Abstract:
An automotive paint installation providing additionally to standard paint application, automated application of small rare color shade paint volumes. The installation includes at least a secondary rare color shade paint dispensing and recovery circuit, wherein scrapers are circulated in the part of the circuit supplying painting stations, and including a distribution device for directing the fluid exiting the painting stations towards paint, solvent, or recovery vessels. A plurality of connecting pipes connect each secondary circuit to a painting station, and are provided each with a bleeding system to enable recovery and bleeding to be performed during application of a current paint color shade. A rare color shade point dispensing and recovery method use such an installation.

Description:
BACKGROUND 
     The invention relates to an automobile painting installation and a method using such an installation. 
     Installations for dispensing and applying paint to motor vehicles generally comprise a plurality of painting stations, manual or automatic, each connected to a plurality of paint dispensing circuits. Each paint dispensing circuit corresponds to a particular color and supplies each application station from a paint tank. The paint is circulated in the circuit to prevent it from deteriorating. 
     At each application station, the paint color to be applied is selected by a color change device, called a color changer, comprising a plurality of valves of which the inlet is connected to a paint dispensing circuit by a line and of which the outlet is connected to a feed line connected to the paint application device of the station. Between two applications of paint of different colors, this feed line is rinsed using a bleed system. The opening of the color changer valves is automated in order to automate the application of the paint. 
     The frequent use of the paint colors demands large capacity paint tanks, which must consequently be kept at some distance from the application stations for reasons of size, so that long pipe lengths are necessary. Due to the size of these dispensing circuits, a large quantity of paint is required to fill them (about 1 to 3 tons). 
     Dispensing circuits of this size are inconceivable for rarely used paint colors, especially since a small quantity of paint, about five liters, is needed to paint a car. These colors are hence usually applied manually but with a finish inferior to that of the common colors applied automatically. In certain installations, smaller tanks are positioned closer to the application stations to also reduce the length of the dispensing circuit. However, a non-negligible volume of paint is still necessary to load the dispensing circuit (several hundred liters) and the paint must be circulated permanently. Moreover, if the consumption of paint is too low, the paint deteriorates so that the quality and color are no longer satisfactory, and the product must be destroyed and replaced. 
     Thus, up until the present, the automatic installations used to apply a rare color paint to a vehicle, to obtain a good quality finish, require quantities of paint which are disproportionate to the quantities actually applied, so that a large quantity of paint deteriorates. 
     Furthermore, space considerations around each color changer preclude the direct connection of a dispensing circuit to a changer valve, making it necessary to use a line connecting the circuit to the changer. A color change or a circuit cleaning accordingly requires cleaning this connecting line. Such a bleed can only be obtained today using the color changer, implying the shutdown of the painting station and a decrease in the paint application rate in the installation. 
     Documents U.S. Pat. No. 6,090,450 and U.S. Pat. No. 5,221,047 describe methods and devices for recovering or cleaning the feed line between the color change device and the paint application device. In document U.S. Pat. No. 5,221,047, the paint is pushed in the feed line using a scraper, up to the application device. All the paint is thus used and a return line repositions the scraper at the inlet of the feed line. This first scraper is followed by a given quantity of solvent, and then by air following a second scraper, in order to clean the feed line. In document U.S. Pat. No. 6,090,450, a scraper circulates back and forth in the feed line. At the end of the paint application, the scraper pushes the remaining paint outside the line and the application device, and is then returned to its starting point. However, these cleaning methods are only used on a short length of feed line, and not for a larger closed circuit. 
     There is therefore a need for an automobile painting installation which, in addition to the known paint application, permits the automated application of paints of a rare color with low circulation, the recovery of the unused paint, and the bleeding of the system. These recovery and bleed steps must preferably be carried out without reducing the automated rate of paint application to the vehicles, that is, during the application of a common paint color. 
     BRIEF SUMMARY 
     For this purpose, the subject of the invention relates to an automobile painting installation comprising a plurality of painting stations each connected to a plurality of main common color paint dispensing circuits, each painting station comprising an application device supplied with paint via the outlet of a main color changer provided with a bleed system, each main color changer comprising a plurality of inlet valves each connected to a main common color dispensing circuit, the valves and application devices being controlled by a control system, 
     characterized in that it further comprises a secondary rare color paint dispensing and recovery system controlled by the control system comprising at least one secondary paint dispensing and recovery circuit supplying the plurality of painting stations, with smaller dimensions compared with the main circuits, the secondary circuit comprising:
         a scraper storage and circulating system of which the inlet and the outlet are connected respectively downstream and upstream of the painting stations to circulate the scrapers in the part of the circuit supplying the stations,   at least one rare color paint tank, one solvent tank and one spent solvent recovery tank, connected upstream of the outlet of the scraper storage system,   a dispensing device connected to the inlet of the scraper storage system, to send the fluid exiting the painting stations to the paint, solvent or recovery tanks,   a plurality of connecting lines of which one end is connected to the secondary circuit by a flush three-way valve and the other end is connected to an inlet valve of a main color changer, each connecting line being provided with an independent bleed system to bleed it between the flush three-way valve and the inlet valve of the main color changer.       

     The reduced dimensions of the secondary dispensing and recovery circuit serve to reduce the quantity of rare color paint used. Moreover, the scraper circulation system associated with the dispensing device serves to recover the excess rare color paint at the outlet of the painting stations and store it appropriately in a tank. This makes it unnecessary to circulate the paint in the circuit to prevent its deterioration, and only the paint tank is maintained with stirring. The use of flush valves between the secondary circuit and the connecting lines serves to improve the capacity to recover paint by the scrapers, the specific cleaning of these valves therefore being superfluous. 
     Furthermore, the independent bleed system of each connecting line permits its cleaning during the bleeding of the secondary circuit, without requiring the shutdown of the main color changers which dispense another paint color originating from a main circuit. Cleaning operations on the connecting line and the secondary circuit can thus be performed in masked time without affecting the production rate of the installation. 
     Advantageously, a secondary color changer is connected to each connecting line, the outlet of the color changer being connected to the inlet valve of the corresponding main color changer, and which comprises at least one inlet valve connected to a secondary circuit via the flush three-way valve. This color changer, with a similar structure to the main color changers, can be connected to a single secondary circuit. One or more rare colors can then be applied according to the number of paint tanks connected to this circuit. As a preferable alternative, this changer is connected to two or more secondary circuits, each comprising one or more paint tanks. 
     Advantageously, each secondary circuit and/or each bleed system of a connecting line is connected to a compressed gas feed. Blowing gas through the entire secondary circuit and/or the connecting lines serves to remove any traces of solvent subsisting after the cleaning. 
     Advantageously, the scraper storage and circulating system comprises a storage trap of which the inlet and outlet are controlled by solenoid valves. The entry and exit of the scrapers can thus be automated. 
     Advantageously, the storage trap has a substantially L-shaped tubular shape, of which the upper and lower ends form the inlet and the outlet respectively, the scrapers being stored in the substantially vertical part. The scraper introduction and recovery system is thus compact, and suitable for rapidly and easily placing, by gravity, each scraper entering the trap, in a position in which it is ready to be reintroduced into the circuit. 
     The invention further relates to a rare color paint dispensing and recovery method using an installation according to the invention, 
     characterized in that it comprises the steps consisting in:
         pushing, between two scrapers, a predetermined quantity of paint in a secondary dispensing circuit to feed the painting stations via the connecting lines,   sending the unused paint leaving the painting stations to the paint tank using the dispensing device, then rinsing the secondary circuit by circulating solvent between scrapers, the flush valves between the secondary circuit and the connecting lines being closed,   bleeding the connecting lines using their independent bleed system, the valves via which they are connected to the main color changers and to each secondary circuit being closed.       

     The unused paint is thus recovered between each use, and the secondary circuit is cleaned, thereby considerably limiting the paint losses. The secondary circuit can then be used later to dispense paint of the same color, or another color. 
     Advantageously, the secondary circuit is rinsed by introducing two predetermined quantities of solvent separated by a scraper following a scraper according to the quantity of paint, at least part of the second quantity of solvent introduced being sent to the solvent tank using the dispensing device. Smaller quantities of solvent are thus used. The use of scrapers also serves to recover part of the second quantity of solvent and thereby reduce the solvent consumption. 
     Advantageously, when each secondary circuit is provided with scraper sensors, some of the steps of paint introduction, recovery and bleeding of the secondary circuit are controlled by the control system in response to detection signals transmitted by the scraper sensors. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention is now described with reference to the drawings appended hereto, which are nonlimiting, in which: 
         FIG. 1  is a schematic representation of an installation according to the invention; 
         FIG. 2  is a schematic representation of a connecting line connecting a secondary circuit to a painting station; 
         FIG. 3  is a schematic representation of a particular embodiment of a connecting line; 
         FIG. 4  is a schematic representation of a scraper storage and circulating system. 
     
    
    
     DETAILED DESCRIPTION 
     In these figures, the arrows indicate the fluid flow direction. 
       FIG. 1  shows an automobile painting installation according to the invention. 
     The installation comprises a plurality of painting stations  1 , manual or robotized, arranged in a cabin  2  into which the vehicles to be painted are introduced in the direction of the arrow F in  FIG. 1 . 
     Each painting station  1  comprises an application device  3  supplied with paint via an outlet line  4  of a main color changer  5 , as shown in  FIG. 2 . In this figure, the broken line represents the wall of the cabin  2 . Each main paint changer  5  comprises a plurality of paint inlet valves  6 . 
     Each inlet valve is connected on the one hand to a main paint dispensing circuit (not shown) and, on the other, to the paint outlet line  4 . The main paint dispensing circuits are conventional and are not described. They are used to apply the commonly applied paint colors and referred to below as “common colors”. In practice, each valve is connected to a paint dispensing circuit corresponding to a predetermined common color. 
     Each main paint changer is further provided with a bleed system comprising two valves  7  and  8  upstream of the inlet valves  6  and connected respectively to a solvent feed and a compressed gas feed (not shown). The latter is generally compressed air, while the solvent is selected according to the type of paint. The bleed system also comprises a discharge line  9  connected to the application device  3  and leading to a bleed manifold  10 . 
     A main color changer  5  is thereby bled as follows: after the application of a paint, the inlet valves  6  are all closed, the solvent inlet valve  7  is then opened and the solvent flows into the outlet line  4 , passes through the application device  3 , and then into the discharge line  9 , and is recovered in the bleed manifold  10 . The solvent inlet valve  7  is then closed and the compressed gas inlet valve  8  is opened to allow the gas to enter along the same route and to dry the interior of the lines. This valve is then closed and another paint inlet valve  6  can be opened to apply a different color. 
     All the valves  6  to  8 , and the application devices  3 , are controlled by a control system (not shown). Obviously, other bleed systems can be used. 
     Each main color changer  5  is also connected to a secondary paint dispensing circuit  11  for applying a less commonly employed color, called “rare color”. For this purpose, an inlet valve  12  connected to the outlet line  4  of the main color changer is connected to a connecting line  13 , sometimes called antenna, which is connected to the secondary circuit  11  via a flush three-way valve  14 . A bleed system independent of the bleed system of the main changer is associated with the connecting line  13 . This bleed system comprises a first bleed line  15  connected to the third passage of the flush valve  14 , this first line  15  being connected to a solvent feed  16  and to a compressed gas feed  17  via a three-way valve  115 . The bleed system comprises a second bleed line  18  of which one end is connected to a third passage of the inlet valve  12 , to which the connecting line  13  is connected, and the other end is connected to the bleed manifold  10  of the main changer bleed system. 
     In the embodiment shown in  FIG. 2 , the connecting line  13  is preferably as short as permitted by the space available around the main changer  5 . The bleeding is then carried out by closing the three-way valve  14  on the secondary circuit  11  side, the inlet valve  12  of the main changer on the main changer  5  side. The solvent and then the compressed air accordingly take the following path: first bleed line  15 , connecting line  13 , second bleed line  18 , bleed manifold  10 . The three-way valve  115  is adjusted to select the solvent intake for rinsing, then compressed air to expel the residual solvent to avoid overdiluting the next color. 
     In a preferred embodiment shown in  FIG. 3 , a secondary color changer  5 ′ is connected to the connecting line  13 . This secondary changer  5 ′ has a similar structure to that of a main changer  5 . In the example, it comprises two inlet valves  20 ,  20 ′ each connected to a secondary dispensing circuit  11 ,  11 ′ via a flush valve  14 ,  14 ′, and connected to the outlet line  21  of the secondary changer. The outlet of this outlet line is connected to the inlet valve  12  of the main changer. The secondary changer comprises, upstream of the inlet valves  20 ,  20 ′, a solvent inlet solenoid valve  22  connected to a solvent manifold  16 ′, and a compressed gas inlet valve  23  connected to a compressed air source (not shown). The inlet of the outlet line  21  from the secondary changer  5 ′, located upstream of the solenoid valve  22  and of the valve  23 , is connected via the first bleed line  15 ′ to the third passages of the flush valves  14 ,  14 ′. The solvent manifold  16 ′ is connected to this first bleed line  15 ′ in order to supply solvent to the flush valves  14 ,  14 ′ and the secondary changer  5 ′. 
     The bleeding of the connecting line  13  and the secondary color changer  5 ′ is then carried out as follows. When the paint application is completed, the corresponding flush valve  14  (or  14 ′) is closed on the secondary circuit  11  side, while the inlet valve  12  of the main changer is closed on the main changer side. The solvent, then the compressed gas, accordingly take the following path: first bleed line  15 ′, flush valve  14 , connecting line  13 , corresponding inlet valve  20  of the secondary changer  5 ′, outlet line  21  thereof, connecting line  13 , inlet valve  12  of the main changer  5  (closed on the main changer side), then second bleed line  18 , and bleed manifold  10 . This bleed can therefore be carried out while another common color from a main circuit is applied in the cabin using the main changer  5 . 
     During this bleed phase of the connecting line  13 , the unused paint from the secondary circuit can be recovered and this circuit can be cleaned. 
     The structure of a secondary circuit is now described with reference to  FIG. 1 . A single secondary circuit  11  is shown in this figure. It comprises two paint tanks P 1  and P 2  each containing a rare color, a solvent tank S and a spent solvent recovery tank R. Each paint tank P 1  and P 2 , and the solvent tank S, is associated with a circulating pump  24  controlled by the installation control system. 
     The secondary circuit also comprises a scraper storage and circulating system  25  and a dispensing device  26 , such as a distribution plate, to send the fluids leaving the painting stations to one of the paint, solvent or recovery tanks. 
     The scraper storage and circulating system  25  is described with reference to  FIG. 4 . It comprises a substantially L-shaped scraper storage trap  25 , with a substantially vertical cylindrical part  27  in which the scrapers are stacked, and a substantially horizontal part  28 . The scrapers are introduced from the top of the vertical part  27  via an inlet lock  29 . The substantially horizontal part  28  of the storage trap has an outlet lock  30  at its end for the outlet of the scrapers. The inlet of the inlet lock  29  is connected to the secondary circuit via a valve  31 , while its outlet communicates with the vertical part  27  via another valve  32 . Similarly, the outlet lock  30  is connected in series to the secondary circuit via two three-way valves  33 ,  34  respectively permitting the inlet and outlet of the fluid in the lock  30 . The outlet lock also communicates with the horizontal part  28 . A solenoid valve  35  located at the end of the horizontal part  28 , at the opposite end of the outlet lock, and connected to a compressed gas source, serves to move the scrapers from the bottom of the vertical part to the outlet lock  30 . 
     The various components of the secondary circuit  11  are connected as follows. 
     A dispensing line  36  serves the painting stations  1  of the cabin. It supplies the connecting lines  13  of the painting stations. This dispensing line  36  is connected, upstream of the painting stations  1 , to the outlet valve  34  of the outlet lock  30  of the storage trap. The line  36  is also connected to the inlet valve  29  of the trap inlet lock, downstream of the painting stations. The scrapers thereby only circulate in the dispensing line  36 , between the outlet and inlet of the storage trap. 
     A valve  37  is connected to the dispensing line  36  downstream of the last painting station, immediately next to it. 
     The inlet valve  33  of the outlet lock  30  of the trap is connected to a paint feed line  38  and to a solvent feed line  39 . 
     The paint feed line  38  is connected to the pump of the paint tank P 1  via a quick coupling  40 . Alternatively, it can also be connected to the pump of the paint tank P 2 . Upstream of the inlet valve  33  of the outlet lock  30 , the paint feed line  38  is connected to the recovery tank R via a return line  41 . A valve  42  placed on this line  41  is used to close it when the paint is sent to the painting stations. 
     The solvent feed line  39  is connected to the pump  24  of the solvent tank S via a valve  43 . It is also connected, between the inlet valve  33  of the outlet lock  30  and this valve  43 , to each of the paint tanks via two three-way valves  44  connected between the paint tank P 1  or P 2 , and the associated circulating pump  24 . 
     The inlet lock  29  of the trap comprises an outlet connected to a recovery line  45  to which the dispensing device  26  is connected. This device  26  is connected to the paint tanks P 1 , P 2 , the solvent tank S and the spent solvent recovery tank R, to send the fluid flowing in the recovery line  45  to the appropriate tank. 
     A compressed gas circuit  46  is connected to the solvent feed line  39 , downstream of the valve  43  and close to it, via a check valve  47 . A valve  48  upstream of this check valve is used to control the flow of compressed gas throughout the circuit. 
     A series of scraper position sensors C 1  to C 5  is distributed in the secondary circuit. Two sensors C 1  and C 5  are located at the outlet and inlet locks respectively of the storage trap, two other sensors C 2  and C 3  being located along the dispensing line  36  at the painting stations, and another sensor C 4  being located just after the shutoff valve  37  of the dispensing line  36 . These sensors are connected to the installation control system. 
     The lines of the secondary circuit  11  preferably have a smaller diameter than that of the piping used for the main dispensing circuits in order to decrease the quantity of paint necessary to load the circuit. This quantity is further reduced by placing the paint tanks and their circulating pump close to the painting stations. This makes it possible to use tanks with a capacity of about 25 liters, 5 liters being necessary to paint a vehicle, the remainder being used to load the circuit. Higher capacity tanks can obviously be used when several vehicles have to be painted with the same color. The low capacity of the paint tanks serves to place them on a trolley and to load them easily as required. 
     In an embodiment not shown, it is possible to connect, in parallel to the scraper circulating device, a second scraper circulating device connected to a second dispensing line serving other painting stations of the installation. 
     It is also possible to connect several secondary circuits to the secondary changers of the painting stations. 
     An example of an operating method of this secondary circuit is now described, the paint tank P 1  being connected. 
     A first scraper is introduced into the outlet lock  30  of the storage trap. The inlet valve  33  and outlet valve  34  of this lock are then opened, and the circulating pump  24  of the paint tank P 1  loads the circuit with paint. The paint is introduced through the line  38  of the circuit and pushes this first scraper into the dispensing line  36  until it is detected by the sensor C 3 , causing the stopping of the paint circulating pump  24  and the introduction of a second scraper into the circuit. The position of this sensor C 3  corresponds to a sufficient quantity of paint introduced into the circuit to paint a vehicle. 
     The inlet valve  33  of the outlet lock  30  of the storage trap is then closed on the side of the paint tank P 1  and opened on the side of the solvent feed line  39 . The solvent is introduced by the pump of the solvent tank, and pushes the second scraper as well as the paint. 
     The sensor C 4  is placed so that the quantity of paint introduced into the circuit is sufficient to supply each of the painting stations of the cabin. The detection of the first scraper by this sensor C 4  causes the closure of the valve  37  of the dispensing line  36 . The application of paint is triggered by the control system upon the entry of the car body to be painted in the application zone. During the paint application, the pump of the solvent tank S thereby maintains the pressure in the circuit. During this step, the inlet valves  12  and  20  of the main and secondary color changers of each station, corresponding to the secondary circuit, are opened to convey the paint to each application device  3 . This opening can be controlled simultaneously or successively according to the progress of the vehicle in the cabin. 
     At the end of the paint application step, a signal is sent automatically, and causes the opening of the valve  37  of the dispensing line  36 . The excess paint and solvent advance in the circuit until the second scraper is detected by the sensor C 2 . A third scraper is then introduced into the dispensing line  36 , the solvent circulating pump  24  being temporarily stopped for this purpose, and pushed by a second quantity of solvent. The first scraper, followed by the unused paint, rejoins the inlet lock  29  of the storage trap. When this scraper is in the inlet lock (detection by the sensor C 5 ), the inlet valve  31  of the lock is closed and its outlet valve  32  to the storage trap is opened, then closed after the scraper is removed. The inlet valve  31  of this lock is then opened again, and also its outlet to the recovery line  45 . The paint can thereby be returned to the paint tank P 1  using the dispensing device  26 . 
     Until the first scraper returns to the storage trap, and is detected by the sensor C 5 , the dispensing device is preferably controlled to send the traces of fluids remaining in the lines (solvent or gas issuing from a previous use) to the recovery tank. 
     As soon as the third scraper is detected by the sensor C 2 , the solvent pump is stopped and a fourth scraper is introduced into the dispensing line  36 . This fourth scraper is pushed by compressed gas introduced via the solvent/gas feed line  39 . 
     The end of paint recovery can be controlled following a detection signal of one of the scrapers circulating in the circuit. 
     When the second scraper returns to the storage trap, the solvent that follows it is sent by the recovery line  45  to the dispensing device  26 , then to the recovery tank R. When the third scraper rejoins this storage trap, the quantity of solvent that immediately follows it is sent similarly to the recovery tank, the final part of solvent, following the detection of the fourth scraper in the circuit, can be sent to the solvent tank S. When all the liquids have been recovered, the entire circuit is blown out with compressed gas to remove the solvent from the walls. 
     Before the departure of the fourth scraper, the solvent feed line  39  is used to circulate solvent in the paint feed line  38  and in its return line  41 , the inlet valve  33  of the outlet lock of the storage trap being closed on the lock side, the valve  42  of the return line  41  to the spent solvent tank R being opened. 
     It is also possible to circulate solvent in the storage trap in order to rinse it, for example by using a line  49  provided with a valve  50  connecting the upper part of the storage cylinder  27  to the solvent feed line  39  upstream of the inlet valve  33  of the outlet lock of the storage trap, and a line  51  connecting a third passage of the outlet valve  34  from the outlet lock to the recovery tank. The solvent takes the following path, for example, (the outlet valve  32  of the inlet lock being closed, as well as the inlet valve  33  of the outlet lock): solvent feed line  39 , line  49  (inlet valve  33  of the outlet lock closed on the line  39  side), vertical part  27 , horizontal part  28 , outlet valve  34  to the line  51 , recovery tank R. 
     Other embodiments of a scraper storage and circulating device can obviously be used. The use of quick couplings to connect the various components of the secondary circuit makes it easier to change or replace these components.