Patent Description:
Material spray systems are used in the art to apply coating materials onto components. Some known spray systems are configured with a pressure pot to facilitate, among other things, the mixing of the coating material. After a component is coated, the pressure pot and its components are cleaned to remove residue coating material from its surfaces. This cleaning process is typically a manual cleaning process and, thus, labor intensive and time consuming. There is a need in the art therefore for methods and systems operable to automate the cleaning process of a pressure pot and, for example, an associated pressure pot cover assembly. <CIT> discloses systems and cleaning methods of the prior art. <CIT> discloses the preamble of claims <NUM> and <NUM>.

According to an aspect of the invention, a cleaning method is provided according to claim <NUM>.

According to another aspect of the invention, a method is provided during which coating material is applied onto a component of a gas turbine engine using a material spray system according to claim <NUM>.

According to still another aspect of the invention, a cleaning system is provided for a pressure pot cover assembly of a material spray system according to claim <NUM>.

The following optional features may be applied to any of the above aspects.

The cleaning system may also include a supply tank and a reclaim tank. The supply tank is fluidly coupled with the cleaning assembly. The supply tank is configured to provide the cleaning solution to the cleaning assembly. The reclaim tank is fluidly coupled with the internal cavity of the wash tank. The reclaim tank is configured to receive the cleaning solution after being directed against the pressure pot cover assembly.

The cleaning assembly may be configured as or otherwise include a jet ring configured to circumscribe and direct the cleaning solution against a mixing device. The one or more tools may be or include the mixing device.

The cleaning assembly may be configured as or otherwise include a jet ring configured to direct the cleaning solution against an underside of a lid of the pressure pot cover assembly.

The cover assembly may include a lid and a tool. When the cover assembly is mated with the wash tank: (A) the lid may close the opening into the wash tank; and/or (B) the tool may project into the cavity of the wash tank from the lid.

The tool may be configured as or otherwise include a mixing device.

The tool may be configured as or otherwise include a material pickup device.

When the cover assembly is mated with the pressure pot: (A) the lid may close and seal an opening into the pressure pot; and/or (B) the tool may project into a cavity of the pressure pot and interact with spray material within the cavity of the pressure pot.

The directing of the cleaning solution may include directing the cleaning solution into the cavity of the wash tank and against the cover assembly from a jet ring.

The jet ring may be configured to circumscribe and direct the cleaning solution against a mixing device of the cover assembly.

The jet ring may be configured to direct the cleaning solution against an underside of a lid of the cover assembly.

The jet ring may be disposed within the cavity. The jet ring may include a plurality of orifices arranged circumferentially in an annular array.

The method may also include receiving the cleaning solution from a cleaning solution supply tank.

The method may also include directing the cleaning solution that was directed against the cover assembly within the wash tank into a cleaning solution reclaim tank.

The material residue may be residue material from applying a coating onto a component of a gas turbine engine using the pressure pot.

The present disclosure includes systems and methods for cleaning or otherwise involving a material spray system, which may also be referred to as a material application system and/or a coating system. An exemplary material spray system <NUM> is schematically illustrated in <FIG> and briefly described below. The present disclosure, however, is not limited to the exemplary material spray system configuration shown in <FIG>. Rather, the systems and methods of the present disclosure may be implemented with various different material spray system configurations that utilize a pressure pot cover assembly.

The material spray system <NUM> of <FIG> includes a pressure pot <NUM> configured with a pressure pot cover assembly <NUM>. The material spray system <NUM> also includes an applicator <NUM> such as, but not limited to, a device with one or more nozzles.

The cover assembly <NUM> includes a lid <NUM> and one or more tools <NUM> and <NUM>. The lid <NUM> is configured to mate with a tank <NUM> of the pressure pot <NUM>. More particularly, the lid <NUM> is configured to be placed onto a top end <NUM> of the pressure pot tank <NUM> so as to close and seal an opening into the pressure pot tank <NUM>. At least a combination of the lid <NUM> and the pressure pot tank <NUM> may thereby collectively form a pressure vessel.

The one or more tools may include a mixing device <NUM> and a material pickup device <NUM>. The mixing device <NUM> of <FIG> includes a rotatable shaft <NUM> and a rotatable mixing head <NUM> such as, but not limited to, a mixing impeller. The shaft <NUM> projects downward into an internal cavity <NUM> of the pressure pot tank <NUM> and the pressure pot <NUM> from an underside <NUM> of the lid <NUM> to a distal shaft end <NUM>. The mixing head <NUM> is connected to the shaft <NUM> at (e.g., on, adjacent or proximate) the distal shaft end <NUM>. The mixing head <NUM> is thereby arranged within the cavity <NUM> and is operable to mix (e.g., stir) material within the cavity <NUM> of the pressure pot tank <NUM>. Examples of material which may be contained in the pressure pot internal cavity <NUM> include, but are not limited to, polyurethanes, adhesives, sealants, conversion, lubricant type coatings.

The material pickup device <NUM> is configured to provide (e.g., flow and/or direct) the mixed material from within the cavity <NUM> to the applicator <NUM>. The material pickup device <NUM> of <FIG>, for example, is fluidly coupled to the applicator <NUM> through at least an external conduit <NUM>. The material pickup device <NUM> of <FIG> includes a length of conduit <NUM> and a pickup tube <NUM>. The conduit <NUM> projects downward into the cavity <NUM> from the underside <NUM> of the lid <NUM> to a distal conduit end. The pickup tube <NUM> is connected to the conduit <NUM> at the distal conduit end. The specific pickup tube <NUM> of <FIG> is configured as either a straight body or a cupped body, where an opening either straight or into a recess formed by the cupped body faces a bottom <NUM> of the pressure pot tank <NUM>. This pickup tube <NUM> is located vertically beneath the mixing head <NUM>.

During operation of the material spray system <NUM>, the material within the pressure pot cavity <NUM> is mixed by the mixing device <NUM>. This mixed material is directed out of the cavity <NUM> via the material pickup device <NUM> and provided to the applicator <NUM> for application (e.g., spraying) onto at least a portion of a surface of a component <NUM>. An example of the component <NUM> is a component of a gas turbine engine; e.g., air airfoil for a rotor blade (e.g., a fan blade, a compressor blade or a turbine blade) or a stator vane. Of course, various other gas turbine engine components as well as non-gas turbine engine components may alternatively be coated using the material spray system <NUM>. For example, the component <NUM> may be a platform or a gas path wall (e.g., a liner).

After the coating component process, leftover / remaining coating material is removed from the pressure pot <NUM>. However, wet and/or dried residue of this coating material may still coat various surfaces of the pressure pot <NUM>. These surfaces include, but are not limited to, (a) a surface on the underside <NUM> of the lid <NUM>, (b) exterior surfaces of the mixing device <NUM> and its elements <NUM> and <NUM>, (c) exterior surfaces of the material pickup device <NUM> and its elements <NUM> and <NUM> and (d) internal surfaces of the material pickup device <NUM> and its elements <NUM> and <NUM> (e.g., interior conduit and pickup tube surfaces). To prevent this residue material from contaminating subsequent coating processes and/or reducing efficiency / operability of the material spray system <NUM>, the pressure pot cover assembly <NUM> may be cleaned utilizing a cleaning system <NUM> as illustrated, for example, in <FIG>.

The cleaning system <NUM> of <FIG> is configured to remove (partially or completely) the wet and/or dried residue material from one or more surfaces (e.g., the above described surfaces) of the pressure pot cover assembly <NUM>. This cleaning system <NUM> includes a wash tank <NUM> and an associated cleaning assembly <NUM>. The cleaning system <NUM> of <FIG> also includes a supply tank <NUM> and/or a reclaim tank <NUM>.

Referring to <FIG>, the wash tank <NUM> is configured as an open ended container such as a bucket or basin. The wash tank <NUM> includes a tubular sidewall <NUM> and an endwall <NUM> that form an internal cavity <NUM>. This internal cavity <NUM> is sized to receive the one or more tools <NUM> and <NUM> of the pressure pot cover assembly <NUM>. The wash tank <NUM> is similarly configured to mate with the lid <NUM> of the pressure pot cover assembly <NUM>. More particularly, as similarly described above with respect to the pressure pot tank <NUM>, the wash tank <NUM> is configured such that the lid <NUM> may be placed onto a top end <NUM> of the wash tank <NUM> (e.g., contacting a rim <NUM> of the tubular sidewall <NUM>) so as to close and seal an opening <NUM> into the wash tank <NUM>. At least a combination of the lid <NUM> and the wash tank <NUM> may thereby collectively form a pressure vessel.

The cleaning assembly <NUM> is configured to direct cleaning solution into the wash tank cavity <NUM> and against the pressure pot cover assembly <NUM> and its surfaces to remove the residue material from the cover assembly <NUM>. The cleaning assembly <NUM> of <FIG> includes a (e.g., standalone) spray nozzle <NUM> and one or more jet rings <NUM> and <NUM> (schematically shown).

The spray nozzle <NUM> is configured to direct the cleaning solution against the pickup tube <NUM> of the material pickup device <NUM>. The nozzle <NUM> is also configured to direct the cleaning solution into the recess of the pickup tube <NUM> as well as into an internal passage of the conduit <NUM>. The nozzle <NUM>, for example, is disposed within the wash tank <NUM> and its cavity <NUM>. This nozzle <NUM> is aligned with the material pickup device <NUM> and oriented to direct a jet or spray of the cleaning solution upwards towards the material pickup device <NUM>. Of course, in other embodiments, the nozzle <NUM> may be mated with the pickup tube <NUM> so as to flow the cleaning solution through the material pickup device <NUM>; e.g., through internal passage of the conduit <NUM>.

The first (e.g., lower) jet ring <NUM> is disposed within the wash tank <NUM> and its cavity <NUM>. The first jet ring <NUM> circumscribes the mixing device <NUM> and its head <NUM> as well as the conduit <NUM>. The first jet ring <NUM> includes one or more orifices <NUM> (e.g., nozzle orifices) arranged circumferentially in an annular array. Each of these orifices <NUM> is configured to direct a jet or spray of the cleaning solution radially inwards towards the mixing head <NUM>.

The second (e.g., upper) jet ring <NUM> is disposed within the wash tank <NUM> and its cavity <NUM>. The second jet ring <NUM> circumscribes the shaft <NUM>, mixing head <NUM> and conduit <NUM>. The second jet ring <NUM> includes one or more orifices <NUM> (e.g., nozzle orifices) arranged circumferentially in an annular array. Each of these orifices <NUM> is configured to direct a jet or spray of the cleaning solution radially inwards towards the tool elements <NUM>, <NUM> and <NUM> and/or upwards towards the underside <NUM> of the lid <NUM>.

Referring to <FIG>, the supply tank <NUM> is configured to store the cleaning solution prior to use in the wash tank <NUM>. The supply tank <NUM> is further configured to provide the stored cleaning solution to the wash tank <NUM>. The supply tank <NUM> of <FIG>, for example, is fluidly coupled with the cleaning assembly <NUM> and its components through a supply line <NUM> and a manifold <NUM> of the cleaning assembly <NUM>. At least a portion of the supply line <NUM> is external to the wash tank <NUM> and the supply tank <NUM>. The manifold <NUM> is arranged within the wash tank cavity <NUM>. A pump <NUM> may be fluidly coupled inline with the supply line <NUM> to draw the cleaning solution out from the supply tank <NUM> and pump that solution into the cleaning assembly <NUM> and, therethrough, the wash tank cavity <NUM>.

The reclaim tank <NUM> is configured to receive used cleaning solution from the wash tank <NUM>. The term "used cleaning solution" describes cleaning solution that has already been directed against the pressure pot cover assembly <NUM> by the cleaning assembly <NUM>. The reclaim tank <NUM> of <FIG>, for example, is fluidly coupled to a sump area of the wash tank <NUM> through a reclaim line <NUM> that is external to the wash tank <NUM> and the reclaim tank <NUM>. A pump <NUM> may be fluidly coupled inline with the reclaim line <NUM> to draw the used cleaning solution out from the wash tank <NUM> and pump that solution into the reclaim tank <NUM>.

In some embodiments, the reclaim tank <NUM> may be further fluidly coupled with the supply tank <NUM> by a return line <NUM>. This return line <NUM> may enable at least some of the reclaimed cleaning solution to be reused for subsequent cleaning operations. Of course, in other embodiments, the return line <NUM> may be omitted such that the tanks <NUM> and <NUM> are only fluidly coupled through the wash tank <NUM>.

<FIG> is a flow diagram of a method <NUM> for utilizing a cleaning system such as the cleaning system <NUM> of <FIG>. This method <NUM> is also described utilizing a material spray system such as the material spray system <NUM> of <FIG>. The method <NUM>, however, may also be implemented with alternative cleaning systems and/or material spray systems.

In step <NUM>, coating material is applied to a component <NUM>. For example, the material spray system <NUM> may be used to coat one or more surfaces of the component <NUM> with the coating material.

In step <NUM> and subsequent to performance of the application (the step <NUM>) of the coating material, the pressure pot cover assembly <NUM> is removed from the pressure pot <NUM>.

In step <NUM>, the pressure pot cover assembly <NUM> is mated with the wash tank <NUM>. The tools <NUM> and <NUM>, for example, are inserted into the wash tank cavity <NUM>. The lid <NUM> is placed onto the rim <NUM> of the tubular sidewall <NUM> so as to cover and seal the opening <NUM> in the wash tank <NUM>.

In step <NUM>, cleaning solution is directed against the pressure pot cover assembly <NUM> to remove (completely or partially) wet and/or dried residue coating material. The cleaning assembly <NUM>, for example, directs the cleaning solution into the cavity <NUM> and against the surfaces of the cover assembly elements <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> and/or <NUM>. The cleaning solution may remove the residue coating material from the pressure pot cover assembly <NUM> via the force of impact of the cleaning solution onto the residue coating material and/or via chemically dissolving the residue coating material.

In step <NUM>, used cleaning solution is reclaimed. The used cleaning solution, for example, is directed out of the wash tank cavity <NUM> and into the reclaim tank <NUM>. This reclaimed cleaning solution may then be stored within the reclaim tank <NUM> until a subsequent cleaning operation. Alternatively, the used cleaning solution may be recirculated to the supply tank <NUM> to replenish the cleaning solution contained therein; e.g., via return line <NUM>. Of course, the used cleaning solution may first be processed (e.g., filtered, tested, etc.) prior to being provided back to the supply tank <NUM>.

Claim 1:
A cleaning method comprising:
removing a cover assembly (<NUM>) from a pressure pot (<NUM>) of a material spray system (<NUM>);
mating the cover assembly (<NUM>) with a wash tank (<NUM>), wherein the cover assembly (<NUM>) closes an opening (<NUM>) into the wash tank (<NUM>);
directing cleaning solution into a cavity (<NUM>) of the wash tank (<NUM>) and against the cover assembly (<NUM>) from a nozzle (<NUM>) to remove material residue from the cover assembly (<NUM>); and
directing the cleaning solution into a conduit (<NUM>, <NUM>) of the cover assembly (<NUM>) to remove material residue from within the conduit (<NUM>, <NUM>); characterised in that
the nozzle (<NUM>) is configured to direct the cleaning solution upwards and against a tube (<NUM>) of a material pickup device (<NUM>) of the cover assembly (<NUM>), and the nozzle (<NUM>) is further configured to direct the cleaning solution into a recess of the tube (<NUM>) and into an internal passage of the conduit (<NUM>).