MOBILE SELF-CONTAINED ABRASIVE CLEANING, PRESSURE WASHING, AND POWDER

COATING APPARATUS AND METHOD

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of the filing of U.S. Provisional Patent

Application Serial No. 61/175,082, entitled "Mobile Self-Contained Blasting, Washing, and Painting Apparatus and Method", filed on May 4, 2009, and the specification thereof is incorporated herein by reference.

BACKGROUND OF THE INVENTION Field of the Invention (Technical Field):

[0002] Embodiments of the present invention relate to a method and apparatus for abrasive cleaning/blasting, pressure washing and/or powder coating objects.

Description of Related Art:

[0003] There are many devices that provide blasting, washing, and painting for surfaces. For example, U.S. Patent 4,036,437 by Dreher discloses a grit-blasting or liquid-spraying machine that operates in two dimensions along the direction of travel. This machine is used for spraying primarily flat surfaces while moving along a straight path.

[0004] U.S. Patent 5,220,933 by Albers discloses a cleaning tank for work pieces to be cleaned. U.S. Patent 6,132,509 by Kuschnereit discloses a trailer-mounted, portable wash and paint facility that uses a boom and winch to draw an object into the trailer-mounted wash and paint facility.

[0005] None of the prior art discloses an apparatus that can enshroud an object and then blast, wash and/or powder coat the surface of the fixed object using variable speed sprays that reciprocate linearly up and down and oscillate clockwise or counterclockwise. Embodiments of the present invention comprise a method and apparatus that can surround an object, such as a fire hydrant, spray the entire object and also vacuum the sprayed liquid or material and removed debris.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS [0006] The accompanying drawings, which are incorporated into and form a part of the specification, illustrate one or more embodiments of the present invention and, together with the description, serve to explain the principles of the invention. The drawings are only for the purpose of illustrating one or more preferred embodiments of the invention and are not to be construed as limiting the invention. In the drawings:

[0007] Fig. 1 is a drawing illustrating an embodiment of the present invention comprising a mobile multi-functional washer, powder coat or paint sprayer, media blaster, and debris recovery apparatus;

[0008] Fig. 2 is a drawing illustrating an embodiment of the present invention comprising a shroud;

[0009] Fig. 3 is a drawing illustrating an embodiment of the present invention comprising a motor drive assembly;

[0010] Fig. 4 is a drawing illustrating an embodiment of the present invention comprising a drive column assembly;

[0011] Fig. 5 is a drawing illustrating an embodiment of the present invention comprising a vacuum wand assembly;

[0012] Figs. 6A-6C are drawings illustrating an embodiment of the present invention comprising a spray chassis assembly, a spray manifold, and a blast manifold; and

[0013] Fig. 7 is a drawing illustrating an outside view of an embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0014] As used herein "channel" is defined as a course, pathway, or conduit with at least an inlet and preferably an outlet that can contain an amount of fluid having an interior shape selected from rectangular, square, elliptical, oblate circular, round, octagonal, heptagonal, hexagonal, pentagonal, and triagonal.

[0015] As used herein "sprocket" is defined as any device that performs a motion transfer function in or for an apparatus or machine, for example, a sprocket can include, but is not limited to, a gear, a cog, a pulley, combinations thereof and the like.

[0016] As used herein "bearing" is defined as any part or apparatus in which another part or apparatus at least partially turns, rotates, moves within or slides.

[0017] As used herein "sleeve" is defined as any member or device that can fit over or surround another member or device.

[0018] As used herein "fastener" is defined as a bolt, screw, threaded connection, nail, adhesive, weld, snap, button, strap, clip, combinations thereof and the like.

[0019] As used herein "shroud" is defined as any covering, screen, or other device that can at least partially surround, encapsulate or cover an object.

[0020] An embodiment of the present invention comprises a mobile multi-functional washer, powder coat or paint sprayer, media blaster, and debris recovery apparatus that performs power washing, powder coating or painting, and media blasting/abrasive cleaning for objects, preferably fixed objects, and more preferably permanently fixed objects, such as, for example, fire hydrants. The apparatus is preferably fully contained so there is minimal debris left at the site. The apparatus preferably comprises a shroud or other covering that is placed around an object. The shroud can be positioned around the object either manually or automatically, but preferably by using an articulating arm. The apparatus also preferably comprises at least one door, preferably two doors and preferably an adjustable door, a moveable chassis, and a vacuum assembly for removing debris. The apparatus also preferably comprises a manifold with spray heads and at least one nozzle, preferably adjustable spray heads and an adjustable nozzle. The vacuum assembly preferably comprises a vacuum wand, -A- preferably an adjustable wand end. There is also at least one motor for operating the moveable chassis. The motor is preferably controlled by one or more switches and/or one or more relays and/or one or more sensors via a programmable logic controller.

[0021] Another embodiment of the present invention comprises an apparatus having a shroud cabinet that encapsulates an object. The apparatus then preferably sprays media and/or liquid while reciprocating linearly up and down and orbiting clockwise and counter-clockwise. The spraying of the object can optionally be performed automatically and at variable speeds. The apparatus can be manually or remotely positioned over an object with the use of an articulating arm. Powder coating, washing, vacuuming, and/or blasting systems are optionally monitored via a tethered control box containing manual or programmable switches, relays, speed controllers, and/or a programmable logic controller. One or more motors capable of operating at a variety of speeds, preferably through the use of pulse width modulated speed controllers, are used to maneuver an actuator with a chassis attached to the actuator. A motor, preferably a reversible horizontal motor, turns a sprocket system which oscillates or rotates a drive assembly anywhere from about zero degrees to in excess of about 180 degrees suspended on a thrust bearing. Attached below the drive assembly is a support, preferably a horizontal support. Mounted on one end of the support is an actuator and on the other end of the support a vacuum wand. The actuator preferably reciprocates the chassis up and down while inside the shroud. A sprocket system, preferably by way of the drive assembly, oscillates the actuator and attached chassis clockwise and counterclockwise from anywhere between about zero degrees to in excess of about 180 degrees from within the shroud. The actuator preferably moves clockwise and counterclockwise around the inner circumference of the shroud. A chassis houses powder coating, washing, and abrasive blasting nozzles and orifices. Each system delivers pressurized abrasives, powder coating, and air, or water through the use of manifolds to deliver balanced volumes of each. The vacuum wand, also preferably mounted on the shield but opposite the actuator is maneuvered anywhere from about zero degrees to in excess of about 180 degrees clockwise and counter clockwise. The end of the vacuum wand preferably travels along the bottom of the apparatus and recovers abrasive media and/or particulate removed during washing, powder coating, or blasting. All channels, hoses, and cables preferably enter and/or exit the apparatus through the drive assembly.

[0022] Referring to Fig. 1 , one embodiment of the present invention comprises mobile self- contained blasting, washing, and powder coating or painting apparatus 10. Apparatus 10 preferably comprises shroud 12 that surrounds an object to be blasted, washed, and/or powder coated. Inside shroud 12 is preferably chassis 14 comprising spray heads 15 to spray the object. Chassis 14 is preferably connected to channel 17 for spraying the object. Vacuum 16 is also preferably inside shroud 12 for cleaning debris from the spraying. Telescoping mounting apparatus 18 preferably couples to a fixed object such as, for example, the operating nut of a fire hydrant. Apparatus 10 preferably comprises a closeable opening used to enshroud an object to be blasted, washed and/or powder coated. The opening is preferably closeable using doors 20. Doors 20 preferably comprise leg stabilizers 22. When doors 20 are closed with an object inside, apparatus 10 is fully self-contained. Thus, debris from the spraying is contained inside apparatus 10 without contaminating the outside environment.

[0023] Embodiments of the present invention are preferably installed on a vehicle such as a truck or trailer. Thus, apparatus 10 is mobile. Once apparatus 10 is near a fixed object to be sprayed, apparatus 10 is lifted off the vehicle and is placed around the object. Apparatus 10 is preferably lifted off the vehicle and placed around the object using an articulating arm that is affixed to the vehicle.

[0024] In an embodiment of the present invention and as illustrated in Fig. 2, shroud 200, preferably made of metal, surrounds media and powder coat spraying equipment (not shown) as well as vacuuming equipment (not shown). Shroud 200 contains any media and powder coat debris and prevents contamination from spilling outside shroud 200. Shroud 200 preferably comprises doors 202 and 203 that open allowing shroud to be placed over a fixed object. Once shroud 200 is placed over the fixed object, doors 203 and 204 close, they are preferably closed using actuating legs 210 which are attached to pull rods 206 and spring retractors 208. Activating leg 210 preferably opens and closes doors 203 and 204. Spring retractors (not shown) serve to add additional retraction tension after doors 203 and 204 close. A leg stabilizer is a sleeve which activating leg 210 is supported by and travels through. Lifting members 212 are used for lifting shroud 200 up and over an object. Shroud 200 is preferably lifted and lowered by an articulating arm. Optional link 214 ensures that one door closes later than the other to avoid binding.

[0025] In one embodiment of the present invention and as illustrated in Fig. 3, a motor drive assembly preferably comprises gear or sprocket 300 which is connected to a drive assembly (see Fig. 4). Belt or chain 302 connects sprocket 300 to second sprocket 304. Alternatively, sprocket 300 comprises a pulley. Motor 306, preferably a reversible gear motor, connects to a shroud, preferably via a NEMA mount and turns second sprocket 304. Bearing 308 is connected between the top of shroud 200 (in Fig. 2) and sprocket 300 to provide rotation from second sprocket 304. Actuator 310, preferably a linear actuator, provides movement of a spray chassis, preferably a reciprocating vertical movement. Actuator 310 is disposed through sleeve 409 (in Fig. 4), which is supported by beam 406 (see Fig. 4). Motor 306 moves actuator 310 by way of drive device 402 (see Fig. 4). Actuator 310 preferably moves spray chassis (see Fig. 6) vertically up and down and around the inner circumference of shroud 200.

[0026] Another embodiment of the present invention, and as illustrated in Fig. 4, comprises drive assembly 400. Drive assembly 400 preferably comprises drive device 402 which transfers rotational force through the shroud (not shown) while suspending and securing spray chassis and vacuum wand assembly (not shown). Drive device 402 is preferably capable of turning in excess of 180° clockwise or counter clockwise. Holder 404 connects drive device 402 to sprocket 300 (as shown in Fig. 3). Support 406 connects to drive assembly 400 and preferably provides a platform to attach spray chassis and vacuum wand assembly. Sleeves 408 and 409 preferably dispose actuator 310 and vacuum wand assembly 500 (see Fig. 5) in the shroud. Mounting sleeve 410 connects to drive assembly 400 and preferably suspends telescoping mounting apparatus 18 for center mounting a fixed object, such as a fire hydrant.

[0027] Fig. 5 illustrates an embodiment of the present invention comprising vacuum assembly 500 which is preferably inserted into the shroud of the apparatus of the present invention. Vacuum assembly 500 is preferably attached to sleeve 408 (see Fig. 4) and preferably comprises channel 502. Channel 502 is preferably a hose and more preferably an abrasive resistant flexible hose for vibration cushioning. Blade 504 connects to vacuum assembly 500 and is preferably a rubber slide blade. Blade 504 improves a squeegee effect for improved media accumulation and recovery. Vacuum wand 500 is preferably securely suspended from the top of beam 406 and disposed through sleeve 408. Support 406 is connected to drive device 402 which is capable of moving vacuum wand 500 in excess of 180° clockwise or counter clockwise around the inner circumference of shroud 200 along the bottom. Brush 506 is optionally disposed on the bottom of vacuum assembly 500 for further improved accumulation and recovery.

[0028] Figs. 6A-6C illustrate an embodiment of the present invention comprising chassis 600.

In this embodiment, support frame 602 houses cleaning and spraying systems and provides structural support for linear actuation of chassis 600. Fasteners 604 and 606, which are preferably "U" bolts, are used to secure chassis 600 along actuator 310 (see Fig. 3). Chassis 600 is preferably mounted in an inverted position such that only fastener 606 secures chassis 600 to actuator 310. Fastener 604 preferably measures slightly larger in diameter than fastener 606 and acts only as a guide through which it loosely slides up and down along an outer tube of actuator 310. A protrusion is preferably affixed to the back of chassis 600 at fastener 604 to allow frictionless or near frictionless sliding along sleeve 409. Powder coat, abrasive media, and/or wash spray manifold 608 preferably comprises one or more spray heads. Spray heads are preferably connected to manifold 608 via a threaded connection. However, spray heads can be connected to manifold 608 using any method known in the art, such as but not limited to welded, glued, screwed, bolted, or snapped. Fig. 6B shows heads 610, 612, and 614 connected to manifold 608. Manifold 608 preferably attaches to chassis 602 using at least one fastener, preferably a bolt, and more preferably a saddled U bolt. Heads 610, 612, and 614 optionally comprise tips to provide even distribution of a wash and/or powder coat spray. The size of tip orifices can vary depending on the object being washed and/or powder coated.

[0029] Blasting manifold 616 preferably comprises one or more media spray heads. Blasting manifold is preferably mounted to support frame 602. Media heads 618, 620, and 622 are shown in Figs. 6B and 6C. Nozzles are preferably attached to media spray heads and can vary in sizes, angles, and positioning depending on the size of the object to be blasted, powder coated, and/or washed. Figs. 6B and 6C illustrate nozzles 624, 626, and 628. Nozzle positions are preferably maintained using set screws at connection points. Nozzles 624, 626, and 628 are preferably manually adjusted at varying positions and angles depending on the object to be sprayed. Removeable and adjustable paddles, preferably deflector paddles and more preferably hardened steel deflector paddles are preferably inserted angularly and held by set screws inside the manifold to evenly distribute media to each of the nozzles. An example paddle is illustrated in Fig. 6B in media head 618.

[0030] Fig. 7 illustrates an outside view of an embodiment of the present invention comprising a shroud, a plurality of channels, a sprocket, and spring retractors.

[0031] Another embodiment of the present invention preferably comprises an adjustabase platform. The adjustabase platform is preferably comprised of one or more hinged scissor-like panels that function as a base for the apparatus, and on which the shroud actuating legs actuate the doors. The adjustabase platform preferably secures and seals itself around the object, for example, a fire hydrants base stem.

[0032] In yet another embodiment of the present invention, a chalking boot is used to seal below and around the lower part of the apparatus to help prevent debris from escaping the shroud. The chalking boot is preferably comprised of a bellow, preferably an adjustable and separable bellow, and more preferably a rubber bellow. The bellow is a trough, preferably made of rubber that surrounds the opening around the bottom of the apparatus doors to retain any abrasive that may have escaped. [0033] One embodiment of the present invention comprises a half-pan, preferably an adjustable half-pan. The adjustable half-pan preferably comprises one or more hinged scissor-like half pans (similar to doors) that serve to establish a base and catch basin instead of using the shroud actuating legs and lower door option. The half-pan secures and seals itself to the shroud and around the object.

Industrial Applicability:

[0034] The invention is further illustrated by the following non-limiting examples.

Example 1

[0035] One embodiment of the present invention comprises a method of operating a mobile multi-functional washer, powder coat sprayer, media blaster, and debris recovery apparatus. The method can be run manually or automatically. A programmable logic controller (PLC) preferably operates the method automatically. The method of this embodiment preferably comprises the steps of:

• Prepare hydrant for apparatus mounting:

■ Option 1 : Ensure doors close below and around hydrant base flange but resting on chaulking boot or adjustabase platform.

■ Option 2: Ensure apparatus securely rests on adjustable half-pans after lowering in place.

• Undock apparatus and mount hydrant using an articulating arm safe operating procedures

• Position apparatus over hydrant by lowering a rod onto hydrant operating nut. (Use adapter to center targeting rod for hydrants missing top-centered operating nut.)

• Lower apparatus around hydrant.

■ Option 1 : Ensure doors close below and around hydrant base flange but resting on adjustabase platform.

■ Option 2: Ensure apparatus securely rests on base after lowering in place. Buckle in place.

• System start

■ Turn on and stabilize compressor ■ Press Start button of apparatus controller, green light will illuminate indicating cleaning, painting or washing system functioning.

■ Press Stop button of apparatus controller to illuminate red light and secure cleaning, painting or washing system.

• Dismount hydrant and dock apparatus using an articulating arm safe operating procedures.

■ Raise apparatus off hydrant.

• Option 1 : Ensure doors properly open away from hydrant base flange and off adjustabase platform.

• Option 2: Unbuckle floorbase from apparatus.

• Ensure floorbase remains securely fastened around hydrant after raising apparatus off hydrant.

• Return apparatus to truck and secure in docking station for travel.

• Vacuum up residual debris on adjustabase (Option 1 ) or floorbase (Option 2). Preferably, leave no remaining debris.

• Remove any chalking boots used (Option 1 ).

Example 2

[0036] The following is an example of a portion of an operating procedure for the embodiments of the present invention.

1. Conduct Hydrant and Isolation Valve Service

a. Disengage apparatus from docking station.

b. Retrieve apparatus using articulating arm to mount hydrant according to apparatus operating procedures.

c. Start cleaning operation

d. Exercise hydrant isolation valve according to manufacturer specifications.

e. Return apparatus to docking station.

f. Secure apparatus in docking station with latch pins. g. Paint hydrant. (Remember to allow sufficient drying time between coats and before removing spray arrester.)

[0037] Although the invention has been described in detail with particular reference to these preferred embodiments, other embodiments can achieve the same results. Variations and modifications of the present invention will be obvious to those skilled in the art and it is intended to cover in the appended claims all such modifications and equivalents. The entire disclosures of all references, applications, patents, and publications cited above are hereby incorporated by reference.