40.
[0033] The atomizer assembly 10 presents an air tight enclosure. To preserve
the air inside the
atomizer assembly 10 a cover 180 is mechanically connected with the annular
wall 30 of the
core member 24 extending between the core member 24 and the air shaping ring
140. The
turbine device 40 includes a plurality of 0-rings 160 disposed respective
annular grooves 162.
To keep the front plate 42, the neck portion 44, the base plate 48, the core
plates 50, 52 at least
one centering pin 166 and a pair screw 168 extend through the front plate 423
the neck portion
44, the base plate 48, the core plates 50, 52 to hold the front plate 42, the
neck portion 44, the
base plate 48, the core plates 50, 52 together.
10034] While the invention has been described with reference to an exemplary
embodiment, it
will be understood by those skilled in the art that various changes may be
made and equivalents
may be substituted for elements thereof without departing from the scope of
the invention. In
addition, many modifications may be made to adapt a particular situation or
material to the
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teachings of the invention without departing from the essential scope thereof.
Therefore, it is
intended that the invention not be limited to the particular embodiment
disclosed as the best
mode contemplated for carrying out this invention, but that the invention will
include all
embodiments falling within the scope of the appended claims.
Atty. Docket No. 60,126-276
