Abstract:
A coating apparatus for coating an associated product includes a conveyor mechanism for advancing the associated product, and an indexing system configured to index the associated product as it is advanced by the conveyor mechanism. The indexing system includes a product support member coupled to the conveyor mechanism for supporting the associated product during movement through the coating apparatus. The product support member includes a rotatable spindle shaft and an indexing member rotationally interlocked with the rotatable spindle shaft. The indexing member is configured to engage a guide surface of an adjacent first guide member as the product support member is advanced by the conveyor mechanism past the guide member to change an orientation of the rotatable spindle shaft. A locking mechanism is also included for locking rotation of the rotatable spindle.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. provisional application Ser. No. 61/523,519 filed Aug. 15, 2011, all of which is incorporated herein by reference 
    
    
     BACKGROUND 
     The present exemplary embodiment relates to an apparatus for coating fiber based products. It also finds particular application in conjunction with a coating process including a system for indexing parts to be coated, and will be described with particular reference thereto. However, it is to be appreciated that the present exemplary embodiment is also amenable to other like coating and/or manufacturing applications. 
     A number of disadvantages exist with prior coating machines and part conveyors. For one, prior art part conveyors typically use a spring detent mechanism to maintain the orientation of the part or product to be coated throughout the entire path that the part travels throughout the machine. If for any reason this detent fails or if the part is bumped out of position, the part may be spoiled and/or severe damage could occur to the machine. In addition, other prior art systems use electric components such as sensors, motors, servos, etc. to locate and reorient parts. These systems are not only highly expensive but also prone to reliability issues due to the harsh and unforgiving environment of the coating and heat curing processes. 
     Still another disadvantage, current chain-on-edge machines use a gear or sprocket attached to the part spindle which engages with a stationary gear/sprocket on the machine to reorient the spindle. The rotational speed of the spindle is thus controlled only by the ratio of the pitch diameters of these driving components and the speed at which the part spindle is moving through the machine. Since only a limited number of combinations of gears/sprockets exist (due to the upper and lower diameter limitations of these driving components), there are only a limited range of speeds at which the part spindle could be rotated. In addition, since a sprocket&#39;s diameter will remain constant, it will turn at the same speed in relation to the speed of the chain conveyor, regardless of where it is placed along the chain conveyor path in the machine. 
     Moreover, the prior art chain-on-edge sprocket systems do not provide for any method to selectively lock or fix the orientation of one or more part spindles in relation to the conveyor chain and/or the direction of travel. Also, such prior art sprocket systems cannot force a rotational stop which could allow inertia to cause the spindle to rotate too far. As such, the part spindles and the parts or products supported thereon, may become randomly oriented which further leads to quality control issues in the manufacturing process. 
     BRIEF DESCRIPTION 
     In accordance with one aspect, a coating apparatus for coating an associated product comprises a conveyor mechanism for advancing the associated product, and an indexing system configured to index the associated product as it is advanced by the conveyor mechanism. The indexing system includes a product support member coupled to the conveyor mechanism for advancement therewith, the product support member adapted to support the associated product during movement through the coating apparatus, the product support member including a rotatable spindle shaft and a first indexing member rotationally interlocked with the rotatable spindle shaft, the indexing member configured to engage a guide surface of an adjacent first guide member as the product support member is advanced by the conveyor mechanism past the guide member to change an orientation of the rotatable spindle shaft from a first angular position to a second angular position thereby rotating the associated product. 
     The coating apparatus can further comprise a second guide member for engaging a second indexing member rotationally interlocked with the rotatable spindle shaft, the second indexing member configured to engage a guide surface of the second guide member as the product support member is advanced by the conveyor mechanism past the second guide member to change an angular position of the rotatable spindle shaft and the associated product to a position different than at least one of the first angular position and the second angular position. The conveyor mechanism can include a chain supported for movement in a track of a frame, and wherein the product support member is received by the track for movement therealong. 
     The apparatus can also include a plurality of indexing members rotationally interlocked with the rotatable spindle shaft and a corresponding plurality of guide members, each indexing member configured to engage a guide surface of a corresponding guide member as the product support member is advanced by the conveyor mechanism along the track past the corresponding guide member to change an orientation of the rotatable spindle shaft. The plurality of guide members can be spaced along a length of the track such that, as the product support member is advanced along the length of the track, the rotatable spindle shaft is rotated to different orientations. At least two of the plurality of guide members can include guide surfaces spaced at different distances from the track for engaging with first and second indexing members spaced apart along an axial dimension of the rotatable spindle shaft. 
     The apparatus can further comprise a plurality of product support members having at least one indexing member and/or a plurality of guide members spaced along the track, two or more of said guide members having guide surfaces with different profiles for rotating respective rotatable spindle shafts at different rates at different locations along the track. 
     The apparatus can further include a spindle lock assembly for locking the rotatable spindle shaft against rotation. The spindle lock assembly can include a locking bushing fixed to the rotatable spindle shaft for rotation therewith, and a locking arm movable between a locked position whereat a portion of the locking arm is engaged with a portion of the locking bushing thereby restricting rotation of the locking bushing, and an unlocked position whereat rotation of the locking bushing is not restricted by the locking arm. The locking bushing can include a concave surface thereof, and the locking arm can include a corresponding convex surface thereof adapted to be received along the concave surface of the locking bushing when the locking arm is in the locked position. A biasing member can be provided for biasing the locking arm towards the locked or unlocked position. At least one toggle member can be provided for urging the locking arm to the locked or unlocked position. 
     The indexing member and/or or guide member(s) can have a variable slope surface whereby a variable rate of rotation of the spindle shaft is produced as the indexing member engages the guide member. The indexing system can include a smooth lobed cam and a smooth guide surface upon which the cam impinges. 
     In accordance with another aspect, a method of indexing a product in a coating apparatus comprises supporting the product on a rotating spindle shaft of an indexing system, advancing the rotating spindle through the coating apparatus with a conveyor mechanism, and rotating the product to a prescribed orientation with the indexing system as the conveyor mechanism advances the product through the coating apparatus. The rotating the product includes providing an indexing member fixed to the spindle for rotation therewith, the indexing member configured to engage a guide surface of an adjacent first guide member as the spindle shaft is advanced by the conveyor mechanism past the guide member to change an orientation of the spindle shaft from a first angular position to a second angular position thereby rotating the associated product. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a top view of a first embodiment of a coating apparatus and a system for indexing a product to be coated, according to the present disclosure. 
         FIG. 2  is detailed view of a vertically-oriented spray head of the coating apparatus of  FIG. 1 . 
         FIG. 3  is a top view of a series of side-oriented spray heads as well as a series of indexed positions of the product being coated of the coating apparatus of  FIG. 1 . 
         FIG. 4  is a perspective view of a track and frame assembly for a second embodiment of a coating apparatus, according to the present disclosure. 
         FIG. 5  is a perspective view of a portion of the track assembly of the coating apparatus of  FIG. 4 , illustrating a plurality of indexable spindle assemblies engaged therein. 
         FIG. 6  is a perspective view of a portion of the track assembly of  FIG. 5 , illustrating the indexing action of the spindle assembly with a rotary positioning guide member. 
         FIG. 7  is a top view of the portion of the track and spindle assembly of  FIG. 6 . 
         FIG. 8  is a perspective view of an individual spindle assembly engaged within a portion of the track of  FIG. 5 . 
         FIG. 9  is an exploded view of the spindle and track assemblies of  FIG. 8 . 
         FIG. 10  is a further exploded view of the spindle assembly and spindle housing illustrated in  FIG. 9 . 
         FIG. 11  is a top view of a spindle locking assembly with an upper portion of the spindle housing removed for clarity. 
         FIG. 12  is a detailed view of  FIG. 11  illustrating the spindle locking assembly in a disengaged or unlocked state. 
         FIG. 13  is a detailed view of  FIG. 11  of the spindle locking assembly in an engaged or locked state. 
     
    
    
     DETAILED DESCRIPTION 
     With reference to  FIGS. 1-3 , a coating apparatus  10  is shown for coating parts or products, such as fiber based products with various types of coatings, such as a waterproof film, etc. Generally, the coating apparatus  10  includes a plurality of spindle assemblies  12  which are secured to a chain-on-edge type conveyor  14 . Both the spindle assemblies  12  and the chain-on-edge conveyor  14  can be slidably engaged within a track assembly  15  ( FIG. 4 ). Once a product or part to be coated PRT is mounted or otherwise loaded onto an individual spindle assembly  12  within the loading area LDA, the chain conveyor  14  may advance the spindle assembly  12  and part PRT through a spray booth SPR. As the part to be coated PRT advances through the spray booth SPR, a series of spray heads  18  may be located in various orientations, such as a top or side orientation with respect to the part to be coated PRT. By way of example, the part PRT may have its top side coated by a top or vertically-oriented coating spray head  18 A ( FIG. 2 ) and the sides of the part PRT coated using on or more side-oriented spray heads  18 B ( FIG. 3 ). In addition, as shown in  FIG. 3 , and as will be described in greater detail below, the spindle assemblies  12  may be selectively locked and unlocked allowing the part PRT to rotate or index about a vertical axis. As such, the spindle assembly  12  can be manipulated so as to present the various facets or sides of the part PRT to be coated to one or more spray heads while the part PRT moves through the spray booth SPR or at any desired location along the track  15 . 
     Permitting the product or part to be manipulated in such a manner provides a particular advantage in the coating process as it allows the part to be uniformly coated in a very compact space while utilizing a generally unidirectional flow of air and spray coating material through the spray booth. Once the part to be coated PRT is coated, it may then be advanced through a curing oven OVN through which the conveyor  14  and track assembly  15  may make several passes in a serpentine-like course. Once the coated parts PRT have dwelled for an adequate period of time within the oven OVN, the parts may advance through a cooling chamber CC to be cooled to an appropriate handling temperature. Finally, the parts PRT may advance to an unloading area UDA where they may be unloaded, packaged or presented to another machine for further processing. Naturally, one or more aspect of the coating apparatus  10  may be fully automated (e.g., as in the automated loading and unloading of parts, heating and cooling control, part detection, etc.) 
     Now with reference to  FIG. 4 , a track  16  and frame assembly  20  is illustrated for an alternate embodiment of a coating apparatus, but which is generally similar to the first embodiment of the coating apparatus  10 . As illustrated in  FIG. 4 , the plurality of spindle assemblies  12  can be slidably engaged within the track  16  which may also house the chain-on-edge conveyor  14  previously described or any other conveyor mechanism that is capable of advancing the spindle assemblies  12  through the track  16 . While only a small portion of the track  16  is shown as being populated with spindle assemblies  12 , the entire course of the track  16  would generally be used and filled with spindles  12  in order to make the most effective and productive use of the coating apparatus. In addition, the track  16  can be constructed from a series of linear track portions  16 A, one or more U-shaped end portions  16 B, and one or more corner portions  16 C. The U-shaped and corner portions  16 B,  16 C may otherwise include drive systems used in driving or advancing the chain on edge conveyor or other conveyor type system. Furthermore, the radius of curvature of the track portion within the U-shaped and corner portions or segments are fashioned to accommodate the spindle assemblies  12  so that they may traverse the entire track length without interference or otherwise binding. In alternate embodiments, the U-shaped end and corner portions may be entirely eliminated as a chain-on-edge conveyor may provide adequate vertical rigidity when a portion of the conveyor is temporarily disengaged from the track (as one or more spindle assemblies negotiate a turn or curved portion of the course). Also, as noted with regard to the first embodiment of the coating apparatus  10  ( FIG. 1 ), the overall course of the track  16  can be divided into various regions for spraying, curing, cooling, loading and unloading, or other operations as needed to achieve the desired end result for the part to be coated. 
     Now with reference to  FIG. 5 , a portion of the track  16  is illustrated containing the plurality of spindle assemblies  12  previously discussed. In addition, a part to be coated PRT is also illustrated in a mounted or loaded configuration on the first spindle in  FIG. 5 . Furthermore, and as will be discussed in greater detail with reference to  FIGS. 6-9 , the track assembly  16  is designed to accommodate the individual spindles, as well as the individual segments of the chain-on-edge conveyor  14 . In addition, a series of guide member  22  can be used to control the indexing or rotational orientation of the parts PRT supported by the spindle assemblies as they traverse past the guide members  22 . Generally, as a spindle  12  encounters a first guide  22 A, an upper or first indexing member  24  of the spindle  12  will slidably engage an edge portion  23 A, causing the indexing member  24  to rotate a spindle shaft  25  of the spindle assembly  12 . By way of example, in the instant embodiment the spindle shaft will rotate by approximately 90° as it passes by the first guide  22   a . Of course, the amount and rate of rotation of the spindle shaft  25  and the part PRT can be controlled by the profile, slope, or lead angle of the edge  23 A as illustrated in  FIG. 6 . Naturally, the more aggressive the profile or lead angle of edge  23 A, the greater or faster the rate of turn will be per unit travel of the conveyor. Also of note here, the guides could be positioned in sequence to cause constant rotation of the part at any rate desired. 
     As the spindle  12  passes the first guide  22 A, the spindle  12  may encounter a second or subsequent guide  22 B. The second guide  22 B may be disposed at a lower elevation with respect to the first guide  22 A, such that a second or lower indexing member  26  may slidably engage a lead in profile or edge  23 B. As the second indexing member  26  engages the edge  23   b , the spindle shaft  25  will be urged to rotate by approximately another 90°, thus presenting the next side of the mounted part PRT to be coated. Next, the indexing process is repeated (as described with regard to the first guide  22 A) by the third guide  22 C since the third guide  22 C is at the same or similar elevation of the first guide  22 A. Here again, the upper or first indexing member  24  will engage the profile or edge of the guide  23 C, thus causing the spindle to rotate yet another 90° and present a different surface of the part to be coated. Finally, the fourth guide  22 D is disposed at the same level as the second guide  23 B which again engages the second or lower indexing member  26  to bring the part PRT back to its original orientation. 
     It should be noted that any number of indexing members and guides could be combined at various heights and contours, respectively, to achieve any number of spindle/part orientations and angular rates of turn. Furthermore, the spindle assemblies may be modified to include multiple degrees of freedom so that a part can be manipulated in different planes/axes. By way of example, a mounted part could be manipulated in more than one plane/axis by using a combination of nested part spindles, angled drive systems, multiple guide/indexing members, and/or spindle locks, etc. 
     The process of indexing or rotation of the spindle  12  is further illustrated in  FIGS. 6 and 7 . As shown in  FIG. 6 , the spindle  12  and upper indexing member  24  begin to rotate in a counterclockwise direction, as the conveyor is moved in a forward direction FWD. As can be seen by comparing the leading spindle assembly  12 ′ and the upper indexing member  24 ′ to the lagging spindle assembly  12  and the upper indexing member  24  of  FIG. 6 , once the leading spindle assembly  12 ′ has passed the profile or edge  23 A of the guide  22 A, the leading upper indexing member  24 ′ is oriented in a generally parallel direction with the edge surface  23 B of the guide  22 A. It should be noted, that between, during, before, or after the various indexing operations as provided by the guides  22 , the spindle assembly may be locked such that any movement or rotation of the spindle shaft is prevented or precluded. This provides the particular advantage of maintaining the same orientation (relative to the conveyor/track) of all the parts which are moving through the coating apparatus which further simplifies subsequent operations (e.g., loading and unloading of parts, etc.). Of course, the spindle shafts of the spindle assemblies could be rotated and oriented using alternate mechanisms using gears, racks, chains and/or motors. 
     Now with reference to  FIGS. 8 and 9 , a single spindle assembly  12  is illustrated in an assembled view and an exploded view, respectively. As discussed previously, a housing  28  of the spindle assembly  12  is slidably engaged within a first channel  30  of the track  16 . The chain  14  of the chain-on-edge conveyor may also move within the track  16  within a second channel  32 . An upper portion of the chain  14  may be secured to a lower portion of the housing  28 , such that as the chain is urged through the track, the housing  18  and spindle assembly  12  are also urged in the same direction. To prevent the chain or conveyor  14  from interfering or otherwise binding within the channel  32  or track  16 , one or more chain guides  34 A,  34 B may be provided. The chain guides  34 A,  34 B may be fabricated from any common or suitable bearing material (e.g., bronze, brass, nylon, Delrin, etc.). Furthermore, the housing  28  of the spindle assembly may also be provided with similar bearing surfaces to facilitate a low friction and small tolerance interface between the spindle assembly and the track. 
     Now with reference to  FIG. 10 , an exploded view of the upper portion of the spindle assembly  12  is shown further illustrating the spindle shaft  25 ; the first and second indexing members  24 ,  26 ; an upper portion of the housing  28 A; and, a lower portion of the housing  28 B. In addition, a spindle lock assembly  36  is illustrated which includes a locking arm  38  and a locking bushing  40 . The locking arm  38  may generally include a first end  38 A, a second end  38 B, and convex locking surface  38 C. The locking arm  38  may also be pivotally mounted between the upper and lower housing portions  28 A,  28 B, while the locking bushing  40  may otherwise be secured to the spindle shaft  25 . It should also be noted that the locking bushing  40  may include a concave surface  40 A which matches a radius of curvature of the convex portion  38 C of the locking arm  38 . Furthermore, a spring loaded detent may be provided within either the upper or lower housing portions  28 A,  28 B to retain the locking arm  38  in either a locked/engaged state or an unlocked/disengaged state. As illustrated and discussed below with reference to  FIG. 13 , when the locking arm  38  is in the engaged state, the convex surface  38 C is generally in contact with or proximal to the concave surface  40 A of the bushing. 
     Now with reference to  FIGS. 11-13 , the locking action of the spindle lock  36  is illustrated. With particular reference to  FIG. 11 , a leading spindle lock assembly  36 ′ is illustrated in the locked state while the lagging spindle lock assembly  36  is shown in the unlocked state. As the spindle assembly traverses in the forward direction FWD through the track  16  and encounters a first toggle  42 , the first toggle  42  urges the first end  38 A of the locking arm  38  urged in a clockwise direction. As the locking arm  38  rotates clockwise, the convex portion  38 C moves away from and disengages the concave surface  40 A of the bushing  40  thereby allowing the bushing  40  (spindle shaft) to rotate freely within the spindle housing  28 . Similarly, and in a generally opposite sequence of events, as the conveyor  14  moves forward FWD within the track  16 , the same spindle assembly may eventually encounters a second toggle  44 . As the second end  38 B of the locking arm  38  encounters the second toggle  44 , it is urged in a counterclockwise direction thereby placing the spindle lock assembly  36 ′ into a locked or engaged state. Specifically, this occurs because the convex portion  38 C engages the concave portion  40 A of the bushing  40  thereby precluding any relative movement between the bushing  40  and spindle  25  with respect to the housing  28  of the spindle assembly  12 . 
     As disclosed above, the spindle assemblies and chain can be contained and guided by a track with a specific profile. The profile of the track could be made by extruding aluminum or plastic or it could be machined. Other parts, channels, or surface features can be added to the track (or formed therein as part of the extrusion) for additional stability or functionality. Other guides can be attached to capture the chain or more complicated guides could be added to capture the chain and add stability. Here, the track design may accomplish multiple objectives. It may support the chain as well as provide a surface for the spindle housing to ride upon. By capturing the chain and spindle housing, it provides stability to the whole assembly. As illustrated, various chain guide designs could be employed to capture more or less of the chain, depending on the level of chain stability that is required. Furthermore, externally accessible channels could be incorporated as part of the design of the track profile to allow for the ease of securing the track to the frame and for the mounting of other components (e.g., part spindle index guides, spindle interlock trigger/toggle, electrical/mechanical sensors, and/or machine guards, etc.). 
     As discussed previously, prior art chain-on-edge machines use a gear or sprocket attached to the part spindle which engages with a stationary gear/sprocket on the machine to index or reorient the spindle. This offers only a limited range of speeds at which the part spindle can be rotated and whichever speed is selected is the only speed that can be used throughout the pathway of the driving chain conveyor. By contrast, and in accordance with the indexing system of the present disclosure, the indexing guides could be shaped differently in different areas of the machine so that various rates of rotation could be accomplished regardless of chain conveyor speed, etc. The indexing guides could even be contoured to achieve non-linear rates of rotation if needed. 
     Also, as previously mentioned, the prior art chain-on-edge sprocket systems do not provide for any method to selectively lock or fix the orientation of one or more part spindles in relation to the conveyor chain and/or the direction of travel. As such, the part spindles and the parts or products supported thereon, may become randomly oriented which further leads to quality control issues in the manufacturing process. The interlock system of the present disclosure addresses this problem by allowing the machine to force an absolute spindle orientation. As described previously, toggles placed in the track can engage or disengage the interlock or locking assembly of the spindle assemblies at any desired point. Due to its design, the interlock can only be engaged when the spindle is in its proper orientation. This design allows for the simple addition of electronic sensors for the control system to verify proper spindle orientation in various areas of the machine. If improper spindle orientation is detected via the position of the locking arm, the machine can be programmed to automatically stop. In areas of the machine where the spindle needs to be reoriented, the spindle locking assembly would be disengaged and the previously disclosed indexing system could be used. 
     The exemplary embodiment has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the exemplary embodiment be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.