Description:TECHNICAL FIELD
The present disclosure generally relates to welding devices. Specifically, the present disclosure relates to a system for coating an engine valve.
BACKGROUND
In recent years there has been significant advancement in the field of engine valve coating processes, driven by the widespread application of the engine valves in various industries. The engine valves play an essential role in controlling the flow of fluids and gases in a wide range of combustion engines. The proper functioning of the engine valves is essential for maintaining the integrity and safety of said combustion engines. However, a seat area of the engine valves is subjected to corrosion, wear and tear, and other forms of damage at high temperatures over time, which can lead to engine failure, leakage, reduced performance, and high maintenance costs. The existing techniques for coating the seat area of the engine valves include welding processes such as tungsten inert gas (TIG) welding, and plasma transferred arc (PTA) welding, and oxyacetylene flame welding.
Although, the present techniques offer effectiveness in coating the seat area of the engine valves, the existing techniques have certain challenges associated therewith. Firstly, both TIG and PTA welding processes involve high heat input, which requires cooling of the engine valves and fixture elements. Moreover, it also requires the engine valves to be held in a fixed position, often using fixtures or clamps, to ensure precise deposition of material on the engine valves. Furthermore, the use of fixtures or clamps to hold the engine valves in place can be cumbersome and may limit the accessibility of certain areas of the engine valves, making it challenging to achieve uniform and consistent weld deposition in the engine valves. Secondly, the existing coating techniques offer limited process control, leading to inconsistencies in weld deposition and quality. Thirdly, the existing coating techniques have relatively slow cycle times, typically ranging from 12 to 18 seconds, depending on the size of the engine valves, and are often labor-intensive and time-consuming, hence require skilled operators to perform the welding process, which results in longer downtimes and increased costs. Furthermore, the present techniques produce parts with a high amount of defects in the coating like blowholes, excessive dilution of deposit materials, lower hardness, and the like. Furthermore, the present techniques lack repeatability and requires human intervention.
Therefore, in light of the foregoing discussion, there exists a need to overcome the aforementioned drawbacks.
SUMMARY
The present disclosure provides a system for coating an engine valve. The present disclosure seeks to provide a solution to the existing problem of how to eliminate inconsistencies in weld deposition and quality. An aim of the present disclosure is to provide a solution that overcomes at least partially the problems encountered in the prior art and provide an improved system for coating an engine valve which enables to remove inconsistencies in weld deposition and quality.
In one aspect, an embodiment of the present disclosure provides a system for coating an engine valve having a seat portion and a stem portion. The system comprises a laser deposition torch having a welding-axis positioned orthogonal to a horizontal plane. Moreover, the system comprises a base plate positioned adjacent to the laser deposition torch and mounted on a base support assembly configured to rest on the horizontal plane, wherein the base plate is positioned at an inclined-angle with respect to the horizontal plane. Furthermore, the method comprises a maneuvering mechanism mounted on the base plate, the maneuvering mechanism operable to move the engine valve relative to the laser deposition torch. Furthermore, the method comprises a job-holding mechanism mounted on the base plate, the job-holding mechanism operable to hold the stem portion of the engine valve to align the engine valve with respect to the laser deposition torch for the coating. Furthermore, the method comprises a reference-stopper mounted on the base plate, the reference-stopper comprises an opening to receive the stem portion of the engine valve therethrough with the help of maneuvering mechanism to allow the engine valve to attain a coating-position, wherein in the coating-position the seat portion of the engine valve is positioned inclined and aligned to the welding-axis and at a pre-determined distance from the laser deposition torch, and wherein in the coating-position the job-holding mechanism is operable to rotate the engine valve for the coating of the seat portion using the laser deposition torch.
Beneficially, the embodiments of the present disclosure provide a system that offers a precise and efficient system for coating the engine valve by using a laser cladding or a directed energy deposition (DED) technology. The system allows for precise positioning of the seat portion of the engine valve, which is inclined and aligned to the welding-axis at a predetermined distance from a laser deposition torch, which ensures accurate and uniform coating of the seat portion. The system's precise alignment and rotation capabilities, along with the inclined positioning of the valve's seat portion, result in a uniform and controlled coating application. Moreover, a job-holding mechanism and a maneuvering mechanism enable efficient movement and rotation of the engine valve during the coating. This efficiency leads to higher productivity and lower cycle times and improves the quality and durability of the coating that meets the industry standards. Furthermore, the system enables to reduce a dilution of the material deposited via the coating into a valve material, which leads to higher quality coatings with better material properties and performance, and subsequently, results in a longer operational life of the engine valve with an improved engine performance. Furthermore, the system is designed to be accurate, user-friendly, with easy-to-use maneuvering and job-holding mechanisms, which makes it easier for operators to perform the coating efficiently. The system is simple, robust, fast, reliable, and can be implemented with ease. Furthermore, the system is repeatable in its implementation and requires minimal human intervention.
It must be noted that all devices, elements, circuitry, units and means described in the present application could be implemented in the software or hardware elements or any kind of combination thereof. All steps which are performed by the various entities described in the present application as well as the functionalities described to be performed by the various entities are intended to mean that the respective entity is adapted to or configured to perform the respective steps and functionalities. Even if, in the following description of specific embodiments, a specific functionality or step to be performed by external entities is not reflected in the description of a specific detailed element of that entity which performs that specific step or functionality, it should be clear for a skilled person that these methods and functionalities can be implemented in respective software or hardware elements, or any kind of combination thereof. It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
Additional aspects, advantages, features and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative implementations construed in conjunction with the appended claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a system for coating an engine valve having a seat portion and a stem portion, in accordance with an embodiment of the present disclosure;
FIGs. 2A and 2B illustrate schematic representations of a laser deposition torch, in accordance with an embodiment of the present disclosure;
FIGs. 3A-C collectively illustrates schematic representations of a maneuvering mechanism, in accordance with an embodiment of the present disclosure;
FIG. 4 illustrates an exemplary scenario of the coating position of the engine valve, in accordance with an embodiment of the present disclosure; and
FIG. 5 illustrates steps of a method for coating an engine valve having a seat portion and a stem portion, in accordance with an embodiment of the present disclosure.
The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those skilled in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION OF EMBODIMENTS
The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
FIG. 1 is a system 100 for coating an engine valve 102 having a seat portion 104 and a stem portion 106, in accordance with an embodiment of the present disclosure. With reference to FIG. 1, the system 100 comprises a laser deposition torch 108 having a welding-axis 110, positioned orthogonal to a horizontal plane 112. Moreover, the system 100 comprises a base plate 114 positioned adjacent to the laser deposition torch 108 and mounted on a base support assembly 116 configured to rest on the horizontal plane 112, wherein the base plate 114 is positioned at an inclined-angle with respect to the horizontal plane 112. Furthermore, the system 100 comprises a maneuvering mechanism 118 mounted on the base plate 114, the maneuvering mechanism 118 operable to move the engine valve 102 relative to the laser deposition torch 108. Furthermore, the system 100 comprises a job-holding mechanism 120 mounted on the base plate 114, the job-holding mechanism 120 operable to hold the stem portion 106 of the engine valve 102 to align the engine valve 102 with respect to the laser deposition torch 108 for the coating. Furthermore, the system 100 comprises a reference-stopper 122 mounted on the base plate 114, the reference-stopper 122 comprises an opening 124 to receive the stem portion 106 of the engine valve 102 therethrough with the help of maneuvering mechanism 118 to allow the engine valve 102 to attain a coating-position, wherein in the coating-position the seat portion 104 of the engine valve 102 is positioned inclined and aligned to the welding-axis 110 and at a pre-determined distance from the laser deposition torch 108, and wherein in the coating-position the job-holding mechanism 120 is operable to rotate the engine valve 102 for the coating of the seat portion 104 using the laser deposition torch 108.
Throughout the present disclosure the term "engine valve" refers to a device that is used in an internal combustion engine to allow or stop the flow of fluid or gas from a cylinder or a combustion chamber while the internal combustion engine is operating. The engine valve 102 is typically made of durable materials such as nickel, steel alloys and the like, to withstand high temperatures and pressures. The engine valve 102 has different components that work together to control the flow of air and fuel into the combustion chamber and the exhaust gases out of the combustion chamber. The working of the engine valve 102 is well known in the art.
In this regard, the engine valve 102 has the seat portion 104 and the stem portion 106. Herein the term "seat portion" refers to a surface area of the engine valve 102 where it makes contact with a valve seat in a cylinder head or engine block. The seat portion 104 of the engine valve 102 forms a seal with the valve seat to prevent the escape of gases during the combustion process. The seat portion 104 is typically made of a wear-resistant material, such as hardened steel or a special alloy, to withstand the high temperatures and pressures in the combustion chamber.
Herein, the term "stem portion" refers to the elongated, cylindrical section of the engine valve 102 that connects the cylindrical head of the engine valve 102 to a valve guide within the internal combustion engine. The stem portion 106 is the part of the engine valve 102 that moves up and down (or side to side in some designs) to open and close the engine valve 102. The stem portion 106 is typically made of a durable material, such as hardened steel, to withstand the mechanical stresses and high temperatures from the internal combustion engine's operation.
Herein, the term "coating" refers to the process of applying a layer of material onto the surface of the engine valve 102, which is typically done to improve the performance, durability, and longevity of the engine valve 102. It will be appreciated that the process of coating incorporates processes of hardfacing, welding, deposit welding, and the like. The coating may be made of various materials, such as iron, cobalt, nickel, cobalt, titanium- based alloys and also in combination of all alloying elements, depending on the desired properties to be achieved after coating the engine valve 102. Moreover, the coating may be used to build up material on worn or damaged engine valve surfaces, restoring them to their original dimensions and functionality. In this regard, the coating is typically done on the seat portion 104 of the engine valve 102. The coating of the seat portion 104 improves wear resistance, enhances sealing properties, and provides benefits that contribute to the overall improvement in the performance and durability of the engine valve 102.
Herein, the term "laser deposition torch" refers to a tool used in welding to generate and control intense energy or heat source, required to melt a base metal and a filler material to create a weld overlay or layer of the coating material. In this regard, the laser deposition torch 108 is used to apply a coating material onto the seat portion 104 of the engine valve 102 by guiding a raw laser beam generated from a laser source (such as fiber lasers, disk lasers, diode lasers, and the like) in the laser deposition torch 108. The raw laser beam is guided for the coating by using a collimation lens, focusing lens and optionally, a defocusing mechanism, to adjust a size of the raw laser beam to the width of the seat portion 104. Moreover, the laser deposition torch 108 comprises powder nozzle to focus a powder on the seat portion 104, and a powder switching mechanism to activate and deactivate a flow of the powder according to the requirement, which melts the coating material, allowing it to bond to the seat portion 104 of the engine valve 102. Optionally, the laser deposition torch 108 comprises a digital camera used for alignment and positioning of the laser deposition torch 108. Optionally, the focusing lens of the laser deposition torch 108 is adjusted for achieving different size of the raw laser beam, using a rotating knob in the laser deposition torch 108 that allows to change the size of the raw laser beam via defocusing, without the need to change a tool center point (TCP) of the laser deposition torch. Optionally, the powder nozzle is designed to be of an annular shape, wherein powder flows from the powder nozzle through an annular gap between two cones in the powder nozzle for accurate and precise feeding of the powder, thus, enabling timely dosage of the powder and minimizing wastage of the powder flow. Moreover, the term "welding-axis" refers to an imaginary line that represents the direction in which the welding is performed. The welding-axis 110 determines the orientation of the laser deposition torch 108 relative to the engine valve 102. In this regard, the laser deposition torch 108 is positioned in such a way that the welding-axis 110 passes through the seat portion 104 of the engine valve 102 and is perpendicular to the horizontal plane 112, which ensures that the coating material is deposited correctly onto the seat portion 104 of the engine valve 102.
Optionally, the laser deposition torch 108 is associated with one of: a laser cladding technology or a directed energy deposition technology. In this regard, the coating material is added layer by layer in the seat portion 104 of the engine valve 102 by using one of: laser cladding technology or directed energy deposition (DED) technology. In the laser cladding technology, a high-powered laser beam is used to melt and fuse a powdered coating material onto the surface of the seat portion 104 of the engine valve 102. Furthermore, the laser beam is precisely controlled to deposit the coating material in the desired pattern, creating the coating with specific properties such as hardness, wear resistance, or corrosion resistance. Alternatively, the laser deposition torch 108 may be associated with the directed deposition technology (DED) that uses a focused thermal energy source, such as a laser or electron beam, to melt and deposit the coating material onto the seat portion 104 of the engine valve 102, where the coating material is typically in the form of wire or powder. The technical benefit of using one of: the laser cladding technology or the directed energy deposition technology, for the laser deposition 108 is that precise control over the coating and the ability to coat material layer by layer on the engine valve 102 is achieved. The laser cladding technology allows a fast and efficient process for coating. Moreover, the DED technology enables a minimal heat transfer to the surrounding material, reducing the size of the heat affected zone and minimizing distortion and metallurgical changes in the base coating material.
Throughout the present disclosure, the term "base plate" refers to a flat, rigid, and typically rectangular or circular, metal plate that serves as a foundation or support for the other components (such as the maneuvering mechanism 118, the job mechanism 120, and the reference-stopper 122). It will be appreciated that the base plate 114 is positioned adjacent to the laser deposition torch 108, to align the engine valve 102 to the laser deposition torch 108. Moreover, the base plate 114 is mounted on the base support assembly 116. Herein the term "base support assembly" refers to a structure that provides support and stability to securely hold the base plate 114. In this regard, the base support assembly 116 is configured to rest on the horizontal plane 112, which may be ground, a workbench, or a machine bed. Additionally, the base support assembly 116 may include legs, brackets, or other supporting elements to ensure the stability of the base plate 114. In this regard, the laser deposition torch 108 is connected to the base support assembly 116 such as using a bracket, using arm, and similar, therefore providing a stable connection between the base plate 114 and the laser deposition torch 108. It will be appreciated that the base plate 114 is positioned at the inclined-angle with respect to the horizontal plane 112 on which the base support assembly 116 rests, which allows for the proper positioning of the engine valve 102 during the coating, ensuring that the seat portion 104 is inclined and aligned to the welding-axis 110 of the laser deposition torch 108 for precise coating. In other words, inclining the base plate 114 allows the seat portion 102 to be aligned and inclined to the welding-axis 110 at a predetermined angle, which enables to achieve precise and uniform coating. Optionally, the base support assembly 116 is stationary or moveable for allowing to change an inclination angle of the base plate 114.
Optionally, the inclined-angle is configured to be within a range of 30 to 75 degrees. Herein the inclined-angle of the base plate 114 with respect to the horizontal plane 112 may lie in a range of 30, 35, 40, 50, 60, or 70 degrees to 35, 40, 50, 60, 70 or 75 degrees. In this regard, such a range of inclined angles is chosen to optimize the coating for the seat portion 104 of the engine valve 102. The inclined-angle being a steeper value may provide better access and positioning for the coating, while the inclined-angle being a shallower value may allow for easier manipulation of the engine valve 102. Moreover, the specific angle to be within the range of 35 to 70 degrees may be selected based on factors such as the geometry of the engine valve 102 and the properties of the coating material to achieve the desired coating results. A technical benefit of having the inclined-angle to be within the range of 35 to 70 degrees is that it helps to ensure that the coating material is applied evenly across the seat portion 104 of the engine valve 102, improving the uniformity and consistency of the coating. Furthermore, the inclined-angle may help optimize the distribution of laser beam 204 from the laser deposition torch 108, reducing the risk of overheating and distortion of the seat portion 104.
Herein, the term "maneuvering mechanism" refers to a component that is designed to control the movement of the engine valve 102 relative to the laser deposition torch 108 during the coating. In this regard, the maneuvering mechanism 118 is mounted on the base plate 114 such that it is positioned flat or horizontally on the base plate 114. Optionally, the maneuvering mechanism 118 may be mounted on the side of the base plate 114, allowing for horizontal movement of the engine valve 102. Moreover, the maneuvering mechanism 118 is operable to carry the engine valve 102 which allows the engine valve 102 to move along with the movement in the maneuvering mechanism 118, as the engine value 102 is positioned for the coating. The movement of the maneuvering mechanism 118 involves moving the engine valve 102 closer to or farther away horizontally from the laser deposition torch 108, depending on the requirements of the coating. The ability to adjust this distance allows for precise control over the application of the coating material, ensuring that it is applied at the correct distance and angle for optimal results.
Herein, the term "job-holding mechanism" refers to the device that is used to hold the stem portion 106 of the engine valve 102 in place during the coating. The job-holding mechanism 120 is mounted on the surface of the base plate 114 (wherein, the job-holding mechanism 120 is optionally, mounted at a perpendicular angle on the base plate 114). Notably, the job-holding mechanism 120 tightly grips the stem portion 106. Therefore, the seat portion 104 of the engine valve 102 is positioned at the correct angle and distance from the laser deposition torch 108 to ensure that the coating material is applied accurately and uniformly. Furthermore, the job-holding mechanism 120 rotates the stem portion 106 of the engine valve 102 so that the coating can be done uniformly on the seat portion 104 using the laser deposition torch 108. Optionally, the job-holding mechanism 120 comprises an endless rotating device (for example, an endless rotating motor) that is pneumatically or electrically controlled to hold the stem portion 106 of the engine valve 102.
Optionally, the job-holding mechanism 120 is a chuck. In this regard, the term "chuck" refers to a specialized type of clamp used to hold an object with radial symmetry, typically a cylindrical workpiece. The chuck is most commonly used to hold rotating tools or workpieces, such as drill bits or rotating shafts, allowing them to be held securely in place while being worked on. In this regard, the chuck is used as the job-holding mechanism 120 to hold the stem portion 106 of the engine valve 102. The chuck provides a secure grip on the stem portion 106, allowing for precise positioning and alignment of the engine valve 102 with respect to the laser deposition torch 108 for the coating. The chuck may include features such as adjustable jaws or gripping mechanisms to accommodate the engine valve 102 of different sizes and shapes. Examples of the chuck that is used as the job-holding mechanism 120 may include but not limited to, three-jaw chucks, four-jaw chucks, and collet chucks. Additionally, the chuck may be operated automatically. A technical benefit of the job-holding mechanism 120 being the chuck is that the engine valve 102 is effectively kept in the correct position during the coating which helps in preventing any slippage that could affect the quality of the coating. Moreover, the chuck allows for precise alignment of the engine valve 102 with respect to the laser deposition torch 108, ensuring that the coating material is applied accurately and uniformly to the seat portion 104.
Herein, the term "reference-stopper" refers to a component that is mounted on the base plate 114 and used to limit the movement of the engine valve 102 and assist in positioning it for the coating. The reference-stopper 122 typically consists of a physical barrier with the opening 124 through which the stem portion 106 of the engine valve 102 passes. The reference-stopper 122 is designed to work in conjunction with the maneuvering mechanism 118 to guide the engine valve 102 into the coating position. Optionally, the reference-stopper 122 moves the engine valve 102 in a linear or rotational manner to be positioned in the coating position. Herein the term "coating position" refers to the specific orientation and alignment of the engine valve 102 when it is positioned for the coating, where the seat portion 104 of the engine valve 102 is inclined and aligned to the welding-axis 110 at a predetermined distance from the laser deposition torch 108. Notably, the coating position includes the stem portion 104 of the engine valve 102 aligned with a rotatory axis of the job-holding mechanism 120. Herein the term "predetermined distance" refers to the specific distance between the seat portion 104 of the engine valve 102 and the laser deposition torch 108 when the engine valve 102 is in the coating position. The predetermined position distance depends on the requirements of the coating, such as the type of coating material being used, the desired coating thickness, and the properties of the engine valve material.
It will be appreciated that the coating position is achieved by passing the stem portion 106 of the engine valve 102 through the opening 124 in the reference-stopper 122 and aligning it with the welding-axis 110 using the maneuvering mechanism 118. Once in the coating position, the stem portion 106 of the engine valve 102 is held securely in place by the job-holding mechanism 120, allowing for precise rotation for the coating of the seat portion 104 using the laser deposition torch 108. The coating position ensures that the coating material is applied accurately and uniformly to the seat portion 104 of the engine valve 102, which allows for optimal access and visibility of the engine valve 102 for the coating, ensuring that the coating material is deposited exactly where it is needed to achieve the desired coating thickness and quality. Moreover, the shape of the opening 124 varies depending on the specific design of the reference-stopper 122 and the engine valve 102 being used. In some implementations, the opening 124 may be circular or cylindrical in shape to match the shape of the stem portion 106 of the engine valve 102, which helps to ensure a snug fit and provides stability to the engine valve 102 while being in the coating position. Optionally, the opening 124 may also be designed with features such as grooves or ridges to help guide the engine valve 102 into the correct position and prevent it from slipping during the coating, that allows for precise positioning of the engine valve 102, leading to high-quality and consistent coatings. Notably, the reference-stopper 122 automatically aligns the engine valve 102 into the job-holding mechanism 120, which impacts both the precision of the coating and the overall efficiency of the system.
FIGs. 2A and 2B are schematic representations of the laser deposition torch 108, in accordance with the embodiment of the present disclosure. Herein, the laser deposition torch 108 comprises a nozzle 200, an energy source 202 that generates a raw laser beam 204, a powder nozzle 206, a focusing lens 208, wherein a weld overlay 210 is created on the seat portion 104 during coating process. Moreover, the laser deposition layer 108 comprises a collimation lens 212, a powder switch 214 for controlling the precise dosage of the powder through the powder nozzle 206, and a digital camera 216. FIGs. 2A and 2B are merely examples, which should not unduly limit the scope of the claims herein. A person skilled in the art will recognize many variations, alternatives, and modifications of embodiments of the present disclosure.
In this regard, the energy source 202 is responsible for generating the raw laser beam 204 used in the coating. The energy source 202 generates the raw laser beam 204, which then provides the energy necessary to melt the coating material and deposit it onto the seat portion 104 of the engine valve 102. Examples of the energy source 202 used in the laser deposition torch 108 may include but are not limited to, a diode laser, a fiber laser, a carbon dioxide laser, a neodymium-doped yttrium aluminum garnet laser, and an excimer laser. Furthermore, the energy source 202 is chosen based on factors such as power requirements, beam quality, and cost. Herein, the term "focusing lens" refers to the component used to manipulate various forms of radiation or waves. In this regard, the focusing lens 208 are used to shape and focus the raw laser beam 204 generated by the energy source 202, to achieve the desired characteristics for the coating. Additionally, the focusing lens 208 help to control the size and intensity of the raw laser beam 204. Examples of the focusing lens 208 may include but are not limited to, lenses, mirrors, beam expanders, beam splitters, and polarizers.
Moreover, the nozzle 200 is the part of the laser deposition torch 108 that directs the raw laser beam 204 onto the seat portion 104 of the engine valve 102. It will be appreciated that the nozzle 200 is designed with a coaxial ring gap so that the coating material is fed through this gap that surrounds the raw laser beam 204. Moreover, the coating material is typically fed into the nozzle 200 through a feeding mechanism that surrounds the raw laser beam 204. The feeding mechanism may vary depending on the specific design of the laser deposition torch 108. In some cases, the coating material may be fed into the nozzle 200 through a tube or channel that surrounds the raw laser beam 204. The coating material is then propelled through the coaxial ring gap by a gas or air flow, ensuring a continuous and controlled supply of coating material to the seat portion 104 of the engine valve 102. In other cases, the coating material may be fed into the nozzle 200 using a screw or auger, where the coating material is fed into the nozzle 200 and propelled through the coaxial ring gap by rotating the screw or the auger.
A technical benefit of the nozzle 200 along with the coaxial ring allows precise control over the deposition of the coating material onto the seat portion 104 of engine valve 102, which ensures that the coating material is deposited exactly onto the seat portion 104 of the engine valve 102. Moreover, the focusing lens 208 ensure that the coating material is deposited accurately and uniformly, improving the coating quality and efficiency. Additionally, the energy source 202 ensures that the coating material is efficiently melted so that it can be deposited onto the seat portion 104 of the engine valve 102.
Referring to FIGs. 3A-C collectively, illustrated are schematic representations of a maneuvering mechanism 118, in accordance with the embodiment of the present disclosure. As shown, the maneuvering mechanism 118 comprises a maneuvering-base 302 and a valve-holder 304. Optionally, the maneuvering mechanism 118 further comprises a push road 306. As shown in FIG.3A, the engine valve 102 is at a first position 308. As shown in FIG. 3B, the engine valve 102 is moved by the maneuvering mechanism 118 to a second position 310. As shown in FIG. 3C, the engine valve 102 is moved by the maneuvering mechanism 118 to a coating position 312. FIGs. 3A-C are merely examples, which should not unduly limit the scope of the claims herein. A person skilled in the art will recognize many variations, alternatives, and modifications of embodiments of the present disclosure.
Optionally, the maneuvering mechanism 118 comprises:
a maneuvering-base 302 moveably coupled to the base plate 114 and operable to be pneumatically moved with respect to the base plate 114, and
a valve-holder 304 moveably coupled to the maneuvering-base 302 and operable to be pneumatically moved with respect to the maneuvering-base 302, the valve-holder 304 configured to hold the engine valve 102,
wherein at least one of the maneuvering-base 302 or the valve-holder 304 are operable to be moved to align the engine valve 102 with respect to the reference-stopper 122.
In this regard, the term "maneuvering-base" refers to a component that is used as the foundation or support for the valve-holder 304 and the engine valve 102. The maneuvering-base 302 provides a stable platform for the valve-holder 304 to move, ensuring that the engine valve 102 is accurately aligned with the reference-stopper 122. In this regard, the maneuvering-base 302 is operable to pneumatically move relative to the base plate 114 using a pneumatic mechanism, which utilizes compressed air or gas to generate linear motion. The pneumatic mechanism includes one or more pneumatic cylinders, and when compressed air or gas is introduced into the one or more pneumatic cylinders, which pushes a piston that is inside the one or more pneumatic cylinders, and further generates linear motion of maneuvering-base 302. The pressure of the air or gas pushes the piston, which in turn moves the maneuvering-base 302 in the base plate 114. Alternatively, the valve-holder 304 can also be pneumatically moved, using the pneumatic mechanism. The valve-holder 304 is positioned on the top of the maneuvering-base 302 and then the engine valve 102 is plugged on the valve-holder 304. Moreover, the valve-holder 304 includes a clamping structure to hold the engine valve 102. The clamping structure may consist of adjustable jaws or grips that can be tightened around the engine valve 102 to hold it securely. In this regard, a control mechanism regulates the flow of compressed air to the one or more pneumatic cylinders, controlling the movement of the valve-holder 304 or the maneuvering-base 302. The control mechanism may be automated, and when the valve-holder 304, is moved and adjusted using the control mechanism, where the engine valve 102 is moved along with the valve-holder 304 and aligns relative to the reference-stopper 122. A technical benefit of this configuration of the maneuvering mechanism 118 is that precise alignment of the engine valve 102 with respect to the reference-stopper 122 is achieved which is crucial for the coating. The ability to move either the maneuvering-base 302 or the valve-holder 304 provides flexibility in how the engine valve 102 is aligned, which allows for adjustments to be made based on the specific requirements of the coating.
Optionally, the maneuvering mechanism 118 further comprises a push road 306 moveably coupled to the valve-holder 304, the push rod 306 is pneumatically operable to push the engine valve 102 for receiving the stem portion 106 of the engine valve 102 through the opening 124 of the reference-stopper 122 when the engine valve 102 is aligned with respect to the reference-stopper 124. In this regard, the term "push rod" refers to a rod like component that is designed to extend and retract pneumatically. Optionally, the push rod 306 may have a cylindrical shape and could be made of metal. The push rod 306 is connected to a pneumatic mechanism, that controls its movement and facilitates the positioning of the engine valve 102 for the coating. In this regard, the push rod 306 may be attached to the valve-holder 304, by means of a joint, linkage, and the like, that allows the push rod 306 to move back and forth while remaining connected to the valve-holder 304. Furthermore, when the engine valve 102 is positioned in the valve-holder 304 and is pneumatically moved to the position relative to the reference-stopper 122, then the push rod 306 is pneumatically activated to push the seat portion 104 of the engine valve 102, which allows the stem portion 106 of the engine valve 102 to be inserted through the opening 124 of the reference-stopper 122. In other words, as the valve-holder 304 moves, the push rod 306 moves along with , maintaining a consistent position relative to the valve-holder 304.
A technical benefit of the push road 306 being moveably coupled to the valve-holder 304, is that the push rod 306 moves in sync with the valve-holder 304, allowing for precise and coordinated movement of the engine valve 102 during the coating. By pushing the engine valve 102 into the correct position, the push rod 306 ensures that the engine valve 102 is securely held in place and properly aligned with the reference-stopper 122 for the coating to proceed smoothly and accurately.
Optionally, the valve-holder 304 is configured to receive the engine valve 102 when the job-holding mechanism 120 releases the stem portion 106 after the coating with the help of gravitational pull. In this regard, during the coating, the job-holding mechanism 120 securely grips the stem portion 106 of the engine valve 102 to hold it in place for coating, and once the coating is complete, the job-holding mechanism 120 releases the stem portion 106 automatically. With the stem portion 106 released, the engine valve 102 is no longer held in place and is free to fall. Moreover, the at least one of the maneuvering-base 302 or the valve-holder 304 is pneumatically moved in the base plate 114, as the engine valve 102 falls, and is guided into the valve-holder 304 by the force of gravity. A technical benefit is that an efficient transfer of the engine valve 102 from the coating position to the valve-holder 304 is enabled.
Referring to FIG. 4, illustrated an exemplary scenario of the coating position 312 of the engine valve 102 in accordance with the embodiment of the present disclosure. As shown, optionally, the reference-stopper 122 is mounted orthogonally on the base plate 114 and adjacent to the job-holding mechanism 120 allowing a job-holding-axis 402 to pass centrally through the opening 124 of the reference-stopper 122 and the job-holding mechanism 120 in the coating position of the engine valve 102. In this regard, the term "job-holding-axis" refers to an imaginary line or axis around which the stem portion 106 of the engine valve 102 is positioned or rotated during the coating. In this regard, when the engine valve 102 is in the coating position, the job-holding mechanism 120 and the opening 124 in the reference-stopper 122 are aligned along the job-holding-axis 402, which passes centrally through the job-holding mechanism 120 and the opening 124. In other words, the job-holding-axis 402 serves as a central reference line along which the engine valve 102 is positioned and aligned during the coating. A technical benefit is that the engine valve 102 is held securely in place and that the coating is applied accurately and uniformly to the seat portion 104 of the engine valve 102. Additionally, the job-holding-axis 402 determines the accurate rotation of the engine valve 102 during the coating, resulting in a high-quality coating that meets the required specifications.
Optionally, in the coating position the job-holding-axis 402 and the welding-axis 110 intersects and allows a seat face 404 of the seat portion 104 to be orthogonal to the welding-axis 110. In this regard, the term "seat face" refers to a specific surface on the seat portion 104 that is being coated. In this regard, the job-holding mechanism 120 rotates the stem portion 104 of the engine valve 102 and when the seat face 404 of the seat portion 104 lies perpendicular to the welding-axis 110, then the laser deposition torch 108 directs the laser beam for coating, which means the job-holding-axis 402 intersects with the welding-axis 110 at this specific point, to ensure that the coating material is applied to the seat face 404 of the seat portion 104 at a precise angle, resulting in a uniform and consistent coating. A technical benefit is that the coating is carried out accurately and efficiently, leading to a high-quality coating on the engine valve 102.
FIG. 4 is merely an example, which should not unduly limit the scope of the claims herein. A person skilled in the art will recognize many variations, alternatives, and modifications of embodiments of the present disclosure.
In an implementation, the engine valve 102 is moved relative to the laser deposition torch 112, using the maneuvering mechanism 118. Moreover, the stem portion 106 of the engine valve 102 is held by the job-holding mechanism 120 to align the engine valve 102 with respect to the laser deposition torch 108 for the coating. Furthermore, the stem portion 106 of the engine valve 102 is received by the opening 124, with the help of the maneuvering mechanism 118, to allow the engine valve 102 to attain the coating-position, wherein in the coating-position the seat portion 104 of the engine valve 102 is positioned inclined and aligned to the welding-axis 110 and at a pre-determined distance from the laser deposition torch 108, and wherein in the coating-position, the engine valve 102 is rotated using the job-holding mechanism 120, for the coating of the seat portion 104 using the laser deposition torch 108.
Modifications to embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as "including", "comprising", "incorporating", "have", "is" used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural. The word "exemplary" is used herein to mean "serving as an example, instance or illustration". Any embodiment described as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments and/or to exclude the incorporation of features from other embodiments. The word "optionally" is used herein to mean "is provided in some embodiments and not provided in other embodiments". It is appreciated that certain features of the present disclosure, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the present disclosure, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable combination or as suitable in any other described embodiment of the disclosure.

, Claims:CLAIMS
I/We claim:
1. A system (100) for coating an engine valve (102) having a seat portion (104) and a stem portion (106), the system comprising:
a laser deposition torch (108) having a welding-axis (110) positioned orthogonal to a horizontal plane (112);
a base plate (114) positioned adjacent to the laser deposition torch and mounted on a base support assembly (116) configured to rest on the horizontal plane, wherein the base plate is positioned at an inclined-angle with respect to the horizontal plane;
a maneuvering mechanism (118) mounted on the base plate, the maneuvering mechanism operable to move the engine valve relative to the laser deposition torch;
a job-holding mechanism (120) mounted on the base plate, the job-holding mechanism operable to hold the stem portion of the engine valve to align the engine valve with respect to the laser deposition torch for the coating; and
a reference-stopper (122) mounted on the base plate, the reference-stopper comprises an opening (124) to receive the stem portion of the engine valve therethrough with the help of maneuvering mechanism to allow the engine valve to attain a coating-position (312), wherein in the coating-position the seat portion of the engine valve is positioned inclined and aligned to the welding-axis and at a pre-determined distance from the laser deposition torch, and wherein in the coating-position the job-holding mechanism is operable to rotate the engine valve for the coating of the seat portion using the laser deposition torch.
2. The system (100) according to claim 1, wherein the reference-stopper (122) is mounted orthogonally on the base plate (114) and adjacent to the job-holding mechanism (120) allowing a job-holding-axis (402) to pass centrally through the opening (124) of the reference-stopper and the job-holding mechanism in the coating position of the engine valve (102).
3. The system (100) according to claim 2, wherein in the coating position the job-holding-axis (402) and the welding-axis (110) intersects and allows a seat face (404) of the seat portion (104) to be orthogonal to the welding-axis.
4. The system (100) according to claim 1, wherein the laser deposition torch (108) is associated with one of: a laser cladding technology or a directed energy deposition technology.
5. The system (100) according to claim 1, wherein the laser deposition torch (108) comprises:
an energy source (202) for generating a laser beam (204),
one or more optical elements (206) for shaping the laser beam, and
a nozzle (208) having a coaxial ring gap, around the laser beam, for feeding a coating material therethrough.
6. The system (100) according to claim 1, wherein the maneuvering mechanism (118) comprises:
a maneuvering-base (302) moveably coupled to the base-plate and operable to be pneumatically moved with respect to the base plate (114), and
a valve-holder (304) moveably coupled to the maneuvering-base and operable to be pneumatically moved with respect to the maneuvering-base, the valve-holder configured to hold the engine valve (102),
wherein at least one of the maneuvering-base or the valve-holder are operable to be moved to align the engine valve with respect to the reference-stopper (122).
7. The system (100) according to claim 6, wherein the maneuvering mechanism (118) further comprises a push rod (306) moveably coupled to the valve-holder (304), the push rod is pneumatically operable to push the engine valve (102) for receiving the stem portion (106) of the engine valve through the opening (124) of the reference-stopper (122) when the engine valve is aligned with respect to the reference-stopper.
8. The system (100) according to claim 6, wherein the valve-holder (304) is configured to receive the engine valve (102) when the job-holding mechanism (120) releases the stem portion (106) after the coating with the help of gravitational pull.
9. The system (100) according to claim 1, wherein the job-holding mechanism (120) is a chuck.
10. The system (100) according to claim 1, wherein the inclined-angle is configured to be within a range of 30 to 75 degrees.