Genesis develops Robotic Flame Spray Workcell

The Flame Spray Process is utilized to add a hardened surface on precision wear parts in multiple industries and applications. The process is inherently labor intensive and dangerous, requiring fusing temperatures to over 2000-degree F.  Genesis designed a custom robotic system to automatically perform the entire process, utilizing auto-gage and auto-temperature sensing for predictable process control.

Project Challenges

• Multiple part sizes and heat requirements
• Extreme heat of reaching 2000-degrees
• Traditional fusing process is achieved by sight and is very operator dependant
• Robust controls package to closely monitor the process while allowing for easy operator interface

Genesis Solution

• The Genesis Team designed a lathe system to turn the part using a Cone Drive gearbox and VFD. The tailstock needed to adjust for two different length parts. Tool changers and torch lighters needed to be designed into the system to enable the robot to automatically change between the double rosebud torch and the flame spray gun. Torch lighters are automatic and the flames are monitored. Every process is tightly controlled for quality and operator safety.
• The tailstock and headstock were designed using a special spacer to isolate the heat from the tailstock bearings and the headstock gearbox. Special linear bearing seals were included in the design. A 1500-degree robot suite was employed to protect the robot. Gearboxes and cylinders were ordered with high temperature seals. Guards and covers were added to deflect the heat from reaching the robot.  A special side draft heat/smoke extraction wall was included.
• Since the fusing process is normally completed by sight, the Genesis Team needed to develop a process that is consistent and repeatable. To aid in the process, Genesis automated the temperature sensing and the measurement of the thickness of the sprayed on material. The number of robot passes is defined and adjustable based upon multiple conditions, such as humidity, metallurgy, ambient temperature, and mass of material. Robust and flexible!