1. A reciprocator (100) for simultaneous application of a coating formulation over at least two-predefined surfaces, the reciprocator (100) comprising: a frame (120) defining a longitudinal axis (xx’) of a reciprocator (100), the frame (120) including a plurality of channels (120b); a carriage assembly (150) being coupled to the frame (120), the carriage assembly (150) being capable of slidable movement along the longitudinal axis (xx’) of the reciprocator (100) via one or more linear blocks (20b); a plurality of arms (140) coupled to the carriage assembly (150) and extending from the frame (120) through the plurality of channels (120b), each of the plurality of arms (140) being positioned at a pre-defined angle with respect to the longitudinal axis (xx’) of the reciprocator (100), each of the plurality of arms (140) being provided with at least one spray gun (140d); a driving assembly (160) configured to allow slidable movement of the carriage assembly (150) thereby allowing linear motion of the plurality of arms (140) along the longitudinal axis (xx’) of the reciprocator (100); and a microcontroller (200) configured to control switching of the at least one spray gun (140d) and speed of the linear motion of the plurality of arms (140), wherein each of the plurality of arms (140) extends from a different side of the frame (120) thereby allowing simultaneous application of a coating formulation over at least two-predefined surfaces positioned at different sides of the reciprocator (100), wherein the microcontroller (200) being capable of switching the at least one spray gun (140d) based on dimensions of the at least two pre-defined surfaces, wherein the microcontroller (200) controls the speed of linear motion of the plurality of arms (140) on the basis of user inputs.

2. The reciprocator (100) as claimed in claim 1 wherein, the frame (120) is placed over a pedestal (110).

3. The reciprocator (100) as claimed in claim 2 wherein, the pedestal (110) includes a gliding means for easy movement of the reciprocator (100) and a locking means for locking the reciprocator (100) at a pre-defined position.

4. The reciprocator (100) as claimed in claim 1 wherein, the frame (120) includes a plurality of proximity sensors for detecting the position of the linear block (20b).

5. The reciprocator (100) as claimed in claim 1 wherein, the one or more linear blocks (20b) are slidably coupled to respective guide rails (20a).

6. The reciprocator (100) as claimed in claim 1 wherein, each of the plurality of arms (140) include a mechanism for adjusting its length.

7. The reciprocator (100) as claimed in claim 1 wherein, the plurality of arms (140) includes two oppositely extending arms.

8. The reciprocator (100) as claimed in claim 1 wherein, the pre-defined angle between the longitudinal axis (xx’) and the arms (140) is adjustable.

9. The reciprocator (100) as claimed in claim 1 wherein, each of the spray guns (140d) includes a mechanism for adjusting its angle with respect to the longitudinal axis (xx’) of the reciprocator (100).

10. The reciprocator (100) as claimed in claim 1 wherein, the driving assembly (160) includes a single driving means (160a) having a direct drive mechanism for movement of the plurality of arms (140).

11. The reciprocator (100) as claimed in claim 1 wherein, the driving assembly (160) includes a single driving means (160a) having an indirect drive mechanism for movement of the plurality of arms (140).

12. The reciprocator (100) as claimed in claims 10 and 11 wherein, the driving means (160a) includes an explosion proof motor.

13. The reciprocator (100) as claimed in claim 1 wherein the reciprocator (100) includes a pneumatic accessories box (130) coupled to the frame (120).

14. The reciprocator (100) as claimed in claim 1 wherein each of the spray guns (140d) is supplied with a same or different coating formulation for spray painting the pre-defined surfaces simultaneously.

[001] The present invention relates to a reciprocator and method of operation thereof. More specifically, the present invention relates to a reciprocator and method thereof for applying a coating formulation over at least two side surfaces simultaneously.
BACKGROUND
[002] A coating formulation in the form pigmented liquids, liquefiable or solid mastic composition is used to coat a surface of a substrate for the purpose of decoration, protection or prolonging the life of the substrate. Coating formulation can be applied to one or more surfaces using various methods and equipment to form one or more coats on the surface of the substrate.
[003] Coating formulation is generally applied directly by manual application using brushes, paint rollers, scrappers, or any other instrument such as spray guns etc. However, manual application of coating formulation requires a significant amount of time as well as physical labor. Moreover, as manual application is subject to a painter’s capability, it may result in unsatisfactory coating owing to the associated risks of non-uniform coat, incomplete coverage, etc.
[004] In order to overcome this challenge, automated machine in the form of a reciprocator was introduced. The reciprocator is an automatic system that is used for applying a coating formulation over a pre-defined surface without any human intervention. The reciprocator is provided with one or more arms. The arms include one or more spray guns that move back and forth at varying speeds to apply a precise and uniform layer of coating to an exposed surface of the substrate. The reciprocator is further equipped with a motor that drives the automated operation of the reciprocator.
[005] However, in a conventional reciprocator, there is a single arm or in few cases a plurality of arms that are provided on a single side of the reciprocator. Hence, the conventional reciprocator can only paint a surface facing the arm(s) at a time. Therefore, once the surface is painted, the reciprocator may be accordingly adjusted to paint other surfaces which increases the time of application. Alternately, in order to paint the other surfaces of the substrate, a different reciprocator is needed which requires more energy as well as space and makes the overall process cost intensive.
[006] Further, a conventional reciprocator is non-explosion proof i.e. the surface of the reciprocator may become so hot during operation that it may ignite vapor, gas or dust. Also, a single arc from a motor malfunction, such as a winding insulation failure or power supply issue, may ignite an ambient material which may lead to accidents.
[007] Further, in a conventional reciprocator, the motor directly rotates with a cam belt pulley which may wear out quickly. Further, this assembly may pose challenges such as heavy load on the rotation system, short life span of the rotation system, and more energy consumption.
[008] Further, the conventional motor moves back and forth for facilitating up and down motion which has drawbacks such as more friction generation, over heating of the motor windings, wear and tear, etc.
[009] Also, the conventional reciprocator is provided without any pneumatic accessories box and such a box is placed outside the reciprocator resulting in additional cost of extra hose as well as inefficient control of the spray guns.
[0010] Therefore, there arises a requirement to devise a reciprocator which overcomes the aforementioned challenges associated with the conventional reciprocator.
SUMMARY
[0011] The present invention relates to a reciprocator for simultaneous application of a coating formulation over at least two-predefined surfaces. The reciprocator incudes a frame which defines a longitudinal axis of the reciprocator. The frame includes a plurality of channels.
[0012] The reciprocator further includes a carriage assembly that is coupled to the frame. The carriage assembly is capable of slidable movement along the longitudinal axis of the reciprocator via one or more linear blocks.
[0013] A plurality of arms are coupled to the carriage assembly and extend from the frame through the plurality of channels of the frame. Each of the plurality of arms is positioned at a pre-defined angle with respect to the longitudinal axis of the reciprocator. Each of the plurality of arms is provided with at least one spray gun.
[0014] The reciprocator further includes a driving assembly that is configured to allow slidable movement of the carriage assembly thereby allowing linear motion of the plurality of arms along the longitudinal axis of the reciprocator.
[0015] A microcontroller is configured to control switching of the at least one spray gun and speed of the linear motion of the plurality of arms. The microcontroller controls switching of the at least one spray gun based on dimensions of the at least two surfaces while the microcontroller controls the speed of linear motion of the plurality of arms on the basis of user inputs.
[0016] Each of the plurality of arms extends from a different side of the frame thereby allowing simultaneous application of the coating formulation over at least two-predefined surfaces positioned at different sides of the reciprocator.
[0017] The foregoing features and other features as well as the advantages of the invention will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures.
BRIEF DESCRIPTION OF DRAWINGS
[0018] The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the apportioned drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale.
[0019] Figure 1 depicts a perspective view of a reciprocator in accordance with an embodiment of the present invention.
[0020] Figure 2 shows a front view of the reciprocator in accordance with an embodiment of the present invention.
[0021] Figure 3 shows an exploded view of a carriage assembly of the reciprocator 100 in accordance with an embodiment of the present invention.
[0022] Figure 4 shows a drive assembly of the reciprocator in accordance with an embodiment of the present invention.
[0023] Figure 5 shows the coupling between a joint pin and a chain of the reciprocator in accordance with an embodiment of the present invention.
[0024] Figure 6 shows an alternate embodiment of the drive assembly of the reciprocator in accordance with an embodiment of the present invention.
[0025] Figure 7 shows connections of microcontroller in accordance with an embodiment of the present invention.
[0026] Figure 8 shows an exemplary method of operation of reciprocator in accordance with an embodiment of the present invention.
[0027] Figure 9 shows an exemplary layout in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE DRAWINGS
[0028] Prior to describing the invention in detail, definitions of certain words or phrases used throughout this patent document will be defined: the terms "include" and "comprise", as well as derivatives thereof, mean inclusion without limitation; the term "or" is inclusive, meaning and/or; the phrases "coupled with" and "associated therewith", as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have a property of, or the like; Definitions of certain words and phrases are provided throughout this patent document, and those of ordinary skill in the art will understand that such definitions apply in many, if not most, instances to prior as well as future uses of such defined words and phrases.
[0029] Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment, but mean “one or more but not all embodiments” unless expressly specified otherwise. The terms “including,” “comprising,” “having,” and variations thereof mean “including but not limited to” unless expressly specified otherwise. An enumerated listing of items does not imply that any or all of the items are mutually exclusive and/or mutually inclusive, unless expressly specified otherwise. The terms “a,” “an,” and “the” also refer to “one or more” unless expressly specified otherwise.
[0030] Although the operation of exemplary embodiments of the disclosed method may be described in a particular, sequential order for convenient presentation, it should be understood that the disclosed embodiments can encompass an order of operations other than the particular, sequential order disclosed. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Further, descriptions and disclosures provided in association with one particular embodiment are not limited to that embodiment, and may be applied to any embodiment disclosed herein. Moreover, for the sake of simplicity, the attached figures may not show the various ways in which the disclosed system, method, and apparatus can be used in combination with other systems, methods, and apparatuses.
[0031] Furthermore, the described features, advantages, and characteristics of the embodiments may be combined in any suitable manner. One skilled in the relevant art will recognize that the embodiments may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments. These features and advantages of the embodiments will become more fully apparent from the following description and apportioned claims, or may be learned by the practice of embodiments as set forth hereinafter.
[0032] In accordance with the present disclosure, a reciprocator and a method of operating the same is disclosed. The reciprocator of the present invention may be used to simultaneously apply one or more layers of a coating formulation to at least two pre-defined side surfaces of same or different substrates (or objects). The surfaces of the substrate/object may include walls of a building or surfaces of objects such as cylinders, automobiles, pipes, sheet cover, motor frame, etc.
[0033] The reciprocator of the present invention includes a plurality of arms mounted with one or more spray guns. The arms of the reciprocator are disposed on different sides of the reciprocator and also extend in different directions. Therefore, each arm of the reciprocator faces different surfaces positioned at different sides of the reciprocator thereby allowing simultaneous application of one or more layers of the coating formulation over pre-defined surfaces positioned at different sides of the reciprocator. As the reciprocator of the present invention can simultaneously paint multiple surfaces, the requirement of multiple conventional reciprocators is completely eliminated which reduces overall cost and time required for painting. Also, owing to the above, the reciprocator of the present invention saves space.
[0034] Each of the spray guns of the present invention include respective stroke length which may be altered depending upon the dimensions of the surface(s) required to be painted.
[0035] The arms of the reciprocator of the present invention may be detachable. Hence, if a surface is not required to be painted then in that case, the arm facing that particular surface may be detached/removed or made non-operational.
[0036] The arms are capable of moving linearly along a longitudinal axis of the reciprocator. The reciprocator includes a common drive assembly which enables the linear motion of the arms so that the arms move simultaneously thereby painting the surfaces placed in front of the arms. The said arrangement saves approximately 50% of energy consumption for operation of the reciprocator.
[0037] The drive assembly of the present invention includes a driving means, a first unit and a second unit. The drive assembly used in the present invention is an explosion proof motor which prevents an internal motor explosion from igniting a larger, ambient, combustible atmosphere thereby, providing safety to the user as well as the reciprocator itself.
[0038] The drive assembly is coupled to the first unit which is in turn coupled to the second unit. The second unit transmits power from the driving means to the arms. The driving means is itself stationery and powers the first unit which in turn activates the second unit to cause movement of the arms. Hence, the reverse and forward movement of the driving means as required in conventional systems is completely eliminated.
[0039] Further, the reciprocator includes a pneumatic accessories box housed within a body of the reciprocator. The pneumatic accessories box helps to store at least one of a pressure regulator, a pressure gauge, a paint hose, a pneumatic hose, etc. at one place. As pneumatic accessories box forms an integral component of the reciprocator, components controlling the spray gun parameters i.e. pressure regulator, pressure gauge are placed near the spray guns, the parameters of the spray guns can be controlled precisely. Further, the cost of extra hose length which would have been required if the box would have been placed outside the reciprocator is minimized.
[0040] Now referring to figures, Figure 1 depicts a perspective view of a reciprocator 100. The reciprocator 100 may be used to simultaneously apply a coating formulation over a plurality of pre-defined surfaces (or side surfaces). The pre-defined surfaces are disposed on different sides of the reciprocator 100. The pre-defined surfaces may include walls of a building, automobiles, cylinders, etc.
[0041] The reciprocator 100 of the present invention can be used with different compositions of coating formulations. The coating formulations may include, without limitation, enamel, emulsion, top-coat, primer, etc.
[0042] The reciprocator 100 of the present invention includes various components that can be easily assembled/dissembled by a user as per user’s convenience without requiring any specialized equipment/expertise. Further, in case of damage to any of the components of the reciprocator 100, the damaged component(s) can be easily replaced instead of replacing the entire assembly of the reciprocator 100.
[0043] As provided above, the reciprocator 100 is an assembly of, one or more of, a pedestal 110, a frame 120, a pneumatic accessories box 130, at least two arms 140, a carriage assembly 150 (shown in Figure 3) and a driving assembly 160 (shown in Figures 4-6).
[0044] The pedestal 110 of the present invention may act as a base to hold the other components of the reciprocator 100 of the present invention. Hence, the pedestal 110 may be disposed at the bottom of the reciprocator 100 as shown in Figures 1 and 2.
[0045] The pedestal 110 may be a solid or hollow structure. The pedestal 110 may include a pre-defined shape such as without limitation, rectangular, square, circular, oval, etc. In an exemplary embodiment, the pedestal 110 is a hollow structure having a rectangular shape. The pedestal 110 may be made up of a material having properties such as, without limitation, powder coated, corrosion resistance and high strength (to withstand the weight of the reciprocator 100). The material may include, but not limited to, galvanized iron, mild steel, stainless steel, nickel, cobalt, copper, aluminum, etc. In an embodiment, the pedestal 110 is made up of galvanized iron or mild steel.
[0046] The pedestal 110 may include pre-defined dimensions. The height of the pedestal 110 may range between 100 to 300 mm. In an exemplary embodiment, the height of the pedestal 110 is 150 mm. The height of the pedestal 110 may be adjustable to allow adjustment of the overall height of the reciprocator 100. Such a provision may allow painting a wide range of surfaces having different heights. As an exemplary embodiment, owing to the height adjustable pedestal 110, the reciprocator 100 is equipped to paint surfaces having a height of upto 1000mm. Any height adjusting mechanism can be employed in the height adjustable pedestal 110.
[0047] The width of the pedestal 110 may vary according to the dimensions of the frame 120. As an example, the width of the pedestal 110 may range between 200 to 700 mm. In an exemplary embodiment, the width of the pedestal 110 is 410 mm.
[0048] The pedestal 110 may include an upper surface and a lower surface. In an embodiment, the upper surface is in direct contact with the frame 120 as shown in Figure 1. The lower surface may be in direct contact with the ground. In an embodiment, the lower surface of the pedestal 110 includes four legs 110a placed at the corners of the pedestal 110 for support as shown in Figure 1. In an alternate embodiment, the lower surface of the pedestal 110 may be provided with a gliding means which helps in easy movement of the reciprocator 100 from one place to another with minimal manual effort. In an embodiment, the reciprocator 100 is provided with wheels positioned at the corners of the pedestal 110 (not shown). The gliding means may be further provided with a locking means which helps to lock the reciprocator 100 at a pre-defined position as selected by the user thereby preventing any unwanted/accidental movement of the reciprocator 100.
[0049] The frame 120 forms a structural framework of the reciprocator 100 of the present invention. The frame 120 defines longitudinal axis (xx’) of the reciprocator 100. The frame 120 may be used to mount or enclose all the remaining components of the reciprocator 100 (described below in detail). In an exemplary embodiment, the frame 120 is placed over the pedestal 110. Alternately, the frame 120 of the reciprocator 100 may be attached to the upper surface of the pedestal 110 to form an integral structure as shown in Figures 1 and 2. The frame 120 may be attached to the pedestal 110 temporarily or permanently. The temporary attachment may include, without limitation nuts and bolts, fasteners, etc. The permanent attachment may include, without limitation welding, soldering etc. In an embodiment, the frame 120 is attached to the pedestal 110 permanently by welding.
[0050] The frame 120 may be made of any material that is durable and corrosion resistant. The frame 120 may be made of, without limitation, galvanized iron, mild steel, stainless steel, composites, alloys (cobalt, nickel, copper), etc. In an exemplary embodiment, the frame 120 is made of galvanized iron or mild steel.
[0051] The frame 120 may have a solid or a hollow structure. In an exemplary embodiment, the frame 120 is a hollow structure and hence, is used for housing different components of the reciprocator 100. Further, the frame 120 may include any shape, without limitation rectangular, square, cylindrical etc. In an exemplary embodiment, the frame 120 is rectangular in shape.
[0052] The frame 120 may be dimensioned in such a way that the frame 120 can incorporate all the components of the reciprocator 100 and yet occupy less space. The height of the frame 120 may range between 1000 to 3000 mm. In an exemplary embodiment, the height of the frame 120 is 1500 mm. The width of the frame 120 may range between 200 to 600 mm. In an exemplary embodiment, the width of the frame 120 is 400 mm. The above dimensions of the frame 120 enable the reciprocator 100 to occupy less space for painting any pre-defined surface. The dimensions of the frame 120 may vary according to the requirement of the user.
[0053] As an exemplary embodiment, in order to enhance the accessibility of the components of the reciprocator 100 placed within the frame 120, the frame 120 may be in the form of a skeleton of a plurality of rods covered with removable covers 120a. The removable covers 120a may cover the frame 120 from all sides. The removable covers 120a may be attached to the rods by any attachment means including, nuts and bolts, fasteners, snap-fit mechanism, press-fit mechanism, etc. Owing to the removable covers 120a, the user may easily replace a damaged component inside the frame 120 by removing the removable covers 120a of the frame 120. The removable covers 120a may be provided with a plurality of channels 120b.
[0054] Apart from covering the frame 120, the removable covers 120a of the frame 120 are used for mounting components of the reciprocator such as the pneumatic accessories box 130, the carriage assembly 150, the drive assembly 160, etc.
[0055] In an embodiment, the removable covers 120a include a plurality of proximity sensors for detecting the movement of one or more linear blocks 20b of the carriage assembly 150 (described in detail below). The proximity sensors may be disposed along the length of the frame 120 at different heights. The proximity sensors may be disposed throughout the frame 120 of the reciprocator 100 at a pre-defined distance from each other say, every 5mm.
[0056] The pneumatic accessories box 130 is coupled to the frame 120 and may be mounted over one of the removable covers 120a of the frame 120 disposed at the back of the reciprocator 100 as shown in Figure 1. The pneumatic accessories box 130 helps to store at least one of, a pressure regulator, a pressure gauge, a paint hose pipe, a pneumatic hose, etc. at one place. It should be noted that the pneumatic accessories box 130 may also include other components as required for the operation of the reciprocator 100. As pneumatic accessories box 130 forms an integral component of the reciprocator 100, components that are required for controlling spray gun parameters i.e. air pressure regulator and pressure gauge, are placed near the spray guns which allow the parameters of spray guns to be precisely controlled. Further, the cost of extra hose length which would have been required if the pneumatic accessories box 130 would have been placed outside the reciprocator 100 is reduced considerably. The paint hose pipe may supply coating formulation from an externally placed coating formulation container to the spray guns. In an embodiment, depending upon the application for which the reciprocator 100 is employed, there may be multiple paint hose pipes connected to respective coating formulation containers and supply different coating formulations (different chemical properties, colours, etc.) to different spray guns 140d.
[0057] The frame 120 may house at least two drag chains 10 (or any equivalent means). The drag chains 10 may extend from the pneumatic accessories box 130 to the arms 140. The drag chains 10 are used for carrying one or more of paint hose pipes and electrical wires/cables originating from the pneumatic accessories box 130 to the arms 140. The drag chains 10 may be supported within the frame 120 by means of a mounting plate 10a as shown in Figure 2.
[0058] As mentioned above, the reciprocator 100 includes arms 140. In an embodiment, the reciprocator 100 may have at least two arms 140 mounted on different sides of the reciprocator 100. As an exemplary embodiment shown in Figures 1 and 2, the reciprocator 100 includes two arms 140 that extend from the frame 120 on opposite sides of the frame 120. It should be noted that though the present invention is explained by way of two oppositely extending arms 140, a reciprocator 100 with more than two arms 140 placed on one or more sides of the reciprocator 100 is also within the scope of the present invention.
[0059] The arms 140 may be disposed at a pre-defined angle with respect to the longitudinal axis (xx’). In an embodiment, the two arms 140 are placed perpendicular to the longitudinal axis (xx’) of the reciprocator 100 (as shown in Figures 1 and 2). Alternately, the arms 140 may be angled (0-180 degrees) with respect to the longitudinal axis (xx’) of the reciprocator 100 (other than 90 degrees). In an embodiment, the angle between the arms 140 and the longitudinal axis (xx’) of the reciprocator 100 is adjustable. The angle may be manually adjusted or adjusted on directions of a microcontroller 200 (discussed below) using a titling means. Alternately, the angle between the arms 140 and the longitudinal axis (xx’) of the reciprocator 100 may be fixed.
[0060] As shown in Figures 1 and 2, the arms 140 are placed 180 degrees apart from each other. Such arrangement of the arms 140 enables the reciprocator 100 to simultaneously paint two pre-defined surfaces that are opposite to each other.
[0061] Though the aforesaid embodiment the arms 140 are 180 degrees apart, it should be noted that the angle between the arms 140 of the reciprocator 100 may be varied as desired by the user. In such cases, one of the arms 140 may be detached and then re-attached at another location to alter the angle between the arms 140. It should be noted the reciprocator 100 is structured to facilitate such arrangements and hence, all such arrangements lie within the scope of the present invention.
[0062] The arms 140 may be made of a durable and light weight material such as, but not limited to stainless steel, aluminum, alloys etc. In an exemplary embodiment, the arms 140 are made of stainless steel.
[0063] The arms 140 may be in the form of a tube-type structure having a pre-defined shape including, but not limited to rectangular, cylindrical, square, triangular, etc. In an embodiment, the arms 140 are cylindrical in shape. Further, the arms 140 may be of any pre-defined dimensions. The length of the arms 140 may range between 300 to 900 mm. In an exemplary embodiment, the length of the arm 140 is 600 mm. In an embodiment, the length of the arms 140 is adjustable using a mechanism (manual/automated) such that the arms 140 can be extended towards the pre-defined surface easily without the need to replacing it with a longer arm.
[0064] The arms 140 are capable of moving in a to and fro direction and extend through respective channels 120b provided on the frame 120. The number of channels 120b provided in the frame 120 may correspond to the number of arms 140 provided in the reciprocator 100. Alternately, the number of channels 120b may exceed the number of arms 140 provided with the reciprocator 100 so enable a user to select the channels 120b for installing the arms 140 basis the angle of the surfaces to be painted. The channel 120b may include pre-defined dimensions that are selected based upon the arms 140. For example, the width of the channels 120b may be selected based upon the width of the arms 140. The height of the channels 120b may be selected based upon a path length that can be covered by the arms 140.
[0065] Each arm 140 may include an attached end 140a and a free end 140b as shown in Figure 1. The attached end 140a of the arms 140 may be coupled to the carriage assembly 150 (described below in detail) while the free end 140b of the arms 140 may extend away from the frame 120.
[0066] The free end 140b of the arms 140 may be coupled with at least one cross arm 140c which further supports at least one spray guns 140d and helps in mounting the same. The free end 140b of the at least two arms 140 may include a two-way coupler for attaching the cross arm 140c (Figures 1 and 2). However, there may be other methods too for such coupling and all such methods are within the scope of the present invention.
[0067] The cross arms 140c may be used for mounting at least one gun holder which in turn supports the spray guns 140d for painting the pre-defined surfaces. Hence, the reciprocator 100 allows painting different surfaces via spray painting using spray guns 140d. Each of the spray guns 140d may be supplied with a same or different coating formulation. The differences in coating formulations may include differences in colour, chemical properties, etc. Each of the spray guns 140d may include a mechanism for adjusting its angle with respect to the longitudinal axis (xx’) of the reciprocator 100.
[0068] The shape and material of the at least two cross arms 140c may be similar to that of the arms 140. In an embodiment, at least one of, the cross arms 140c and/or the gun holders are rotatable such that the spray guns 140d may be positioned at different angles with respect to the pre-defined surface to be painted.
[0069] As mentioned above, the parameters of the spray gun 140d such as pressure, flow rate, etc. may be precisely controlled using the components of the pneumatic accessories box 130.
[0070] An exemplary carriage assembly 150 of the present invention may include a plurality of components as illustrated in Figures 3 and 5 for enabling the movement of the arms 140. Other carriage assemblies that serve the same function are to be considered within the scope and spirit of the teachings of the present invention.
[0071] The carriage assembly 150 may be coupled to the frame 120 via a guide rail system. Though the present invention is explained using a guide rail system however, other systems that are functionally equivalent to the guide rail system may also be used and are within the scope of the present invention.
[0072] The guide rail system may include at least two guide rails 20a and at least two linear blocks 20b that are capable of sliding over the guide rails 20a. The guide rails 20a may be positioned at a distance from each other in such a way that the carriage assembly 150 is positioned between the guide rails 20a.
[0073] The guide rails 20a may be mounted over the removable cover 120a of the frame 120 disposed at the back of the reciprocator 100. The guide rails 20a may be mounted using screws, nuts and bolts, welding, etc. In an embodiment, the guide rails 20a are screwed to the removable cover 120a.
[0074] The carriage assembly 150 is coupled to the linear blocks 20b which in turn are slidably coupled to the guide rails 20a. The carriage assembly 150 is capable of slidable movement along the longitudinal axis (xx’) of the reciprocator 100 via one or more linear blocks 20b. The carriage assembly 150 is also connected to the attached end 140a of the arms 140. Hence, the slidable movement of the linear blocks 20b over the guide rails 20a allows linear motion of the carriage assembly 150 which in turn causes to and fro movement of the arms 140.
[0075] As shown in Figure 3, the carriage assembly 150 includes a joint plate 150a, a guide block 150b, a sliding block 150c and a joint pin 150d. It should be noted that Figure 3 of the present invention illustrates an exemplary embodiment of the carriage assembly 150, however, the structure and components of the carriage assembly 150 may be modified depending upon the drive assembly used.
[0076] The components of the carriage assembly 150 may be made of a pre-defined material which is durable and corrosion resistant as mentioned above.
[0077] The joint plate 150a may be in the form of a mounting tray that houses the remaining components of the carriage assembly 150 and helps to connect the carriage assembly 150 with other components of the reciprocator 100. The joint plate 150a includes two ends. The joint plate 150a may be mounted in such a way that each of the ends of the joint plate 150a is mounted over a corresponding linear block 20b as shown in Figure 3. Hence, the joint plate 150a is mounted in between the guide rails 20a. The joint plate 150a may be coupled to the linear block 20b via, without limitation screw, nails, bolts, etc. In an exemplary embodiment, the joint plate 150a is attached to the linear block 20b using screws. The ends of the joint plate 150a are also coupled to the attached end 140a of the arms 140. The joint plate 150a may be attached to the attached end 140a of the arms 140 via, without limitation nails, screws, bolts, glue, etc. In an exemplary embodiment, the joint plate 150a is screwed to the attached end 140a.
[0078] The guide block 150b may be mounted over a center of the joint plate 150a. The guide block 150b may be coupled to the joint plate 150a using, without limitation nuts, bolts, fasteners, etc. In an exemplary embodiment, the guide block 150b is coupled via bolts.
[0079] The guide block 150b may be in the form of a rectangular bracket which includes a cavity for receiving the sliding block 150c. The sliding block 150c may be coupled to the joint pin 150d via a permanent or a temporary means. In an embodiment, the sliding block 150c and the joint pin 150d are permanently coupled to each other via welding to form an integral structure. The sliding block 150c as well as the joint pin 150d are capable of motion. The sliding block 150c is capable of sliding within the cavity of the guide block 150b to facilitate the movement of the arms 140 (described below in detail).
[0080] The joint pin 150d may include a lower surface facing the driving assembly 160 (explained below).
[0081] The above carriage assembly 150 may be covered by a cover that helps to keep the carriage assembly 150 dust and dirt free. The cover may be made up of a strong, light weight and durable material. In an embodiment, the cover is made up of galvanized iron/mild steel. The cover may be structured (shape and dimension) according to the shape and dimensions of the carriage assembly 150. In an embodiment, the cover is rectangular in shape.
[0082] The movement of the carriage assembly 150 of the reciprocator 100 over the guide rails 20a is a resultant of the driving assembly 160. The driving assembly 160 is configured to allow slidable movement of the carriage assembly 150 thereby allowing linear motion of the arms 140 along the longitudinal axis (xx’) of the reciprocator 100.
[0083] In an exemplary embodiment, the driving assembly 160 includes a driving means 160a, a gearbox 160b, a first drive unit 160c and a second drive unit 160d as shown in Figure 4 clearly. It should be noted that in Figure 4, the removable covers 120a of the frame 120 have been removed from all sides so that the components of the driving assembly 160 are clearly visible and understood.
[0084] The driving means 160a may be in the form of a motor. The driving means 160a may be mounted over the bottom wall of the frame 120 as shown in Figure 2. The driving means 160a may include, but not limited to an AC motor, a DC motor, a special motor, etc. In an exemplary embodiment, the driving means 160a is an AC motor. The AC motor may be a synchronous motor, an induction motor, etc. In an exemplary embodiment, the driving means 160a is an explosion proof induction motor which prevents internal motor explosion from igniting a larger, ambient, combustible atmosphere thereby providing safety to the user as well as the reciprocator 100 itself. The driving means 160a may be a geared motor or an ungeared motor. In an exemplary embodiment, the driving means 160a is a geared motor coupled to the gear box 160b as clearly shown in Figure 4. The driving means 160a provides constant torque even at low speed due to the presence of a heavy-duty gear box 160b. Further, the driving means 160 provided with the gear box 160b that increases or reduces the speed of the driving means 160a for generating equivalent torque.
[0085] The placement of the driving means 160a may be dependent upon the size of the gear box 160b. If the size of the gear box 160b is more than the dimensions of the frame 120, then the driving means 160a is positioned outside the frame 120. If the size of the gear box 160b is less than the dimensions of the frame 120, then the driving means 160a is placed within the frame 120. In an embodiment, the driving means 160a is placed inside the frame 120.
[0086] In an embodiment as shown in Figure 2, the driving means 160a is attached to a holder 40 which is further mounted to the frame 120. The driving means 160a is attached to the holder 40 using screws, bolts, fasteners, etc. In an exemplary embodiment, the driving means 160a is screwed to the holder 40 which is further screwed to the frame 120.
[0087] Further, an air vent 50 (Figure 4) may be provided behind the driving means 160a over the frame 120 to dissipate excess heat generated from the driving means 160a/gear box 160b.
[0088] The driving means 160a may be powered by a powering means including, but not limited to battery, direct-plug in, etc. In an exemplary embodiment, the powering means is an AC supply. In case of a battery, the powering means may be placed close to the driving means 160a inside the frame 120. The powering means may be used to supply power to the driving means 160a for the working of the reciprocator 100.
[0089] A single driving means 160a may drive the motion of the carriage assembly 150 and in turn the arms 140 through a direct drive or an indirect drive mechanism. In an alternate embodiment, the driving means 160a has an indirect drive mechanism which helps to translate the motion of arms 140 along the longitudinal axis (xx’) of the reciprocator 100. The motor power is transmitted to the arms 140 by means of one or more intermediary units without any actual movement of the driving means 160a in forward and reverse direction thereby preventing any damage or wear and tear of the driving means 160a.
[0090] The intermediary components of the indirect drive mechanism may include, without limitation belts, pulleys, chains, etc. In an exemplary embodiment, the motion of the arms 140 is facilitated by the driving means 160a with the help of the first unit 160c and the second unit 160d as shown in Figure 4.
[0091] As shown in Figure 4, the first and second units 160c, 160d are in the form of chain and sprocket assemblies. However, other types of power transmission means are also within the scope of the present invention.
[0092] The first unit 160c is directly connected to the gear box 160b and hence, is driven by the driving means 160a directly. The first unit 160c is further connected to the second unit 160d which drives the movement of the second unit 160d.
[0093] The first unit 160c may include without limitation, two first sprockets C1 and a first chain C2 connecting the two first sprockets C1. One of the two first sprockets C1 may be connected to the gear box 160b while the other first sprocket C1 is connected to the second unit 160d. In an embodiment, the connection between the first sprocket C1 with the gearbox 160b is via a shaft.
[0094] The second unit 160d may include without limitation, two second sprockets D1 and a second chain D2 connecting the two second sprockets D1. One of the two second sprockets D1 may be connected to the first sprocket C1 while the other second sprocket D1 is connected to the removable cover 120a placed at the back of the frame 120. In an embodiment, the connection between the second sprocket D1 and the first sprocket C1 is via a shaft. In an embodiment, the second sprocket D1 is mounted over the removable cover 120a via a shaft.
[0095] The second chain D2 may include a cleat 60 which is coupled to the joint pin 150d of the carriage assembly 150 as shown in FIG. 5. The lower surface of the joint pin 150d may be attached to the cleat 60 of the second chain D2 via an attachment means including, without limitation, screws, nuts, bolts, etc. In an embodiment, the attachment means is a coupler screwed to the cleat 60 and the joint pin 150d. Hence, owing to the movement of the second unit 160d, the joint pin 150d connected to the cleat 60 of the chain D2 also moves thereby resulting in sliding movement of the sliding block 150c within the guide block 150b which in turn causes movement of the carriage assembly 150 over the guide rail 20a causing linear motion of the arm 140.
[0096] In an alternate embodiment, the driving means 160a’ may include a direct drive mechanism having a geared stepper motor as shown in Figure 6. The driving means 160a’ provides high torque even at low speeds and has excellent response to starting and stopping. As evident from Figure 6, the driving means 160a’ may be directly placed above the carriage assembly 150.
[0097] The operation of the above-described reciprocator 100 may be controlled by a microcontroller 200. In an exemplary embodiment as shown in Figure 7, the microcontroller 200 may be operatively coupled to the proximity sensors that are provided over the frame 120 as well as the spray guns 140d. The microcontroller 200 is configured to receive inputs from the user and the proximity sensors and accordingly controls the spray gun 140d. In an exemplary embodiment, the microcontroller 200 controls the switching (On/Off) of spray guns 140d and also the speed of discharge of the coating formulation through the spray guns 140d. The microcontroller 200 may control the switching of spray guns 140d based on dimensions of the at least two pre-defined surfaces. The microcontroller 200 may control the speed of linear motion of the arms 140 on the basis of user inputs.
[0098] In an embodiment, the microcontroller 200 is coupled to the arms 140 and is capable of controlling the speed of movement of the arms 140 based upon the user inputs.
[0099] Figure 8 depicts a flowchart for the steps involved in operation of the reciprocator 100. At step 801, the user provides various inputs to the reciprocator 100 via a user interface. The user interface may be in the form of a display attached to the reciprocator 100. Alternately, the user may remotely provide inputs to the reciprocator 100 using an electronic device via wireless communication. The inputs provided by the user may include, without limitation, the type of coating formulation to be applied, number of layers to be applied, type of the object(s) to be coated, dimensions of the object(s) to be coated, speed of the arms 140, flow rate of the spray guns 140d, etc.
[00100] Post obtaining all inputs from the user, the driving assembly 160 is activated at step 803. The driving means 160a/160a’ results in the movement of the carriage assembly 150.
[00101] In case of the driving means 160a, the first sprocket C1 of the first unit 160c is directly coupled to it thereby rotating the first sprocket C1 in a clockwise or an anti-clockwise direction. The rotation of the first sprocket C1 connected to the first unit 160c causes movement of the first chain C2 which in turn moves the other first sprocket C1 thereby activating the second drive unit 160d. The second sprocket D1 connected to the first sprocket C1 starts to rotate on rotation of the first sprocket C1 thereby causing movement of the second chain D2. Owing to the movement of the second chain D2, the joint pin 150d connected to the cleat 60 of the second chain D2 also moves thereby resulting in sliding movement of the sliding block 150c within the guide block 150b. Such a movement of the sliding block 150b in turn causes movement of the carriage assembly 150 over the guide rail 20a resulting in linear motion of the arms 140 at step 805.
[00102] In case of the driving means 160a’, the driving means 160a’ directly causes movement of the carriage assembly 150 which in turn results in linear motion of the arms 140.
[00103] The microcontroller 200 based upon the inputs received at step 801, regulates the speed of the arms 140.
[00104] At step 807, based upon the dimensions of the object(s) to be coated by the reciprocator 100, the microcontroller 200 activates selective proximity sensors corresponding to the length of the object. Hence, if the size of the object is 200cm then two proximity sensors that cover an upper and lower end of the length of 200cm are activated. The proximity sensors are configured to detect the movement of the linear block 20b and accordingly switch the spray guns 140d.
[00105] It should be noted that the arms 140 are configured to move along a fixed path length. However, the spray guns 140d may be selectively switched on or off depending upon the dimensions of the object to be painted.
[00106] Hence, if the path length of the arms 140 is 500cm and the object is only 200cm then the spray guns 140d are switched on only for 200cm and are switched for the remaining 300cm thereby eliminating wastage of coating formulation.
[00107] In case the length of the object to be painted is more than the path length of the arms 140, then the reciprocator 100 includes a provision for adjusting the angle of the spray guns 140b.
[00108] At step 809, the object is coated.
[00109] Figure 9 shows an exemplary embodiment depicting a layout where the reciprocator 100 of the present invention is utilized for applying primer as well as paint over cylinders 900. It should be noted that though Figure 9 has been depicted using cylinders, any other type of objects can also be painted using the reciprocator 100 using the same layout.
[00110] As shown, the layout includes two booths 910 i.e. a primer booth and a paint booth. In an exemplary embodiment, the primer booth is a dedicated space for applying primer to the cylinders 900 while the paint booth is used for applying paint to the cylinders 900. Though the said example includes two booths, the number of the booths 910 may be more than two depending upon the number of arms 140 provided with the reciprocator 100.
[00111] The booths 910 may be placed in front of each other having a pre-defined space in between. The pre-defined space may include a space similar to the width of the reciprocator 100 such that the reciprocator 100 is placed between the two booths 910 for simultaneously applying the paint and primer. In an embodiment, the booths 910 are placed according to the direction in which the arms 140 of the reciprocator 100 are positioned.
[00112] As shown in Figure 9, the reciprocator 100 is positioned between the booths 910. The booths 910 may be provided on a single conveyor system 920. The conveyor system 920 may be in the form of an overhead conveyor and the cylinders 900 are hanged over the conveyor system 900. The conveyor system 920 may move around the reciprocator 100 in a particular direction. (shown in Figure 9) In an embodiment, the conveyer system 920 moves around the reciprocator 100 at a set time speed.
[00113] The reciprocator 100 is configured to apply the primer and paint to the at least two cylinders 900 in different booths 910 at the same time.
[00114] The cylinders 900 hung over the conveyor system 920 may continuously move in such a way that one of the arms 140 applies primer in the primer booth while the other oppositely placed arm 140 applies paint to another object in the paint booth over which the primer has already been applied. Thus, the arms 140 of the reciprocator 100 are utilized simultaneously for applying primer and paint to the cylinder 900 placed in two different booths 910 at a single time.
[00115] The working of the reciprocator 100 may be now explained with the help of examples below:
[00116] EXAMPLE 1: Two walls of a room were painted with the help of the reciprocator 100. The reciprocator 100 was positioned in a manner that each arm 140 of the reciprocator 100 faced a corresponding wall of the room. The path length of the arms 140 of the reciprocator 100 was 8 feet. A user fed inputs such as wall dimensions, type of emulsion, speed of the arms 140 for the operation of the reciprocator 100. The length of one wall was 10 feet while the length of another wall was 6 feet. The reciprocator 100 started its operation by activation of the driving assembly 160 which in turn caused movement of the carriage assembly 150 and both the arms 140 at the same time. As the path length of the reciprocator 100 was less than the length of one of the walls (long wall), the spray guns 140d of the arm 140 positioned facing the long wall were maintained an angle of 90 degrees with respect to the longitudinal axis (xx’) of the reciprocator 100 while the arms 140 traveled the path length. However, once the arm 140d corresponding to the long wall reached the ends of the path length, the angle at which the spray guns 140d were mounted (with respect to the longitudinal axis (xx’) of the reciprocator 100), was adjusted based upon the inputs of the user.
[00117] For the 6 feet wall (short wall), as the length of the short wall was less than the path length of the reciprocator 100, the proximity sensors positioned on the reciprocator 100, at the upper and lower ends of the 6 feet distance were activated. The proximity sensors sense the motion of the linear block 20b. When the linear block 20b while moving from bottom to top, reached the vicinity of the upper proximity sensors as activated and the upper proximity sensor detected the linear block 20b, then the spray gun 140d was switched off. Likewise, when the lower proximity sensor detected the linear block 20b while moving from top to bottom, the spray guns 140d were switched off. When the upper proximity sensor detected the linear block 20b while moving from top to bottom, the spray gun 140d was switched on. Likewise, when the lower proximity sensor detected the linear block 20b while moving from bottom to top, the spray gun 140d was switched on. On detection, the proximity sensors sent inputs to the microcontroller 200 which in turn switched the spray guns 140d.
[00118] Thus, both the walls of the room were simultaneously painted.
[00119] EXAMPLE 2: The reciprocator 100 was used for painting cylinders hanged on a conveyor system as shown in Figure 9 in a paint layout. The layout included a primer booth and a paint booth. The booths were placed in front of each other while the reciprocator 100 was placed between the booths for simultaneously applying the paint and primer to the cylinders. The arms 140 were positioned according to the direction in which the booths were placed.
[00120] A user fed inputs such as dimensions of cylinders, type of primer and paint, speed of the arms 140 for the operation of the reciprocator 100. The length of cylinder was 3 feet. The path length of the arms 140 of the reciprocator 100 was 8 feet. The reciprocator 100 started its operation by activation of the driving assembly 160 which in turn caused movement of the carriage assembly 150 and both the arms 140 at the same time.
[00121] The conveyor system included an overhead conveyor that moved around the reciprocator 100 in a clockwise direction at a set time speed. The cylinders were moved via the conveyor system continuously in such a way that one of the arms 140 applies primer in the primer booth while the other oppositely placed arm 140 applies paint to another cylinder in the paint booth over which the primer has already been applied.
[00122] As the length of the cylinder was less than the path length of the reciprocator 100, the proximity sensors positioned on the reciprocator 100, at the upper and lower ends of the 4 feet distance were activated. The proximity sensors sense the motion of the linear block 20b. When the linear block 20b while moving from bottom to top, reached the vicinity of the upper proximity sensors as activated and the upper proximity sensor detected the linear block 20b, then the spray gun 140d was switched off. Likewise, when the lower proximity sensor detected the linear block 20b while moving from top to bottom, the spray guns 140d were switched off. When the upper proximity sensor detected the linear block 20b while moving from top to bottom, the spray gun 140d was switched on. Likewise, when the lower proximity sensor detected the linear block 20b while moving from bottom to top, the spray gun 140d was switched on. On detection, the proximity sensors sent inputs to the microcontroller 200 which in turn switched the spray guns 140d.
[00123] Thus, the arms 140 of the reciprocator 100 were utilized for applying primer and paint to the cylinder placed in two different booths simultaneously at a single time.
[00124] The scope of the invention is only limited by the appended patent claims. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings of the present invention is/are used.

WE CLAIM:

1. A reciprocator (100) for simultaneous application of a coating formulation over at least two-predefined surfaces, the reciprocator (100) comprising:
a frame (120) defining a longitudinal axis (xx’) of a reciprocator (100), the frame (120) including a plurality of channels (120b);
a carriage assembly (150) being coupled to the frame (120), the carriage assembly (150) being capable of slidable movement along the longitudinal axis (xx’) of the reciprocator (100) via one or more linear blocks (20b);
a plurality of arms (140) coupled to the carriage assembly (150) and extending from the frame (120) through the plurality of channels (120b), each of the plurality of arms (140) being positioned at a pre-defined angle with respect to the longitudinal axis (xx’) of the reciprocator (100), each of the plurality of arms (140) being provided with at least one spray gun (140d);
a driving assembly (160) configured to allow slidable movement of the carriage assembly (150) thereby allowing linear motion of the plurality of arms (140) along the longitudinal axis (xx’) of the reciprocator (100); and
a microcontroller (200) configured to control switching of the at least one spray gun (140d) and speed of the linear motion of the plurality of arms (140),
wherein each of the plurality of arms (140) extends from a different side of the frame (120) thereby allowing simultaneous application of a coating formulation over at least two-predefined surfaces positioned at different sides of the reciprocator (100),
wherein the microcontroller (200) being capable of switching the at least one spray gun (140d) based on dimensions of the at least two pre-defined surfaces, wherein the microcontroller (200) controls the speed of linear motion of the plurality of arms (140) on the basis of user inputs.
2. The reciprocator (100) as claimed in claim 1 wherein, the frame (120) is placed over a pedestal (110).
3. The reciprocator (100) as claimed in claim 2 wherein, the pedestal (110) includes a gliding means for easy movement of the reciprocator (100) and a locking means for locking the reciprocator (100) at a pre-defined position.
4. The reciprocator (100) as claimed in claim 1 wherein, the frame (120) includes a plurality of proximity sensors for detecting the position of the linear block (20b).
5. The reciprocator (100) as claimed in claim 1 wherein, the one or more linear blocks (20b) are slidably coupled to respective guide rails (20a).
6. The reciprocator (100) as claimed in claim 1 wherein, each of the plurality of arms (140) include a mechanism for adjusting its length.
7. The reciprocator (100) as claimed in claim 1 wherein, the plurality of arms (140) includes two oppositely extending arms.
8. The reciprocator (100) as claimed in claim 1 wherein, the pre-defined angle between the longitudinal axis (xx’) and the arms (140) is adjustable.
9. The reciprocator (100) as claimed in claim 1 wherein, each of the spray guns (140d) includes a mechanism for adjusting its angle with respect to the longitudinal axis (xx’) of the reciprocator (100).
10. The reciprocator (100) as claimed in claim 1 wherein, the driving assembly (160) includes a single driving means (160a) having a direct drive mechanism for movement of the plurality of arms (140).
11. The reciprocator (100) as claimed in claim 1 wherein, the driving assembly (160) includes a single driving means (160a) having an indirect drive mechanism for movement of the plurality of arms (140).
12. The reciprocator (100) as claimed in claims 10 and 11 wherein, the driving means (160a) includes an explosion proof motor.
13. The reciprocator (100) as claimed in claim 1 wherein the reciprocator (100) includes a pneumatic accessories box (130) coupled to the frame (120).
14. The reciprocator (100) as claimed in claim 1 wherein each of the spray guns (140d) is supplied with a same or different coating formulation for spray painting the pre-defined surfaces simultaneously.