EP1884293B1 - Masking system for masking a cylinder hole - Google Patents

Masking system for masking a cylinder hole Download PDF

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Publication number
EP1884293B1
EP1884293B1 EP07109434A EP07109434A EP1884293B1 EP 1884293 B1 EP1884293 B1 EP 1884293B1 EP 07109434 A EP07109434 A EP 07109434A EP 07109434 A EP07109434 A EP 07109434A EP 1884293 B1 EP1884293 B1 EP 1884293B1
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EP
European Patent Office
Prior art keywords
masking
cylinder
accordance
masking system
previous
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Not-in-force
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EP07109434A
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German (de)
French (fr)
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EP1884293A1 (en
Inventor
Christian Bohnheio
Gérard BARBEZAT
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Oerlikon Metco AG
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Sulzer Metco AG
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Priority to EP07109434A priority Critical patent/EP1884293B1/en
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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/01—Selective coating, e.g. pattern coating, without pre-treatment of the material to be coated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B12/00—Arrangements for controlling delivery; Arrangements for controlling the spray area
    • B05B12/16—Arrangements for controlling delivery; Arrangements for controlling the spray area for controlling the spray area
    • B05B12/18—Arrangements for controlling delivery; Arrangements for controlling the spray area for controlling the spray area using fluids, e.g. gas streams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B12/00—Arrangements for controlling delivery; Arrangements for controlling the spray area
    • B05B12/16—Arrangements for controlling delivery; Arrangements for controlling the spray area for controlling the spray area
    • B05B12/20—Masking elements, i.e. elements defining uncoated areas on an object to be coated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B12/00—Arrangements for controlling delivery; Arrangements for controlling the spray area
    • B05B12/16—Arrangements for controlling delivery; Arrangements for controlling the spray area for controlling the spray area
    • B05B12/20—Masking elements, i.e. elements defining uncoated areas on an object to be coated
    • B05B12/26—Masking elements, i.e. elements defining uncoated areas on an object to be coated for masking cavities
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
    • B05B7/16—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed
    • B05B7/20—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed by flame or combustion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
    • B05B7/16—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed
    • B05B7/22—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc

Definitions

  • the invention relates to a masking system for masking a cylinder bore of an internal combustion engine during a thermal coating process, as well as the use of a marking system according to the invention according to the preamble of the independent claim of the respective category.
  • thermal coating of cylinder surfaces of internal combustion engines by various thermal spraying methods is state of the art nowadays and is widely used, in particular, but not only, in engines for motor vehicles of all kinds.
  • the corresponding cylinder treads are activated by various methods prior to thermal coating, e.g. by corundum blasting, chilled cast iron, high pressure water jets or by other known activation processes.
  • Substrates made of light metal alloys based on Al or Mg are most commonly used.
  • V-type engines that is, engines having two parallel rows of cylinders, wherein the two longitudinal axes of two adjacent cylinder liners, each belonging to one of the two rows of cylinders, are inclined by a certain angle to each other, whereby the characteristic V-shape of the engine block of a V-shaped engine is formed.
  • thermal coating involves the risk that, during coating of a cylinder wall of a cylinder bore of a first cylinder bank, on the cylinder wall of an adjacent cylinder of the second bank of cylinders, vapors, e.g. Metal vapors of the coating material, which are never completely avoided during thermal coating, are deposited. Due to the deposition of the metal vapors on the relatively cold walls on the cylinder wall of the cylinder of the second row of cylinders, this cylinder wall is contaminated in the second row of cylinders by the metal vapors, which, inter alia, has a negative effect on the adhesion of a later also applied to this cylinder coating , In addition, contamination by unmelted particles and overspray is to be feared.
  • vapors e.g. Metal vapors of the coating material
  • Another problem is the heating of the engine block by the thermal coating process. Since the difference in thermal expansion coefficient between the thermal spray layer and the substrate may be relatively high, a temperature of the substrate above 120 ° C, which is essentially a kind of mean engine block temperature, has a negative effect on the residual stress level of the layers and above 150 ° C, there is even the danger that the made of a light metal alloy component, so the engine block, a distortion of the material suffers and thus unusable.
  • typical expansion coefficients of thermal spray coatings of iron-based alloys are, for example, about 11 ⁇ 10 -6 / ° C, while typical thermal expansion coefficients of aluminum-based substrates at about 23 ⁇ 10 -6 / ° C and magnesium-based substrates typically at 27x10 -6 / ° C.
  • typical coefficients of thermal expansion of the substrates that is to say of the material from which the engine blocks are made, are more than twice the size of the thermal expansion coefficients of the sprayed-on thermal sprayed coatings on the order of magnitude.
  • the EP 1 685 910 A1 discloses a device for applying a coating to an engine block, with which during the coating of a first cylinder bank to protect a second cylinder bank, a nozzle for sucking gas from the second cylinder bank is provided. However, here too, especially the cooling of the cylinder block is not sufficiently guaranteed.
  • the object of the invention is therefore to provide a device with which the problems known from the prior art, in particular the thermal problems and the problems with the contamination by metal vapors, are avoided in the thermal coating of cylinder bores of internal combustion engines At the same time a high degree of automation can be achieved easily and inexpensively.
  • the invention thus relates to a masking system for masking a cylinder bore of an internal combustion engine during a thermal coating process, comprising a masking body, which can be placed during the thermal coating process of a first cylinder of the internal combustion engine to cover a cylinder wall of a second cylinder in the cylinder bore of the second cylinder.
  • the masking body is configured such that a flow gap of predeterminable width can be set to produce a flow of a fluid between the masking body and the cylinder wall of the second cylinder.
  • the masking system comprises a masking body, which on the one hand substantially completely covers a cylinder wall of a cylinder bore which is not to be coated during the coating of another cylinder wall and which therefore covers it before the direct application of metal vapors originating from a coating jet which the other cylinder is coated protects. So prevents the cylinder wall not to be coated from being exposed directly or indirectly to the coating jet.
  • the masking body is configured in such a way that a flow gap remains free between the masking body and the cylinder wall which is currently not to be coated, so that an air flow can be generated therein on the one hand causes cooling of the engine block in the covered cylinder bore and on the other hand prevents indirectly metal dust that spread in the interior of the engine block, reflected on the currently not to be coated cylinder wall.
  • a closed pipe with a controlled flow gap between pipe and cylinder surface is introduced.
  • a flow of air or other fluids is achieved, which cools the cylinder surface and at the same time prevents the deposition of metal vapors on this cylinder surface, since the flows or turbulence of the metal vapors can be effectively suppressed.
  • a row of cylinders is preferably coated in each case.
  • the cylinder row opposite it is protected by a masking system according to the invention such that, for example, a plasma jet of a rotating plasma spray device, which is guided in the axial direction during coating through the cylinder bore, which plasma jet at a lower reversal point in the region of the crankcase of the engine block to the opposite hole can reach, the cylinder walls not to be coated cylinder row reached.
  • the masking body is a hollow masking body or a solid masking body, preferably a hollow masking cylinder or a solid masking cylinder.
  • the masking body is preferably designed such that the flow gap has a width of 0.1 mm to 10 mm, preferably a width between 0.2 mm and 5 mm, in particular a width between 0.4 mm and 3 mm. This ensures at the same time that the flow gap is narrow enough so that a direct contamination of the cylinder wall of the cylinder protected by the masking body can be prevented and at the same time a sufficiently strong flow in the flow gap can be maintained, so that sufficient cooling can be achieved.
  • a masking system comprises at least two masking bodies, so that at least two cylinders, preferably two adjacent cylinders, can be masked simultaneously, wherein in a particularly important practical embodiment the masking system comprises a predeterminable number of masking bodies and is designed such that a complete cylinder row of an internal combustion engine in V-construction is simultaneously maskable.
  • the masking body preferably comprises a masking cover and the masking cover comprises in particular a channel which can be connected to the flow gap, in particular an outlet channel and / or an inlet channel for conveying the fluid.
  • the channel may have openings, one or more of which may be provided in the masking cover over which the fluid, e.g. Air or another gas, for example by a suction device, which may be provided on the crankcase, is sucked, so that thereby the flow in the flow gap between masking body and cylinder wall can be produced.
  • air or other gas may also be provided via the openings, several of which, for example, may be provided in the masking cover and e.g. may be arranged in the vicinity of an edge of the masking cover can be introduced under a predetermined pressure in the flow gap or sucked through the openings, wherein the flow direction of the fluid, depending on whether the fluid is injected under pressure into the openings or sucked out of these is directed either into the crankcase or out of this.
  • the shape of the openings may vary depending on the requirement, e.g. circular openings, slot-shaped openings or openings of other suitable shape can be provided.
  • a gas or a gas mixture in particular air and / or nitrogen and / or a noble gas, in particular argon and / or helium for generating the flow in the flow gap is particularly well suited.
  • a suction means may be provided on the crankshaft space of the motor housing to be coated, so that the flow of the fluid through the flow gap through the crankshaft space of the internal combustion engine can be sucked off.
  • a feed means for feeding the fluid into the flow gap may be provided, so that the flow of the fluid through the flow gap can be generated under a predetermined feed pressure.
  • a flow velocity of the fluid in the flow gap is preferably greater than 1 m / s, in particular greater than 10 m / s, and in particular between 1 m / s and 150 m / s, preferably between 10 m / s and 80 m / s. This on the one hand sufficient cooling of the engine block is achieved and on the other hand generates a sufficiently strong flow in the flow gap, so that no metal vapor on a non-coated cylinder surface, which is protected by a masking system according to the invention, can settle.
  • a manipulator in particular a program-controlled robot system, can be provided for positioning the masking body so that the masking body can be automatically placed in the cylinder bore according to a predefinable program startup pattern.
  • a supply unit for providing the fluid can advantageously be provided, which is preferably programmably controllable and / or regulatable, so that e.g. the flow rate and / or the pressure and / or the flow rate of the fluid flow in the flow gap can be controlled and / or regulated, and e.g. depending on the time, the type of engine block to be coated or depending on certain coating parameters, such as temperature, type of coating device used, type of coating material, type of coating method, etc. controllable and / or regulated.
  • the invention further relates to the use of a masking system according to the invention, as described in detail in this application, wherein the thermal coating process is a plasma spraying process, preferably a plasma APS process, a flame spraying process, In particular, a high-speed flame spraying method and / or another thermal spraying method such as, for example, an arc wire spraying method.
  • the thermal coating process is a plasma spraying process, preferably a plasma APS process, a flame spraying process, In particular, a high-speed flame spraying method and / or another thermal spraying method such as, for example, an arc wire spraying method.
  • an inventive masking system is used in particular as protection against contamination of a cylinder bore and / or for cooling during the thermal coating process.
  • Fig. 1 shows in a representation in section a simple embodiment of a masking system according to the invention during the coating of a cylinder bore of a motor in V-construction, on which the operation of a masking system according to the invention, which is hereinafter referred to in its entirety by the reference numeral 1, is explained schematically.
  • Fig. 1 is a section through an engine block of a motor shown in V-construction, whose two rows of cylinders are arranged in a conventional manner parallel to each other, at an inclination angle ⁇ .
  • the plasma spray gun rotates during the coating process in the cylinder 5 about a longitudinal axis, as the arrow 1002 indicates and is guided under rotation in the axial direction through the cylinder bore during the coating process.
  • a plasma jet 1003 with coating material 1004 exits from a spray opening 1001, with which coating material 1004 the cylinder wall of the cylinder 5 is coated.
  • the plasma spray gun 1000 is just near its lower reversal point, that is, the plasma jet 1003 with coating material 1004 not only applies to the cylinder wall to be coated of the cylinder 5, but extends into the crankcase of the V-engine 3 and even into the not to be coated second cylinder 7 inside.
  • the cylinder wall 6 of the second cylinder 7 would be contaminated with coating material 1004 and moreover heated excessively by the plasma jet 1003.
  • a masking body 4 is provided in the cylinder bore 2 of the second cylinder 7, which in the present example of the Fig. 1 is designed as a hollow cylinder 4 and additionally comprises a masking cover 41.
  • the masking cover 41 which forms a cover on the second cylinder 7 or on the marking body 4, comprises a channel 42 connected to the flow gap 10, which is formed between the masking cylinder 4 and the cylinder wall 6, with openings 421, which in the example of FIG Fig. 1 is formed as an inlet channel 42 for conveying the fluid 9 in the flow gap 10.
  • the flow 8 of the fluid 9 in the flow gap 10 is characterized by an in Fig. 1 not explicitly shown suction generated in a manner known to those skilled in the art in the crankcase a predetermined negative pressure, so that air is sucked through the openings 421 in the masking cover 41, which then flows through the opening 421 connected to the flow gap 10, so that the cylinder 7 and thus the complete engine block of the internal combustion engine 3 on the one hand is cooled and on the other hand, a deposition of metal vapors on the cylinder wall 6 of the second cylinder 7 is prevented.
  • FIG. 2 schematically an eight-cylinder V-engine with a robot-assisted masking system is shown.
  • Fig. 2 shows an eight-cylinder V-engine 3 with a lower cylinder row according to the illustration, in which just the cylinder 5 is coated by means of a plasma spray gun 1000 by a plasma jet with coating material 1004.
  • the upper row of cylinders 11 of the internal combustion engine 3 according to the illustration are simultaneously completely masked by a masking system 1 according to the invention and therefore protected from the dangerous overspray from the coating jet 1003 with which the cylinder 5 of the lower row is coated and at the same time cooled by the fluid 9 ,
  • the particularly important for practice special embodiment of an inventive masking system 1 of Fig. 2 comprises four masking cylinders 4 each having a masking cover 41 which Masking cylinder 4 are placed in the cylinder bores 2 of the second cylinder 7.
  • one or more of the masking cylinders is hollow and one or more of the other masking cylinders are solid.
  • the four masking cylinders 4 are supported via the 4 masking covers 41 on a support arm 141 of a robot system 14, so that all second cylinder bores 7 can be masked or demasked at the same time by the robot system 14, by means of an in Fig. 2 not explicitly shown drive the support arm 141 is moved so that the masking cylinder can be sunk or pulled out into the second cylinder 7.
  • a feed means 13 in the form of a feed line 13 is provided, through which the fluid 9 can be supplied to the flow gaps via the masking covers 41.
  • all masking cylinders 4 can be simultaneously pulled out of the upper row of cylinders by means of the robot system 14 and subsequently placed in the lower row of cylinders to protect the cylinder walls of the lower row of cylinders.
  • the engine block of the engine 3 may be e.g. be arranged on a strip line, so that automatically successively the cylinder bores of several engine blocks can be coated.
  • the motor blocks are additionally mounted on a manipulator or on a movable robot, so that e.g. in order to place the masking system 1 according to the invention, the motor 3 can be pivoted, rotated or aligned in any other suitable way.

Description

Die Erfindung betrifft ein Maskierungssystem zur Maskierung einer Zylinderbohrung einer Brennkraftmaschine während eines thermischen Beschichtungsvorgangs, sowie die Verwendung eines erfindungsgemässen Markierungssystems gemäss dem Oberbegriff des unabhängigen Anspruchs der jeweiligen Kategorie.The invention relates to a masking system for masking a cylinder bore of an internal combustion engine during a thermal coating process, as well as the use of a marking system according to the invention according to the preamble of the independent claim of the respective category.

Das thermische Beschichten von Zylinderlaufflächen von Verbrennungsmotoren durch verschiedene thermische Spritzverfahren ist heutzutage Stand der Technik und findet insbesondere bei Motoren für Kraftfahrzeuge aller Art, aber nicht nur hier, breite Anwendung. Dabei werden gewöhnlich die entsprechenden Zylinderlaufflächen durch verschiedene Verfahren vor dem thermischen Beschichten aktiviert, z.B. durch Korundstrahlen, Hartgussstrahlen, Hochdruckwasserstrahlen oder durch andere an sich bekannte Aktivierungsverfahren. Am häufigsten werden dabei Substrate aus leichtmetallischen Legierungen auf Al oder Mg Basis beschichtet.The thermal coating of cylinder surfaces of internal combustion engines by various thermal spraying methods is state of the art nowadays and is widely used, in particular, but not only, in engines for motor vehicles of all kinds. In doing so, usually the corresponding cylinder treads are activated by various methods prior to thermal coating, e.g. by corundum blasting, chilled cast iron, high pressure water jets or by other known activation processes. Substrates made of light metal alloys based on Al or Mg are most commonly used.

Ein weit verbreiteter Typ von Motoren sind Motoren in V-Bauweise, also Motoren, die zwei zueinander parallel verlaufende Zylinderreihen aufweisen, wobei die zwei Längsachsen von zwei benachbarten Zylinderbuchsen, die jeweils zu einer der beiden Zylinderreihen gehören, um einen bestimmten Winkel gegeneinander geneigt sind, wodurch die charakteristische V-Form des Motorblocks eines Motors in V-Bauweise entsteht.A widespread type of engines are V-type engines, that is, engines having two parallel rows of cylinders, wherein the two longitudinal axes of two adjacent cylinder liners, each belonging to one of the two rows of cylinders, are inclined by a certain angle to each other, whereby the characteristic V-shape of the engine block of a V-shaped engine is formed.

Bei solchen V-Motoren besteht beim thermischen Beschichten die Gefahr, dass, während der Beschichtung einer Zylinderwand einer Zylinderbohrung einer ersten Zylinderreihe, auf der Zylinderwand eines benachbarten Zylinders der zweiten Zylinderreihe Dämpfe, z.B. Metalldämpfe des Beschichtungsmaterials, die beim thermischen Beschichten nie ganz zu vermeiden sind, abgeschieden werden. Durch die Abscheidung der Metalldämpfe an den relativ kalten Wänden auf der Zylinderwand des Zylinders der zweiten Zylinderreihe, wird diese Zylinderwand in der zweiten Zylinderreihe durch die Metalldämpfe kontaminiert, was unter anderem eine negative Wirkung auf die Haftung einer später auf diesen Zylinder ebenfalls noch aufzubringenden Beschichtung hat. Zudem ist eine Kontamination durch ungeschmolzene Partikel und Overspray zu befürchten.In such V-type engines, thermal coating involves the risk that, during coating of a cylinder wall of a cylinder bore of a first cylinder bank, on the cylinder wall of an adjacent cylinder of the second bank of cylinders, vapors, e.g. Metal vapors of the coating material, which are never completely avoided during thermal coating, are deposited. Due to the deposition of the metal vapors on the relatively cold walls on the cylinder wall of the cylinder of the second row of cylinders, this cylinder wall is contaminated in the second row of cylinders by the metal vapors, which, inter alia, has a negative effect on the adhesion of a later also applied to this cylinder coating , In addition, contamination by unmelted particles and overspray is to be feared.

Ein weiteres Problem ist die Erwärmung des Motorblocks durch den thermischen Beschichtungsvorgang. Da der Unterschied im Wärmeausdehnungskoeffizient zwischen thermischer Spritzschicht und Substrat relativ hoch sein kann, hat eine Temperatur des Substrats oberhalb von 120°C, worunter im wesentlichen eine Art mittlere Temperatur des Motorblocks zu verstehen ist, eine negative Wirkung auf das Eigenspannungsniveau der Schichten und oberhalb von 150°C besteht gar die Gefahr, dass das aus einer Leichtmetalllegierung gefertigte Bauteil, also der Motorblock, einen Verzug des Materials erleidet und damit unbrauchbar wird.Another problem is the heating of the engine block by the thermal coating process. Since the difference in thermal expansion coefficient between the thermal spray layer and the substrate may be relatively high, a temperature of the substrate above 120 ° C, which is essentially a kind of mean engine block temperature, has a negative effect on the residual stress level of the layers and above 150 ° C, there is even the danger that the made of a light metal alloy component, so the engine block, a distortion of the material suffers and thus unusable.

Diese Problematik wird besonders deutlich, wenn man die thermischen Ausdehnungskoeffizienten typischer verwendeter Materialien betrachtet: typische Ausdehnungskoeffizienten thermischer Spritzschichten aus Eisenbasis-Legierungen liegen z.B. bei ca. 11×10-6/°C, während typische thermische Ausdehnungskoeffizienten von Aluminium basierten Substraten bei ca. 23×10-6/°C und bei Magnesium basierten Substraten typischerweise bei 27x10-6/°C liegen können. Das heisst, typische thermische Ausdehnungskoeffizienten der Substrate, also des Materials aus dem die Motorblöcke gefertigt sind, sind grössenordnungsmässig mehr als doppelt so gross wie die thermischen Ausdehnungskoeffizienten der aufgespritzten thermischen Spritzschichten.This problem becomes particularly clear when one considers the thermal expansion coefficients of typical materials used: typical expansion coefficients of thermal spray coatings of iron-based alloys are, for example, about 11 × 10 -6 / ° C, while typical thermal expansion coefficients of aluminum-based substrates at about 23 × 10 -6 / ° C and magnesium-based substrates typically at 27x10 -6 / ° C. This means that typical coefficients of thermal expansion of the substrates, that is to say of the material from which the engine blocks are made, are more than twice the size of the thermal expansion coefficients of the sprayed-on thermal sprayed coatings on the order of magnitude.

Im Stand der Technik sind verschiedene Vorrichtungen bekannt, die insbesondere das Problem der Kontamination von Zylinderlaufflächen mit den zuvor erwähnten Metalldämpfen zu lösen versuchen.In the prior art, various devices are known, which in particular try to solve the problem of contamination of cylinder surfaces with the aforementioned metal vapors.

So sind Vorrichtungen bekannt, bei welchen Zylinderbohrungen, die nicht beschichtet werden, mit einer Art aufblasbarem Ballon versiegelt werden, wie z.B. in der US 2001/0029886 A beschrieben, was jedoch zu Wärmestaus führen kann und die oben erwähnten Probleme mit den thermischen Ausdehnungskoeffizienten noch verschärft. Es sind andere Systeme, z.B. gemäss EP 1 136 583 A1 in Gebrauch, bei welchen durch das Kurbelwellengehäuse Abdeckungen zum Schutz der nicht zu beschichtenden Zylinderbohrungen eingeführt werden. Auch hier sind letztlich die thermischen Probleme nicht vollständig gelöst und, was mindestens ebenso wichtig ist, die Verwendung aller bekannten Systeme ist nur sehr schwer oder gar nicht zu automatisieren, insbesondere im Fall von Motoren der V-Bauweise, so dass der Beschichtungsprozess letztlich sehr teuer wird, weil viel Handarbeit bei der Beschichtung einer grossen Zahl von Motorblöcken notwendig ist.Thus, devices are known in which cylinder bores that are not coated with a kind of inflatable balloon are sealed, such as in the US 2001/0029886 A However, this can lead to heat accumulation and aggravates the above-mentioned problems with the thermal expansion coefficients. There are other systems, eg according to EP 1 136 583 A1 in use, in which by the crankshaft housing covers are introduced to protect the not to be coated cylinder bores. Again, ultimately, the thermal problems are not completely solved and, at least as important, the use of all known systems is very difficult or impossible to automate, especially in the case of motors of V-type, so that the coating process ultimately very expensive because a lot of manual work is necessary when coating a large number of engine blocks.

Die EP 1 685 910 A1 offenbart eine Vorrichtung zum Aufbringen einer Beschichtung auf einen Motorblock, mit welcher während der Beschichtung einer ersten Zylinderbank zum Schutz einer zweiten Zylinderbank eine Düse zum Absaugen von Gas aus der zweiten Zylinderbank vorgesehen ist. Allerdings ist auch hier vor allem die Kühlung des Zylinderblocks nicht ausreichend gewährleistet.The EP 1 685 910 A1 discloses a device for applying a coating to an engine block, with which during the coating of a first cylinder bank to protect a second cylinder bank, a nozzle for sucking gas from the second cylinder bank is provided. However, here too, especially the cooling of the cylinder block is not sufficiently guaranteed.

Die Aufgabe der Erfindung ist es daher, eine Vorrichtung zur Verfügung zu stellen, mit welcher die aus dem Stand der Technik bekannten Probleme, insbesondere die thermischen Probleme und die Probleme mit der Kontamination durch Metalldämpfe, beim thermischen Beschichten von Zylinderbohrungen von Brennkraftmaschinen vermieden werden, wobei gleichzeitig einfach und kostengünstig ein hoher Automatisierungsgrad erreichbar ist.The object of the invention is therefore to provide a device with which the problems known from the prior art, in particular the thermal problems and the problems with the contamination by metal vapors, are avoided in the thermal coating of cylinder bores of internal combustion engines At the same time a high degree of automation can be achieved easily and inexpensively.

Die diese Aufgaben lösenden Gegenstände der Erfindung sind durch die Merkmale des unabhängigen Anspruchs der jeweiligen Kategorie gekennzeichnet.The objects of the invention solving these objects are characterized by the features of the independent claim of the respective category.

Die jeweiligen abhängigen Ansprüche beziehen sich auf besonders vorteilhafte Ausführungsformen der Erfindung.The respective dependent claims relate to particularly advantageous embodiments of the invention.

Die Erfindung betrifft somit ein Maskierungssystem zur Maskierung einer Zylinderbohrung einer Brennkraftmaschine während eines thermischen Beschichtungsvorgangs, umfassend einen Maskierungskörper, der während des thermischen Beschichtungsvorgangs eines ersten Zylinders der Brennkraftmaschine zur Abdeckung einer Zylinderwand eines zweiten Zylinders in der Zylinderbohrung des zweiten Zylinders platzierbar ist. Dabei ist der Maskierungskörper derart ausgestaltet, dass zur Erzeugung einer Strömung eines Fluids zwischen dem Maskierungskörper und der Zylinderwand des zweiten Zylinders ein Strömungsspalt von vorgebbarer Breite einstellbar ist.The invention thus relates to a masking system for masking a cylinder bore of an internal combustion engine during a thermal coating process, comprising a masking body, which can be placed during the thermal coating process of a first cylinder of the internal combustion engine to cover a cylinder wall of a second cylinder in the cylinder bore of the second cylinder. In this case, the masking body is configured such that a flow gap of predeterminable width can be set to produce a flow of a fluid between the masking body and the cylinder wall of the second cylinder.

Wesentlich für die Erfindung ist, dass das erfindungsgemässe Maskierungssystem einen Maskierungskörper umfasst, der einerseits eine nicht zu beschichtende Zylinderwand einer Zylinderbohrung während des Beschichtens einer anderen Zylinderwand im wesentlichen vollständig abdeckt und diese damit vor dem direkten Aufbringen von Metalldämpfen, die aus einem Beschichtungsstrahl stammen, mit dem der andere Zylinder beschichtet wird, schützt. Also verhindert, dass die nicht zu beschichtende Zylinderwand mittelbar oder unmittelbar dem Beschichtungsstrahl ausgesetzt wird.It is essential to the invention that the masking system according to the invention comprises a masking body, which on the one hand substantially completely covers a cylinder wall of a cylinder bore which is not to be coated during the coating of another cylinder wall and which therefore covers it before the direct application of metal vapors originating from a coating jet which the other cylinder is coated protects. So prevents the cylinder wall not to be coated from being exposed directly or indirectly to the coating jet.

Anderseits ist der Maskierungskörper derart ausgestaltet, dass zwischen dem Maskierungskörper und der aktuell nicht zu beschichtenden Zylinderwand ein Strömungsspalt frei bleibt, so dass darin eine Luftströmung erzeugbar ist, die einerseits eine Kühlung des Motorblocks in der abgedeckten Zylinderbohrung bewirkt und anderseits verhindert, dass indirekt Metallstäube, die sich im Inneren des Motorblocks verteilen, sich auf der aktuell nicht zu beschichtenden Zylinderwand niederschlagen.On the other hand, the masking body is configured in such a way that a flow gap remains free between the masking body and the cylinder wall which is currently not to be coated, so that an air flow can be generated therein on the one hand causes cooling of the engine block in the covered cylinder bore and on the other hand prevents indirectly metal dust that spread in the interior of the engine block, reflected on the currently not to be coated cylinder wall.

Betrachtet man ein spezielles Ausführungsbeispiel der Erfindung, so wird z.B. auf einem gegenüberliegenden Zylinder während der Beschichtung ein geschlossenes Rohr mit einem kontrollierten Strömungsspalt zwischen Rohr und Zylinderlauffläche eingeführt. Durch entsprechende Öffnungen und einer angemessenen Absaugung wird eine Strömung von Luft bzw. anderer Fluide erreicht, die die Zylinderlauffläche kühlt und gleichzeitig die Abscheidung von Metalldämpfen auf dieser Zylinderlauffläche verhindert, da die Strömungen bzw. Turbulenzen der Metalldämpfe wirksam zurückgedrängt werden können.Considering a particular embodiment of the invention, e.g. On the opposite cylinder during the coating, a closed pipe with a controlled flow gap between pipe and cylinder surface is introduced. Through appropriate openings and adequate suction, a flow of air or other fluids is achieved, which cools the cylinder surface and at the same time prevents the deposition of metal vapors on this cylinder surface, since the flows or turbulence of the metal vapors can be effectively suppressed.

Bei der Beschichtung von Zylinderkurbelgehäusen in V-Bauweise wird jeweils bevorzugt eine Zylinderreihe beschichtet. Die ihr gegenüberliegende Zylinderreihe wird dabei durch ein erfindungsgemässes Maskierungssystem derart geschützt, dass z.B. ein Plasmastrahl einer rotierenden Plasmaspritzvorrichtung, die in axialer Richtung beim Beschichten durch die Zylinderbohrung geführt wird, welcher Plasmastrahl in einem unteren Umkehrpunkt im Bereich des Kurbelwellengehäuses des Motorblocks bis in die gegenüberliegende Bohrung reichen kann, die Zylinderwände der nicht zu beschichtenden Zylinderreihe nicht erreicht. Das heisst es kommt nicht zu dem gefürchteten "Overspraying", also der Kontamination einer nicht zu beschichtenden Zylinderwand durch Übersprühen aus einer Zylinderbohrung, die aktuell beschichtet wird. Dadurch wird verhindert, dass es zu Schichtablösungen kommt, wie sie aus dem Stand der Technik bekannt sind, was auftritt, wenn eine zuvor mit Metalldämpfen kontaminierte Zylinderwand später beschichtet wird.In the coating of cylinder crankcases in V-construction, a row of cylinders is preferably coated in each case. The cylinder row opposite it is protected by a masking system according to the invention such that, for example, a plasma jet of a rotating plasma spray device, which is guided in the axial direction during coating through the cylinder bore, which plasma jet at a lower reversal point in the region of the crankcase of the engine block to the opposite hole can reach, the cylinder walls not to be coated cylinder row reached. This means that it does not come to the dreaded "Overspray", so the contamination of a cylinder wall not to be coated by overspray from a cylinder bore, which is currently coated. This prevents layer delamination as known in the art, which occurs when a cylinder wall previously contaminated with metal vapors is later coated.

Ausserdem wird, wie bereits erwähnt, eine während des Beschichtungsvorgangs zwangsläufig stattfindende Erwärmung des Zylinderblocks durch den Wärmeübergang von geschmolzenem Pulver zum Substrat deutlich reduziert. Eine Überhitzung ist insbesondere bei dünnwandigen Bauteilen unbedingt zu vermeiden, weil dies zur Überhitzung des Zylinderblocks führen kann, was ebenfalls schädliche Schichtablösungen zur Folge haben kann. Auch diese schädlichen Wirkungen werden durch den Einsatz eines erfindungsgemässen Maskierungssystems vermieden, weil durch die Regulierung der Strömung des Fluids durch den Strömungsspalt das Maskierungssystem der vorliegenden Erfindung ein intelligentes Temperaturmanagement während des Beschichtungsprozesses gewährleistet.In addition, as already mentioned, a heating of the cylinder block that inevitably takes place during the coating process is significantly reduced by the heat transfer of molten powder to the substrate. Overheating must be avoided, especially with thin-walled components, because this can lead to overheating of the cylinder block, which can also result in harmful delamination. These harmful effects are also avoided by the use of a masking system according to the invention because, by regulating the flow of the fluid through the flow gap, the masking system of the present invention ensures intelligent temperature management during the coating process.

In einem speziellen Ausführungsbeispiel ist der Maskierungskörper ein hohler Maskierungskörper oder ein massiver Maskierungskörper, bevorzugt ein hohler Maskierungszylinder oder ein massiver Maskierungszylinder.In a specific embodiment, the masking body is a hollow masking body or a solid masking body, preferably a hollow masking cylinder or a solid masking cylinder.

Dabei ist der Maskierungskörper bevorzugt so ausgestaltet, dass der Strömungsspalt eine Breite von 0.1 mm bis 10 mm, bevorzugt eine Breite zwischen 0.2 mm und 5 mm, im speziellen eine Breite zwischen 0.4 mm und 3 mm hat. Dadurch ist gleichzeitig gewährleistet, dass der Strömungsspalt schmal genug ist, so dass eine direkte Kontamination der Zylinderwand des durch den Maskierungskörper geschützten Zylinders verhinderbar ist und gleichzeitig eine ausreichend starke Strömung im Strömungsspalt aufrecht erhalten werden kann, so dass eine ausreichende Kühlung erreichbar ist.In this case, the masking body is preferably designed such that the flow gap has a width of 0.1 mm to 10 mm, preferably a width between 0.2 mm and 5 mm, in particular a width between 0.4 mm and 3 mm. This ensures at the same time that the flow gap is narrow enough so that a direct contamination of the cylinder wall of the cylinder protected by the masking body can be prevented and at the same time a sufficiently strong flow in the flow gap can be maintained, so that sufficient cooling can be achieved.

In einem speziellen Ausführungsbeispiel umfasst ein erfindungsgemässes Maskierungssystem mindestens zwei Maskierungskörper, so dass mindestens zwei Zylinder, bevorzugt zwei benachbarte Zylinder gleichzeitig maskierbar sind, wobei in einem für die Praxis besonders wichtigen Ausführungsbeispiel das Maskierungssystem eine vorgebbare Anzahl von Maskierungskörpern umfasst und derart ausgestaltet ist, dass eine komplette Zylinderreihe einer Brennkraftmaschine in V-Bauweise gleichzeitig maskierbar ist.In a specific embodiment, a masking system according to the invention comprises at least two masking bodies, so that at least two cylinders, preferably two adjacent cylinders, can be masked simultaneously, wherein in a particularly important practical embodiment the masking system comprises a predeterminable number of masking bodies and is designed such that a complete cylinder row of an internal combustion engine in V-construction is simultaneously maskable.

Bevorzugt umfasst der Maskierungskörper eine Maskierungsabdeckung und die Maskierungsabdeckung umfasst insbesondere einen mit dem Strömungsspalt verbindbaren Kanal, insbesondere einen Auslasskanal und / oder einen Einlasskanal zur Förderung des Fluids. Der Kanal kann dabei Öffnungen haben, von denen eine oder mehrere in der Maskierungsabdeckung vorgesehen sein können, über die das Fluid, z.B. Luft oder ein anderes Gas, beispielsweise durch eine Absaugvorrichtung, die am Kurbelgehäuse vorgesehen sein kann, absaugbar ist, so dass dadurch die Strömung im Strömungsspalt zwischen Maskierungskörper und Zylinderwand herstellbar ist.The masking body preferably comprises a masking cover and the masking cover comprises in particular a channel which can be connected to the flow gap, in particular an outlet channel and / or an inlet channel for conveying the fluid. The channel may have openings, one or more of which may be provided in the masking cover over which the fluid, e.g. Air or another gas, for example by a suction device, which may be provided on the crankcase, is sucked, so that thereby the flow in the flow gap between masking body and cylinder wall can be produced.

Es versteht sich, dass in einem anderen Ausführungsbeispiel auch Luft oder ein anderes Gas über die Öffnungen, von denen zum Beispiel mehrere in der Maskierungsabdeckung vorgesehen sein können und z.B. kreisförmig in der Nähe eines Rands der Maskierungsabdeckung angeordnet sein können, unter einem vorgebbaren Druck in den Strömungsspalt einbringbar ist oder über die Öffnungen absaugbar ist, wobei die Strömungsrichtung des Fluids, je nach dem ob das Fluid unter Druck in die Öffnungen eingeblasen oder aus diesen abgesaugt wird, entweder in das Kurbelgehäuse hinein oder aus diesem heraus gerichtet ist. Der Fachmann versteht, dass je nach Anforderung die Form der Öffnungen verschieden sein kann, z.B. kreisförmige Öffnungen, schlitzförmige Öffnungen oder Öffnungen von anderer geeigneter Form vorgesehen sein können.It will be understood that in another embodiment, air or other gas may also be provided via the openings, several of which, for example, may be provided in the masking cover and e.g. may be arranged in the vicinity of an edge of the masking cover can be introduced under a predetermined pressure in the flow gap or sucked through the openings, wherein the flow direction of the fluid, depending on whether the fluid is injected under pressure into the openings or sucked out of these is directed either into the crankcase or out of this. It will be understood by those skilled in the art that the shape of the openings may vary depending on the requirement, e.g. circular openings, slot-shaped openings or openings of other suitable shape can be provided.

Als Fluid ist insbesondere ein Gas oder ein Gasgemisch, im speziellen Luft und / oder Stickstoff und / oder ein Edelgas, insbesondere Argon und / oder Helium zur Erzeugung der Strömung im Strömungsspalt besonders gut geeignet.As the fluid, in particular a gas or a gas mixture, in particular air and / or nitrogen and / or a noble gas, in particular argon and / or helium for generating the flow in the flow gap is particularly well suited.

Wie bereits erwähnt, kann am Kurbelwellenraum des zu beschichtenden Motorgehäuses ein Absaugmittel vorgesehen sein, so dass die Strömung des Fluids durch den Strömungsspalt durch den Kurbelwellenraum der Brennkraftmaschine absaugbar ist.As already mentioned, a suction means may be provided on the crankshaft space of the motor housing to be coated, so that the flow of the fluid through the flow gap through the crankshaft space of the internal combustion engine can be sucked off.

Oder es kann auch, wie ebenfalls für ein spezielles Beispiel zuvor bereits erläutert, ein Einspeisemittel zur Einspeisung des Fluids in den Strömungsspalt vorgesehen sein, so dass die Strömung des Fluids durch den Strömungsspalt unter einem vorgebbaren Einspeisedruck erzeugbar ist.Or it can also, as also already explained for a specific example, a feed means for feeding the fluid into the flow gap may be provided, so that the flow of the fluid through the flow gap can be generated under a predetermined feed pressure.

Eine Strömungsgeschwindigkeit des Fluids im Strömungsspalt ist bevorzugt grösser als 1 m/s, insbesondere grösser als 10 m/s, und liegt im Speziellen zwischen 1 m/s und 150 m/s, bevorzugt zwischen 10 m/s und 80 m/s. Dadurch wird einerseits eine ausreichende Kühlung des Motorblocks erreicht und andererseits eine genügend Starke Strömung im Strömungsspalt erzeugt, so dass sich kein Metalldampf auf einer nicht zu beschichtenden Zylinderlauffläche, die durch ein erfindungsgemässes Maskierungssystem geschützt ist, absetzten kann.A flow velocity of the fluid in the flow gap is preferably greater than 1 m / s, in particular greater than 10 m / s, and in particular between 1 m / s and 150 m / s, preferably between 10 m / s and 80 m / s. This on the one hand sufficient cooling of the engine block is achieved and on the other hand generates a sufficiently strong flow in the flow gap, so that no metal vapor on a non-coated cylinder surface, which is protected by a masking system according to the invention, can settle.

Insbesondere um den Beschichtungsvorgang von Zylinderlaufflächen von Motorblöcken für die industrielle Massenproduktion vorteilhaft zu automatisieren, kann zur Positionierung des Maskierungskörpers ein Manipulator, insbesondere ein programmgesteuertes Robotersystem vorgesehen sein, so dass der Maskierungskörper automatisch nach einem vorgebbaren Programmanlaufschema in der Zylinderbohrung platzierbar ist.In particular in order to advantageously automate the coating process of cylinder running surfaces of engine blocks for industrial mass production, a manipulator, in particular a program-controlled robot system, can be provided for positioning the masking body so that the masking body can be automatically placed in the cylinder bore according to a predefinable program startup pattern.

Vorteilhaft kann darüber hinaus eine Versorgungseinheit zur Bereitstellung des Fluids vorgesehen sein, die bevorzugt programmgesteuert steuer- und / oder regelbar ist, so dass z.B. die Durchflussmenge und / oder der Druck und / oder die Durchflussgeschwindigkeit des Fluidstromes im Strömungsspalt steuer- und / oder regelbar ist und z.B. in Abhängigkeit von der Zeit, der Art des zu beschichtenden Motorblocks oder in Abhängigkeit von bestimmten Beschichtungsparametern, wie Temperatur, Art der verwendeten Beschichtungsvorrichtung, Art des Beschichtungsmaterials, Art des Beschichtungsverfahrens usw. steuer- und / oder regelbar ist.In addition, a supply unit for providing the fluid can advantageously be provided, which is preferably programmably controllable and / or regulatable, so that e.g. the flow rate and / or the pressure and / or the flow rate of the fluid flow in the flow gap can be controlled and / or regulated, and e.g. depending on the time, the type of engine block to be coated or depending on certain coating parameters, such as temperature, type of coating device used, type of coating material, type of coating method, etc. controllable and / or regulated.

Die Erfindung betrifft weiter die Verwendung eines erfindungsgemässen Maskierungssystems, wie in dieser Anmeldung ausführlich beschrieben, wobei der thermische Beschichtungsvorgang ein Plasmaspritzverfahren, bevorzugt ein Plasma APS Verfahren, ein Flammspritzverfahren, insbesondere ein Hochgeschwindigkeits Flammspritzverfahren und / oder ein anderes thermisches Spritzverfahren wie zum Beispiel ein Lichtbogen Drahtspritzverfahren umfasst.The invention further relates to the use of a masking system according to the invention, as described in detail in this application, wherein the thermal coating process is a plasma spraying process, preferably a plasma APS process, a flame spraying process, In particular, a high-speed flame spraying method and / or another thermal spraying method such as, for example, an arc wire spraying method.

Dabei wird ein erfindungsgemässes Maskierungssystem insbesondere als Schutz gegen Kontamination einer Zylinderbohrung und / oder zur Kühlung während des thermischen Beschichtungsvorgangs verwendet.In this case, an inventive masking system is used in particular as protection against contamination of a cylinder bore and / or for cooling during the thermal coating process.

Es versteht sich, dass sich die Verwendung dabei sowohl auf die Verhinderung von Overspray eine bereits beschichtete Zylinderbohrung eines ersten Zylinders, aber selbstverständlich auch auf die Verhinderung von Overspray einer noch unbeschichteten Zylinderbohrung beziehen kann.It is understood that the use of both the prevention of overspray an already coated cylinder bore of a first cylinder, but of course can also relate to the prevention of overspray a still uncoated cylinder bore.

Im Folgenden wird die Erfindung an Hand der Zeichnung näher erläutert. Es zeigen in schematischer Darstellung:

  • Fig. 1 einen Schnitt durch einen Zylinderblock eines Motors in V-Bauweise mit einem erfindungsgemässen Maskierungssystem;
  • Fig. 2 einen acht Zylinder V-Motor mit einem Roboter unterstützten Maskierungssystem.
In the following the invention will be explained in more detail with reference to the drawing. In a schematic representation:
  • Fig. 1 a section through a cylinder block of a motor in V-construction with a masking system according to the invention;
  • Fig. 2 an eight cylinder V engine with a robot assisted masking system.

Fig. 1 zeigt in einer Darstellung im Schnitt eine einfache Ausführungsvariante eines erfindungsgemässen Maskierungssystems während des Beschichtens einer Zylinderbohrung eines Motors in V-Bauweise, an welcher die Funktionsweise eines erfindungsgemässen Maskierungssystems, das im folgenden gesamthaft mit dem Bezugszeichen 1 bezeichnet ist, schematisch erläutert wird. Fig. 1 shows in a representation in section a simple embodiment of a masking system according to the invention during the coating of a cylinder bore of a motor in V-construction, on which the operation of a masking system according to the invention, which is hereinafter referred to in its entirety by the reference numeral 1, is explained schematically.

In Fig. 1 ist ein Schnitt durch einen Motorblock eines Motors in V-Bauweise dargestellt, dessen zwei Zylinderreihen in an sich bekannter Weise parallel zueinander, unter einem Neigungswinkel α angeordnet sind.In Fig. 1 is a section through an engine block of a motor shown in V-construction, whose two rows of cylinders are arranged in a conventional manner parallel to each other, at an inclination angle α.

Ein erster Zylinder 5, der darstellungsgemäss rechte Zylinder, wird gerade mit einer an sich bekannten rotierenden Plasmaspritzpistole 1000 beschichtet. Die Plasmaspritzpistole rotiert während des Beschichtungsvorgans im Zylinder 5 um eine Längsachse, wie der Pfeil 1002 andeutet und wird unter Rotation in axialer Richtung durch die Zylinderbohrung während des Beschichtungsvorgangs geführt. An einem unteren Ende der Plasmaspritzpistole 1000 tritt aus einer Spritzöffnung 1001 ein Plasmastrahl 1003 mit Beschichtungsmaterial 1004 aus, mit welchem Beschichtungsmaterial 1004 die Zylinderwand des Zylinders 5 beschichtet wird.A first cylinder 5, which according to the illustration is a right-hand cylinder, is currently being coated with a rotating plasma spray gun 1000 known per se. The plasma spray gun rotates during the coating process in the cylinder 5 about a longitudinal axis, as the arrow 1002 indicates and is guided under rotation in the axial direction through the cylinder bore during the coating process. At a lower end of the plasma spray gun 1000, a plasma jet 1003 with coating material 1004 exits from a spray opening 1001, with which coating material 1004 the cylinder wall of the cylinder 5 is coated.

Wie Fig. 1 zeigt, befindet sich die Plasmaspritzpistole 1000 gerade in der Nähe ihres unteren Umkehrpunktes, dass heisst der Plasmastrahl 1003 mit Beschichtungsmaterial 1004 trifft nicht nur auf die zu beschichtende Zylinderwand des Zylinders 5, sondern reicht in das Kurbelgehäuse des V-Motors 3 und sogar bis in den nicht zu beschichtenden zweiten Zylinders 7 hinein.As Fig. 1 shows, the plasma spray gun 1000 is just near its lower reversal point, that is, the plasma jet 1003 with coating material 1004 not only applies to the cylinder wall to be coated of the cylinder 5, but extends into the crankcase of the V-engine 3 and even into the not to be coated second cylinder 7 inside.

Das heisst, ohne die Verwendung eines erfindungsgemässen Maskierungssystems 1 würde die Zylinderwand 6 des zweiten Zylinders 7 mit Beschichtungsmaterial 1004 kontaminiert und darüber hinaus durch den Plasmastrahl 1003 über Gebühr erwärmt.That is, without the use of a masking system 1 according to the invention, the cylinder wall 6 of the second cylinder 7 would be contaminated with coating material 1004 and moreover heated excessively by the plasma jet 1003.

Um dies zu verhindern, ist in der Zylinderbohrung 2 des zweiten Zylinders 7 ein Maskierungskörper 4 gemäss der vorliegenden Erfindung vorgesehen, der im vorliegenden Beispiel der Fig. 1 als Hohlzylinder 4 ausgestaltet ist und zusätzlich eine Maskierungsabdeckung 41 umfasst. Die Maskierungsabdeckung 41, die einen Deckel auf dem zweiten Zylinder 7 bzw. auf dem Markierungskörper 4 bildet, umfasst einen mit dem Strömungsspalt 10, der zwischen dem Maskierungszylinder 4 und der Zylinderwand 6 ausgebildet ist, verbundenen Kanal 42 mit Öffnungen 421, der im Beispiel der Fig. 1 als Einlasskanal 42 zur Förderung des Fluids 9 in den Strömungsspalt 10 ausgebildet ist.To prevent this, a masking body 4 according to the present invention is provided in the cylinder bore 2 of the second cylinder 7, which in the present example of the Fig. 1 is designed as a hollow cylinder 4 and additionally comprises a masking cover 41. The masking cover 41, which forms a cover on the second cylinder 7 or on the marking body 4, comprises a channel 42 connected to the flow gap 10, which is formed between the masking cylinder 4 and the cylinder wall 6, with openings 421, which in the example of FIG Fig. 1 is formed as an inlet channel 42 for conveying the fluid 9 in the flow gap 10.

Die Strömung 8 des Fluids 9 im Strömungsspalt 10 wird dabei durch ein in Fig. 1 nicht explizit dargestelltes Absaugmittel erzeugt, das in einer dem Fachmann an sich bekannten Weise im Kurbelgehäuse einen vorgebbaren Unterdruck erzeugt, so dass durch die Öffnungen 421 in der Maskierungsabdeckung 41 Luft angesaugt wird, die dann durch den mit der Öffnung 421 verbundenen Strömungsspalt 10 strömt, so dass der Zylinder 7 und damit der komplette Motorblock der Brennkraftmaschine 3 einerseits gekühlt wird und andererseits eine Abscheidung von Metalldämpfen auf der Zylinderwand 6 des zweiten Zylinders 7 verhindert wird.The flow 8 of the fluid 9 in the flow gap 10 is characterized by an in Fig. 1 not explicitly shown suction generated in a manner known to those skilled in the art in the crankcase a predetermined negative pressure, so that air is sucked through the openings 421 in the masking cover 41, which then flows through the opening 421 connected to the flow gap 10, so that the cylinder 7 and thus the complete engine block of the internal combustion engine 3 on the one hand is cooled and on the other hand, a deposition of metal vapors on the cylinder wall 6 of the second cylinder 7 is prevented.

In Fig 2 ist schematisch ein acht Zylinder V-Motor mit einem Roboter unterstützten Maskierungssystem dargestellt.In Fig. 2 schematically an eight-cylinder V-engine with a robot-assisted masking system is shown.

Fig. 2 zeigt einen acht Zylinder V-Motor 3 mit einer darstellungsgemäss unteren Zylinderreihe, in der gerade der Zylinder 5 mittels einer Plasmaspritzpistole 1000 durch einen Plasmastrahl mit Beschichtungsmaterial 1004 beschichtet wird. Fig. 2 shows an eight-cylinder V-engine 3 with a lower cylinder row according to the illustration, in which just the cylinder 5 is coated by means of a plasma spray gun 1000 by a plasma jet with coating material 1004.

Die darstellungsgemäss obere Zylinderreihe 11 der Brennkraftmaschine 3 ist dabei gleichzeitig komplett durch ein erfindungsgemässes Maskierungssystem 1 maskiert und damit vor dem gefährlichen Overspray aus dem Beschichtungsstrahl 1003, mit dem gerade der Zylinder 5 der unteren Reihe beschichtet wird, geschützt und wird gleichzeitig durch das Fluid 9 gekühlt.The upper row of cylinders 11 of the internal combustion engine 3 according to the illustration are simultaneously completely masked by a masking system 1 according to the invention and therefore protected from the dangerous overspray from the coating jet 1003 with which the cylinder 5 of the lower row is coated and at the same time cooled by the fluid 9 ,

Das für die Praxis besonders wichtige spezielle Ausführungsbeispiel eines erfindungsgemässen Maskierungssystems 1 der Fig. 2 umfasst vier Maskierungszylinder 4 mit jeweils einer Maskierungsabdeckung 41, welche Maskierungszylinder 4 in den Zylinderbohrungen 2 der zweiten Zylinder 7 platziert sind.The particularly important for practice special embodiment of an inventive masking system 1 of Fig. 2 comprises four masking cylinders 4 each having a masking cover 41 which Masking cylinder 4 are placed in the cylinder bores 2 of the second cylinder 7.

Wenn mehr als ein Maskierungszylinder 4 in ein und demselben Maskierungssystem gleichzeitig vorgesehen ist, ist es selbst verständlich, dass zum Beispiel einer oder mehrere der Maskierungszylinder hohl ist, und einer oder mehrer der anderen Maskierungszylinder massiv sind.When more than one masking cylinder 4 is provided in one and the same masking system simultaneously, it is self-evident, for example, that one or more of the masking cylinders is hollow and one or more of the other masking cylinders are solid.

Die vier Maskierungszylinder 4 sind über die 4 Maskierungsabdeckungen 41 an einem Trägerarm 141 eines Robotersystems 14 gehaltert, so dass durch das Robotersystem 14 alle zweiten Zylinderbohrungen 7 gleichzeitig maskiert bzw. demaskiert werden können, indem durch einen in Fig. 2 nicht explizit dargestellten Antrieb der Trägerarm 141 so bewegt wird, dass die Maskierungszylinder in die zweiten Zylinder 7 versenkt bzw. herausgezogen werden können.The four masking cylinders 4 are supported via the 4 masking covers 41 on a support arm 141 of a robot system 14, so that all second cylinder bores 7 can be masked or demasked at the same time by the robot system 14, by means of an in Fig. 2 not explicitly shown drive the support arm 141 is moved so that the masking cylinder can be sunk or pulled out into the second cylinder 7.

Im bzw. am Trägerarm 141 ist ein Einspeisemittel 13 in Form einer Zuleitung 13 vorgesehen, durch die das Fluid 9 über die Maskierungsabdeckungen 41 den Strömungsspalten zuführbar ist.In or on the support arm 141, a feed means 13 in the form of a feed line 13 is provided, through which the fluid 9 can be supplied to the flow gaps via the masking covers 41.

Wenn nach dem Beschichten der darstellunggemäss unteren Zylinderreihe anschliessend die obere Zylinderreihe beschichtet werden soll, können alle Maskierungszylinder 4 gleichzeitig mittels des Robotersystems 14 aus der oberen Zylinderreihe herausgezogen werden und anschliessend in der unteren Zylinderreihe zum Schutz der Zylinderwände der unteren Zylinderreihe platziert werden. Dabei kann der Motorblock des Motors 3 z.B. auf einer Bandstrasse angeordnet sein, so dass automatisch nacheinander die Zylinderbohrungen von mehreren Motorblöcken beschichtet werden können. Es dabei möglich, dass auch die Motorblöcke zusätzlich auf einem Manipulator bzw. an einem bewegbaren Roboter montiert sind, so dass z.B. zum Platzieren des erfindunsggemässen Maskierungssystems 1 der Motor 3 geschwenkt, gedreht oder in anderer geeigneter Weise ausgerichtet werden kann.If, after the coating of the lower row of cylinders according to the illustration, the upper row of cylinders is subsequently to be coated, all masking cylinders 4 can be simultaneously pulled out of the upper row of cylinders by means of the robot system 14 and subsequently placed in the lower row of cylinders to protect the cylinder walls of the lower row of cylinders. The engine block of the engine 3 may be e.g. be arranged on a strip line, so that automatically successively the cylinder bores of several engine blocks can be coated. In this case, it is also possible that the motor blocks are additionally mounted on a manipulator or on a movable robot, so that e.g. in order to place the masking system 1 according to the invention, the motor 3 can be pivoted, rotated or aligned in any other suitable way.

Claims (14)

  1. A masking system for masking a cylinder bore (2) of a combustion engine (3) during a thermal coating procedure, including a masking body (4) which can be placed during the thermal coating process of a first cylinder (5) of the combustion engine (3) in the cylinder bore (2) of a second cylinder (7) to cover a cylinder wall (6) of the second cylinder (7), characterised in that the masking body (4) is designed in such a way that a flow gap (10) of predeterminable breadth can be set between the masking body (4) and the cylinder wall (6) of the second cylinder (7) for the generation of a flow (8) of a fluid (9).
  2. A masking system in accordance with claim 1, wherein the flow gap (10) has a width of 0.1 mm to 10 mm.
  3. A masking system in accordance with one of the previous claims, wherein the masking system includes at least two masking bodies (4) so that at least two cylinders (7) can be masked simultaneously.
  4. A masking system in accordance with one of the previous claims, wherein the masking system includes a predeterminable number of masking bodies (4) and is designed in such a way that a complete row of cylinders (11) of a V-type combustion engine (3) can be masked simultaneously.
  5. A masking system in accordance with any one of the previous claims, wherein the masking body (4) includes a masking cover (41).
  6. A masking system in accordance with any one of the previous claims, wherein the masking cover (41) includes a passage (42) connected to the flow gap (10 for conveying the fluid (9).
  7. A masking system in accordance with any one of the previous claims, wherein the fluid (9) is a gas or a gas mixture.
  8. A masking system in accordance with any one of the previous claims wherein a suction means is provided so that the flow of the fluid (9) can be sucked away through the flow gap (10) through a crank space (12) of the combustion engine (3).
  9. A masking system in accordance with any one of the previous claims, wherein a feed means (13) is provided for feeding the fluid (9) into the flow gap (10) so that the flow (8) of the fluid (9) through the flow gap (10) can be produced at a predeterminable feed pressure.
  10. A masking system in accordance with any one of the previous claims, wherein a flow speed of the fluid (9) in the flow gap (10) is higher than lm/s.
  11. A masking system in accordance with any one of the previous claims, wherein a manipulator (14) is provided so that the masking body can be placed automatically in the cylinder bore (2) in accordance with a predetermined programme starting scheme.
  12. A masking system in accordance with any one of the previous claims, wherein a programme controlled supply unit is provided for the provision of the fluid (9).
  13. Use of a masking system (1) in accordance with any one of the claims 1 to 12, wherein the thermal coating procedure includes a plasma spraying method, a plasma APS method, a flame spraying method, a high speed flame spraying method or another thermal spraying method such as an arc wire spraying method for example.
  14. Use in accordance with claim 13, wherein the masking system (1) is used as protection against contamination of a cylinder bore (2) and/or for cooling during the thermal coating procedure.
EP07109434A 2006-07-24 2007-06-01 Masking system for masking a cylinder hole Not-in-force EP1884293B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP07109434A EP1884293B1 (en) 2006-07-24 2007-06-01 Masking system for masking a cylinder hole

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP06117756 2006-07-24
EP07109434A EP1884293B1 (en) 2006-07-24 2007-06-01 Masking system for masking a cylinder hole

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EP1884293A1 EP1884293A1 (en) 2008-02-06
EP1884293B1 true EP1884293B1 (en) 2009-08-12

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Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102008028959A1 (en) 2008-06-18 2009-01-02 Daimler Ag Device for masking a cylinder cover surface of a cylinder bank during thermal coating of cylinder bores, comprises an insert plate placed on the cylinder cover surface, through-holes, a receiving area, a peripheral rib, and a guiding tube
DE102012112488B4 (en) * 2012-12-18 2017-07-13 Gebr. Heller Maschinenfabrik Gmbh Arc wire spray coating method for cylinder bores of internal combustion engines
DE102016116815A1 (en) 2016-09-08 2018-03-08 Dr. Ing. H.C. F. Porsche Aktiengesellschaft Process for coating a cylinder of an internal combustion engine and cylinder for an internal combustion engine
DE102018206707A1 (en) * 2018-05-02 2019-11-07 MTU Aero Engines AG PROCESS FOR COATING A COMPONENT OF A FLOW MACHINE

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5573814A (en) * 1995-10-30 1996-11-12 Ford Motor Company Masking cylinder bore extremities from internal thermal spraying
US6395090B1 (en) * 1999-08-16 2002-05-28 Ford Global Technologies, Inc. Masking for engine blocks for thermally sprayed coatings
TR200401050T4 (en) * 2000-03-20 2004-07-21 Sulzer Metco Ag Method and apparatus for thermal coating of cylinder walls in internal combustion engines.
DE50102898D1 (en) * 2000-05-03 2004-08-26 Sulzer Metco Ag Wohlen Arrangement for protecting cylinder walls of engine blocks
JP4497086B2 (en) * 2005-01-28 2010-07-07 日産自動車株式会社 Cylinder block spraying masking method, masking apparatus and gas jet nozzle

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