Manufacturing method and facility for coating vehicle structural components

Abstract: A manufacturing facility (20) has substantially reduced space requirements for applying a coating to vehicle structural components such as frames (22, 24). A rotary carousel (28) in a building (26) has a central hub (30) rotatable about a vertical axis and has one or more arms (32) thereon swingable about pivot points (60) on the hub to lower and raise the frames. A loading station (36), preheat wash station (46), rinse station (48), coating station (38), post heat drip station (50) and unloading station (44) are peripherally spaced around the hub such that rotation of the hub moves the arms between the stations for respective functions.

Description: The present invention relates to manufacturing methods and facilities for applying a coating to vehicle structural components, including the application of a hot melt wax coating to vehicle frames for protection against rust and corrosion. The present invention arose during development efforts directed toward reducing the high capital expense of a manufacturing facility for coating vehicle structural components such as frames. Vehicle manufacturers are more commonly requiring vendors and parts suppliers to have local on-site manufacturing or processing facilities coordinating with the assembly operation of the vehicle manufacturer. In the case of suppliers providing vehicle structural components such as frames, this requires erection of a coating facility at each of the various satellite assembly facilities. However, erection of multiple satellite coating facilities is not cost effective due to the extremely high capital expense of same. A vehicle frame is a generally flat longitudinal structural member which in one exemplary size has a longitudinal length of about 4.52 m (178 inches), a lateral width of about 1.07 m (42 inches), and a height of about 0.41 m (16 inches), though the dimensions may of course vary. Prior facilities for applying a hot melt wax coating to such frames typically require buildings of about 56000 m³ (2 million cubic feet), with 4650 m² (50,000 square feet) of lateral area and over 18.3 m (60 feet) in height. The frames are hung vertically and transported to a dipping tank and dipped downwardly into the tank for coating the frame in the hot melt wax liquid, and then raised out of the tank. Hence, the building must be at least twice as high as the longitudinal length of the frame. The tank volume is about 286400 l (63,000 gallons). The building is heated by ovens or the like such that the heated air in the building preheats the frames prior to dipping, to enhance the coating during the dip into the hot melt wax liquid tank (see for example FR-A-2 603 211). Preheating of the frames with air is inefficient and requires long preheat times. The vertical hanging of the frames also requires large openings into and out of the building, causing significant heat loss and energy inefficiency. The construction cost of the building is high because of its special requirements. Furthermore, the building has no other use. US-A-4560592 discloses a manufacturing facility for applying a coating to, for example, refrigeration unit components, by dipping the components in a tank of coating material. The present invention addresses and solves the above noted problems with a simple and effective manufacturing method and facility. The invention reduces the building volume by a factor of 10 or more, eg the new building can be reduced to as little as 5% of the volume of the prior building. The invention also reduces the tank volume requirements for the coating liquid to as little as 4%, eg to as low as 9100 l (2,000 gallons) instead of the 286400 l (63,000 gallons) required for the above noted prior tank. This saves wax cost. The invention also significantly reduces the height requirement of the tank, eg from about 7.63 m (25 feet) deep to about 0.64 m (25 inches) deep. This desirably solves problems of hydrostatic fluid pressure and leakage caused thereby at the bottom of the tank. The construction cost of the building is reduced by a factor of about 10 due to the reduced special requirements of the building and also due to reduced loading capability of the building due to special transport structure within the building in accordance with the invention for carrying the vehicle structural components. The building is adaptable to other uses in the event of changing requirements. The transport mechanism and core within the building can be moved to other buildings and locations. According to a first aspect of the invention there is provided a manufacturing method for preheating and applying a coating to vehicle structural components, comprising: providing a transport mechanism; providing a loading station; providing a preheat station having a preheat liquid at an elevated temperature; providing a coating station having a coating liquid at an elevated temperature; providing an unloading station; attaching said vehicle structural component to said transport mechanism at said loading station; transporting said vehicle structural component to said preheat station, and moving said vehicle structural component into and out of contact with said preheat liquid to provide liquid heat transfer to said vehicle structural component; transporting said vehicle structural component to said coating station, and moving said vehicle structural component into and out of contact with said coating liquid to coat said vehicle structural component; transporting said vehicle structural component to said unloading station and detaching said vehicle structural component from said transport mechanism. In accordance with a second aspect of the invention there is provided a manufacturing facility for preheating and applying a coating to vehicle structural components, comprising a movable transport mechanism, a loading station for attaching said vehicle structural component to said transport mechanism, a preheat station comprising a preheat liquid at an elevated temperature, said transport mechanism moving said vehicle structural component through said preheat station into and out of contact with said preheat liquid to provide liquid heat transfer to said vehicle structural component, a coating station comprising a coating liquid at an elevated temperature, said transport mechanism moving said vehicle structural component through said coating station into and out of contact with said coating liquid to coat said vehicle structural component and an unloading station for detaching said vehicle structural component from said transport mechanism. The invention will further be described, by way of example, with reference to the accompanying drawings, in which: FIG. 1 is a top view of a manufacturing facility constructed in accordance with an embodiment of the invention. FIG. 2 is a sectional view taken along line 2-2 of FIG. 1. FIG. 3 is an enlarged top view of a portion of the structure in FIG. 1. FIG. 4 is a side view of the structure in FIG. 3. FIG. 5 is a sectional view taken along line 5-5 of FIG. 4. FIG. 6 is an enlarged view of a portion of the structure in FIG. 4. FIG. 7 is a perspective view of the structure of FIG. 6. FIG. 8 is an enlarged view of a portion of the structure in FIG. 4. FIG. 9 is an end view of the structure in FIG. 8. FIG. 10 is a perspective view of the structure in FIG. 8. FIG. 11 is a sectional view taken along line 11-11 of FIG. 4. FIG. 12 is a sectional view taken along line 12-12 of FIG. 1. FIG. 13 is a top view of an alternate embodiment of a manufacturing facility constructed in accordance with the invention. FIG. 14 is a sectional view taken along line 14-14 of FIG. 13. FIG. 15 is a sectional view taken along line 15-15 of FIG. 13. FIG. 16 is a sectional view taken along line 16-16 of FIG. 13. FIG. 17 is a sectional view taken along line 17-17 of FIG. 13. FIG. 18 is a top view of another embodiment of a manufacturing facility constructed in accordance with the invention. FIG. 19 is a top view of another embodiment of a manufacturing facility constructed in accordance with the invention. FIG. 1 shows a manufacturing facility 20 with substantially reduced space requirements for applying a coating to vehicle structural components such as frames 22, 24, and the like. The facility includes a building 26 housing a central rotary carousel 28 having a central hub 30 rotatable about a vertical axis and having a plurality of arms 32, 34, etc. thereon. Building 26 also houses a loading station 36, a coating station 38 having coating liquid 40 in tank 42, and an unloading station 44, all spaced peripherally around hub 30 such that rotation of hub 30 moves the arms to the various stations. Building 26 also houses a preheat wash station 46, a rinse station 48, and a post heat drip station 50. Preheat wash station 46 includes a tank 52 with a wash liquid 54 at an elevated temperature. Rinse station 48 includes a tank 56 with a rinse liquid 58 at an elevated temperature. The preheat wash and rinse stations preheat the frame by liquid heat transfer, to enhance the hot melt wax coating at station 38 when the frame is dipped into the hot melt wax coating liquid 40, to be described. Counterclockwise rotation of hub 30 moves arm 32 to loading station 36 as shown in FIG. 1, for attaching frame 22 to arm 32, to be described. Further counterclockwise rotation of hub 30 moves arm 32 to preheat wash station 46, and then to rinse station 48, and then to coating station 38, and then to post heat drip station 50, and then to unloading station 44 for detaching frame 44 from the arm. Arm 32 moves downwardly, FIG. 2, at loading station 36 to engage frame 22 and then moves upwardly to lift the frame and carry the frame during rotation of hub 30. The arm moves downwardly at each of stations 46, 48 and 38 to lower the frame into the liquid in the respective tank, and then moves upwardly to raise the frame out of such liquid in the respective tank. The arm moves downwardly at unloading station 44 to disengage the frame and then moves upwardly and rotates to loading station 36, to begin the next cycle. Arm 32 swings in an arc about pivot point 60 at hub 30, and is actuated between its upwardly raised position as shown in phantom line and its downwardly lowered position as shown in solid line by a hydraulic cylinder 62, or alternatively is pneumatically actuated, or is raised and lowered by a cable, chain, or the like. Frame 22 at loading station 36 is attached in a generally horizontal position to arm 32. The frame is likewise detached in a generally horizontal position from the arm at unloading station 44. The frame is lowered by the arm into the respective tanks at stations 46, 48 and 38 in a generally horizontal position in the respective tank. The horizontal loading, dipped and unloading positions of the frame are all substantially coplanar. Frame 22 has a longitudinal extent of a given length. As seen in FIG. 2, building 26 has a height to roof 64 substantially less than twice the length of frame 22. The transport mechanism provided by carousel 28 moves frame 22 through stations 36, 46, 48, 38 and 44 such that the longitudinal extent of frame 22 is substantially horizontal. The raising and lowering of frame 22 into and out of the tanks at stations 46, 48 and 38 defines a travel path having a vertical height substantially less than twice the length of the frame. Building 26 has a sidewall 66 with an entrance opening 68 therethrough, FIGS. 1, 2 and 11, at loading station 36, and an exit opening 70 therethrough at unloading station 44. Frame 22 is passed longitudinally through such openings in a generally horizontal position into and out of building 26, such that openings 68 and 70 have minimum dimensions, to minimize heat loss from the building. At drip station 50, uncoated excess liquid is allowed to drip from the frame. Additionally or alternatively, uncoated excess liquid is allowed to drip from the frame above tank 42 at coating station 38. The amount of pivoting of the transport arm varies the tilt angle, to provide an adjustable drip angle of the frame. This is particularly desirable because it enables a selectively chosen drip angle, which in some instances may be vertical, or in other instances at a diagonal angle relative to horizontal. The latter is preferred to prevent drips from one of the lateral cross pieces of the frame from dripping onto another lateral cross piece therebelow. The pivoted transport arm thus moves the frame through the coating station into and out of contact with the coating liquid and raises the frame after such coating to a tilted position such that the longitudinal extent of the frame is tilted at an angle relative to horizontal. Hands 72, 74, 76, 78, FIGS. 3 and 4, extend from arm 32 and have fingers 80, 82, 84, 86, 88, 90, 92, 94 engaging frame 22. Frame 22 is attached to the fingers at loading station 36. A conveyance mechanism provided by continuous belt conveyor 96 carries frame 22 longitudinally horizontally through flexible hanging leaves 98 at opening 68 in building wall 66 to loading station 36. Conveyor 96 carries frame 22 rightwardly, FIGS. 1-4, to a first position. Arm 32 is swung downwardly, with at least some of the noted fingers moving downwardly past and below frame 22. Conveyor 96 then carries frame 22 further rightwardly, advancing frame 22 to a second position above the last mentioned fingers, such that upon swinging arm 32 upwardly, such last mentioned fingers engage the underside of frame 22 and lift same. Frame 22 is a generally flat planar member having a pair of longitudinal sides 100 and 102, FIG. 3, and a plurality of lateral cross pieces such as 104, 106, 108, 110, 112. Fingers 80 and 84 engage the underside of cross piece 104. Fingers 82 and 86 engage the underside of longitudinal sides 100 and 102, respectively. Fingers 88 and 92 engage the underside of cross piece 112. Fingers 90 and 94 engage the top side of longitudinal sides 100 and 102, respectively. The noted engagement locates the longitudinal sides of the frame and the respective cross pieces of the frame, to precisely locate the frame both longitudinally and laterally. The fingers are formed with a knife edge laterally crossing the respective portion of the frame, for example as shown at knife edges 114 and 116 for respective fingers 80 and 82 in FIGS. 6 and 7, and knife edges 118 and 120 for respective fingers 88 and 90 in FIGS. 8-10. The lower fingers 80, 84, 88, 92 are slightly angled, such that when arm 32 is in the lowered position, the lower fingers tilt upwardly leftwardly and engage only an edge of the frame to provide only point contact therewith, to enhance the coating of the frame. The lateral lower fingers 82 and 86 and the lateral upper fingers 90 and 94 extend laterally across the longitudinal sides of the frame and are likewise angled, as shown in FIGS. 7 for finger 82, and in FIGS. 9 and 10 for finger 90, to also provide only point contact with the frame, to enhance coating of the frame. The noted lower longitudinal fingers are tilted sufficiently relative to the respective hands such that arm 32 may be lowered to a position slightly beyond horizontal, FIG. 4, and the lower fingers will still engage and lift frame 22. In a further embodiment, finger 90 has an upwardly extending portion 121 facilitating stacking of frames. In this latter embodiment, two or more frames are carried on carousel arm 32, such that two or more frames are dipped during each dipping step, etc. In this embodiment, edge 120 does not engage the top of the frame therebelow, but rather locates the siderails of the frame outboard thereof, and edge 121 is spaced slightly inwardly of the frame siderail. Stationary V-shaped structure 122, FIG. 11, is provided at loading station 36 and spaced above conveyor 96 and is engaged by arm 32 during downward swinging of the arm to guide and locate the arm relative to conveyor 96 and frame 22. Conveyor 96 has a plurality of cones 124, 126, 128, 130, etc., thereon, with angled bevel surfaces forming knife edges such as 132, FIGS. 3 and 5, which extend along a diagonal angle to provide point contact with the frame. Some of the cones such as cones 126 and 130 engage the longitudinal sides of the frame, and others of the cones such as cones 124 and 128 engage lateral cross pieces of the frame. The cones space the frame above conveyor 96 and precisely locate the frame both longitudinally and laterally. In an alternate embodiment, the frame has a plurality of holes in the underside thereof, and conveyor 96 has a plurality of cones extending upwardly partially through such holes and spacing the frame above the conveyor and precisely locating the frame both longitudinally and laterally. Unloading at station 44 is comparable but reversed in sequence from loading at station 36. A conveyor 134 is provided like conveyor 96. The transport arm of the carousel is lowered to lower the frame onto the cones on the conveyor. The above noted knife edges and angles on the fingers provide the noted point contact with the frame and minimize marring of the coating on the frame. In most applications, there is no marring because the hot melt wax coating heals itself, which healing is facilitated by the noted point contact, which minimizes the area which must be healed by continued flow of the hot melt wax coating after disengagement of the frame by the fingers. The above noted beveled surfaces and knife edges such as 132, FIG. 5, of the cones on the conveyor and the angles thereof desirably provide only point contact with the coated frame on exit conveyor 134. After the pivot arm of the carousel is lowered such that the frame now rests on the cones on conveyor 134, the latter moves slightly to partially advance the frame to allow clearance of the lower fingers, and the pivot arm is then raised upwardly, whereafter conveyor 134 carries the frame outwardly through opening 70 of the building. Opening 70 is not provided with the hanging flexible leaves such as 98 of entrance opening 68, because such leaves would drag across and mar the coating on the frame. Instead, opening 70 is provided with a quick acting guillotine door 136, FIG. 12, actuated by pneumatic cylinder 138 to quickly move vertically upwardly and downwardly. This minimizes heat loss from the building. FIG. 13 shows a further embodiment, and like reference numerals are used from the above FIGS. where appropriate to facilitate clarity. Preheat wash and rinse stations 140 and 142 are external of building 144. Preheat wash station 140 includes a tank 146, a heater 148, a pump 150 supplying heated wash liquid to spray nozzles 152, and a return filter 154. Rinse station 142 is comparable for rinse liquid. Conveyor 96 conveys the frame horizontally longitudinally through stations 140 and 142 to provide liquid heat transfer to the frame, and then moves the frame into building 144. This movement is along the direction of the longitudinal extent of the frame. The frame is attached to pivot arm 32 as above described, and the arm swings upwardly to lift the frame from conveyor 96. Coating station 38 of FIG. 1 is replaced by a coating station 154 in FIG. 13 with a tank 156 which is substantially laterally expanded to extend along a significant portion of the inner periphery of the building around hub 30. In FIG. 13, tank 156 has a semicircular shape when viewed from above. Transport arm 32 lowers the frame into and out of tank 156, as above. Transport arm 32 also moves the frame horizontally through tank 156 in a direction transverse to the longitudinal extent of the frame. The lowering and raising of the frame into and out of the tank defines a travel path having a vertical height substantially less than twice the length of the frame, as before. A heater 158 and pump 160 are provided for heating and pumping coating liquid 162 to tank 156. Building 144 has differing heights at loading station 36 and the central portion of coating station 154. At loading station 136, the building must be high enough to allow arm 32 to pivot upwardly to lift the frame from conveyor 96. However, in the central portion of coating station 154, as shown on the right side of FIG. 14, arm 32 need only move horizontally laterally, and hence there is no need for any greater building height other than a small clearance for arm 32 above the tank. The roof of building 144 along this central portion of coating station 154 is provided by access doors 164. At the beginning of coating station 154, an increased building height is necessary as shown at roof 166 at the left side of FIG. 14, to accommodate movement of arm 32 in an upward position over tank 156 and then downward movement of arm 32 to lower the frame into tank 156. The building likewise has a higher roof at the end of coating section 154. The building thus has a first lower height at roof access door 164 over the middle of tank 156, and second higher heights as at roof 166 at the ends of the tank to permit downward and upward swinging of arm 32 to lower and raise the frame into and out of the tank. The unloading station may be provided within the building, as in FIG. 1, or an external loading station 168 may be provided with the frames remaining in a horizontal position but stacked vertically, and then periodically removed by a forklift 170 or the like. Building 144 has an external recess 169 formed in the periphery thereof at which unloading station 168 is located. In a further embodiment, a cam track is provided in the building to assist or eliminate the pivot arm actuators such as 62. FIG. 15 shows a cam track 172 extending at least partially peripherally around central hub 30. Arm 32 has a roller 174 engaging and rolling along the cam track during rotation of hub 30 such that arm 32 is lowered and raised according to the camming profile of the cam track. The cam track has a V-shape at loading station 136 such that roller 174 rides down the V to lower the arm to engage the frame. At coating station 154, the cam track may be provided by the upper lip 176 of the tank having high lobes at the beginning and the end of the tank, and having an extended low lobe along the central portion of the tank. The horizontal circumferential length of the low lobe portion of the cam surface controls the length of horizontal travel of the frame in coating liquid 162 in tank 156 during rotation of hub 30, to control coating of the frame. FIG. 18 shows another embodiment, and uses like reference numerals from the above FIGS. where appropriate to facilitate clarity. A servicing station 180 is spaced along the periphery of hub 30. Building 182 has an opening 184 at station 180. The carousel pivot arm is movable to a lowered position at servicing station 180, passing through opening 184 in building 182 externally of the building to external servicing location 180 for servicing of the transport pivot arm. The arm is movable to an upward position at servicing station 180 remaining within building 182 and bypassing external servicing location 180 and instead passing within building 182 to the next station therein upon rotation of hub 30. Building 182 has an external recess 186 formed therein at servicing station 180 providing the external location for servicing of the pivot arm. Thus, when servicing is desired, the pivot arm is swung downwardly through opening 184 to permit servicing, and then pivoted back upwardly through opening 184 when the servicing is completed. This allows servicing of the pivot arm externally of the building, which is desirable because the servicing technican can remain outside the building and not have to work in the elevated temperatures within the building. When servicing is not desired, the pivot arm merely remains in its upward pivoted position at station 180 without passing through opening 184. FIG. 19 shows another embodiment, and like reference numerals are used from the above FIGS. where appropriate to facilitate clarity. Building 188 has an increased number of stations which may provide various desired combinations of preheat washing, rinsing, coating, and dripping between loading station 36 and unloading station 44. The carousel at the core of the building is supported independently of the building, and may be moved to different locations and buildings as desired. Numerous alternatives are possible. For example, instead of conveying the frames to the loading station with a conveyor, other conveyance mechanisms may be used, such as a cart, a shuttle, loading from beneath rather than through a sidewall opening, etc. While plural transport pivot arm assemblies are shown, single arm assemblies may of course be used. A facility with a single station in the building may also be used, to provide only coating within the building, and to provide loading and unloading externally of the building, as well as preheating if desired. The facilities and methods disclosed may also be used in cold coating processes. In further embodiments, the motor drive for the hub may be provided at the hub within the building, or may be provided externally of the building with an outer ring for mechanical advantage enabling a smaller motor and saving the motor from the harsh environment and elevated temperatures within the building. While a single frame per pivot arm of the carousel is shown, each arm may carry and dip more than one frame at a time. For example, one frame may be carried above the arm, and another frame below the arm. Further alternatively, multiple frames may be stacked, and carried by an arm. It is recognized that various equivalents, alternatives and modifications are possible within the scope of the appended claims.

Claims: A manufacturing method for preheating and applying a coating to vehicle structural components, comprising: providing a transport mechanism (28); providing a loading station (36); providing a preheat station (46) having a preheat liquid (54) at an elevated temperature; providing a coating station (38) having a coating liquid (40) at an elevated temperature; providing an unloading station (44); attaching said vehicle structural component to said transport mechanism (28) at said loading station (36); transporting said vehicle structural component to said preheat station (46), and moving said vehicle structural component into and out of contact with said preheat liquid (54) to provide liquid heat transfer to said vehicle structural component; transporting said vehicle structural component to said coating station (38), and moving said vehicle structural component into and out of contact with said coating liquid (40) to coat said vehicle structural component; transporting said vehicle structural component to said unloading station (44) and detaching said vehicle structural component from said transport mechanism (28). A method as claimed in Claim 1, further comprising providing a second preheat station (48) between said first mentioned preheat station (46) and said coating station (38), providing a wash liquid (54) at an elevated temperature at said first mentioned preheat station (46), and providing a rinse liquid (58) at an elevated temperature at said second preheat station (48), and comprising transporting said vehicle structural component from said loading station (36) to said first preheat station (46) and moving said vehicle structural component into and out of contact with said wash liquid (54), and transporting said vehicle structural component from said first preheat station (46) to said second preheat station (48) and moving said vehicle structural component into and out of contact with said rinse liquid (58), and transporting said vehicle structural component from said second preheat station (48) to said coating station (38). A method as claimed in Claim 1, wherein said preheat station (46) and said coating station (38) each comprise a tank (42, 52) containing the respective said liquid (40, 54), and comprising dipping said vehicle structural component in a generally horizontal position into said tank (52) at said preheat station (46), and dipping said vehicle structural component in a generally horizontal position into said tank (42) at said coating station (38). A manufacturing facility for preheating and applying a coating to vehicle structural components, comprising a movable transport mechanism (28), a loading station (36) for attaching said vehicle structural component to said transport mechanism (28), a preheat station (46) comprising a preheat liquid (54) at an elevated temperature, said transport mechanism (28) moving said vehicle structural component through said preheat station (46) into and out of contact with said preheat liquid (54) to provide liquid heat transfer to said vehicle structural component, a coating station (38) comprising a coating liquid (40) at an elevated temperature, said transport mechanism (28) moving said vehicle structural component through said coating station (38) into and out of contact with said coating liquid (40) to coat said vehicle structural component and an unloading station (44) for detaching said vehicle structural component from said transport mechanism (28).

Inventors: RUEHL PHILLIP C, RUEHL, PHILLIP C.
Applicants: SMITH CORP A O, A.O. SMITH CORPORATION
Application year: 1990
Main classification: B05B13
IPC codes: B05C3, B05C9, B05C13, B05B13, B05D1