System consists of main spray coating equipment, manipulators for positioning workpiece and torch during the spraying process, as well as peripheral components to ensure comfortable and safe working conditions.
The main equipment is required to control the spraying process parameters. When selecting components of main equipment, it is necessary to take into account the various characteristics of these components, the sprayed material properties, the required characteristics of resulting coating, as well as the workpiece geometry.
Manipulators are required to move and position the torch and workpiece during the spraying process. When selecting manipulators, it is necessary to take into account the workpiece geometry. Reasonably selected characteristics of manipulators ensure high process performance and high-quality resulting coatings.
High-velocity oxy-fuel (HVOF) spraying process produces large amounts of dust and flame-generated heat, and is also characterized by high noise levels (130 dB). Sound proof chambers and exhaust filter units are used to ensure an acceptable noise level in the workplace, as well as to remove hot and dusty air from the work area.
Final configuration of each spray system depends on the specific process task and the customer’s requirements.
Main equipment connection scheme for
Main equipment connection scheme for
Versatile platform for thermal spraying
This system is a new generation complete thermal spraying unit. It integrates perfectly into modern automated or robotic spray coating systems and provides unchallenged process control, flexibility and highly repeatable spray performance.
Single platform for 4 types of spraying processes: plasma spraying, HVOF spraying, flame spraying and electric arc spraying. Modular architecture allows the system to be configured in accordance with customer’s requirements, while integrating multiple spray technologies into a single unit.
Main Functions of Software
Graphical operator interface with process parameter visualization function
Spray guns library allowing operator to choose the most suitable device
VPN connection for remote system diagnostics
Options for saving and recalling control programs
Monitoring and control of external modules, such as a robot, exhaust filter unit (EFU), refrigeration unit, etc.
Multi-level access control system with "Operator", "Process Engineer" and "Service Engineer" access levels
On-line monitoring and recording of current process parameters
Servicing planning and control options
Resource consumption per piece/total resource consumption accounting
Single panel for controlling the entire spray system. This panel is used to call, run and edit control programs, as well as display all parameters of spraying process, state of system components and errors that occur during operation.
Module designed to connect cooling water hoses and spray gun. This module measures cooling water flow rate, water temperature at the inlet and outlet, and also includes the high-voltage arc ignition unit for spray gun and other modules necessary for process monitoring and control.
This module is used to control the flow, mixing and supply of all fuel gases to the torch. Module includes mass flow meters with feedback for all process gases, as well as all pressure transmitters, regulators and valves; in addition, a liquid fuel pump is provided for HVOF-LF process.
Powder feeder supplies sprayed material in powder form to spray gun. Powder is poured into corresponding hopper, from which it is transferred to flame zone using a carrier gas. Number of hoppers is selected depending on the number of powder types used and the required process productivity. In standard version, the system provides the ability to simultaneously use up to 4 independent powder feed lines connected to corresponding hoppers.
During operation, the spray gun generates high thermal power, which requires forced water cooling. Refrigeration unit specially designed for HVOF spraying process is the solution for these purposes.
Separate tank is required to store kerosene or ethanol used for the liquid-fueled high velocity oxy-fuel (HVOF-LF) thermal spray process. Tank is installed in separate room, and fuel is supplied to gas management center by specialized pump.
Machine can operate with spray guns using both liquid and gaseous fuel. Control system stores preset operating parameters for each spray gun, which helps prevent its premature failure due to improper operation.
DJ 2600 (HVOF-GF) Spray Gun
| Applicable fuel gases | H2, O2 |
| Sprayable powders | metal, carbides |
| Applicable fuel gases | kerosene, O2 |
| Sprayable powders | metal, carbides |
EGUN 5000 (HVOF-LF) Spray Gun
| Applicable fuel gases | ethanol, O2 |
| Sprayable powders | metal, carbides |
Exhaust filter unit
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