Paint Shop Application In Electric Vehicles
The future belongs to electric cars, since they allow an emission-free and sustainable mobility. The established car manufacturers are increasingly being joined in the market by new competitors, especially in China. We are currently building a fully automatic paint shop for a oversea OEM. The plant in Indonesia is designed to handle 100,000 units per year, and will commence operation in June 2022. The integration of numerous digital solutions turns the paint shop into a Smart Factory with extensive use of data.
The new plant will produce battery-powered cars on behalf of a local electric car manufacturer in the future. The vehicles will be given a modern two-tone color design in the fully automatic our paint shop. The plant in Indonesia combines advanced vehicle drives with intelligent plant technology and modern painting concepts. The entire plant including data acquisition, data evaluation, and plant monitoring is controlled by our software solution. The modular MES system provides detailed information on the production workflows and the consumption data at all times. This paint shop is the first time that atomizers using in a local Indonesia car manufacturer. They are particularly suitable for painting interiors using water-based paints and require no complex voltage block systems. The compact design enables the atomizers to get into each and every angle inside the body. The robust high-voltage technology produces minimal inherent soiling and delivers top quality and paint application efficiency. Short rinsing and color change times as well as fast cleaning intervals in combination with the cleaner increase the paint shop capacity and the productivity.
“Industry 4.0” is the keyword for the digital evolution of classical production technology into the smart factory. With our digital approach, we offers a wide range of solutions. This includes not only the production control , but also the integration of a new software solution for fresh and exhaust air control with the ovens. Our smart air management system operates fully automatically, delivering energy on demand. This technology significantly reduces gas and electricity consumption when drying the freshly painted bodies. With conventional oven systems heated using purified gas, the fresh air supply system and exhaust air extraction system are operated with a constant volumetric flow rate. Our smart air management system, on the other hand, is a predictive control system. It controls the volumetric flow rate of the fresh and exhaust air depending on the current number of vehicles in the oven and their position. The system therefore ensures that each individual oven zone is optimally and individually supplied with air at all times, and combines energy efficiency and consistently high paintwork quality. The exhaust air from the ovens is purified via the integrated afterburning system with heat recovery and then made available again for the oven heating system. The new version of operating software features further smart programming and simulation options. The software is the perfectly coordinated tool for parameterizing, programming, and simulating robots. The new 3D kernel supports all popular CAD data formats. The robot controller provides smart test functions like valve, brake, or pump tests, which provide a detailed picture of the status of the plant technology at any time. The results of the tests are visualized using traffic light functions. This allows the paint operator to easily tell whether, for example, a valve needs to be replaced immediately or whether everything is working reliably in the green range. Another smart software function controls the interaction of the main needle in the atomizer and metering pump. The self-learning system enables high-precision switching points for the robots’ painting paths and at the same time determines the wear to the pump and needle. The sensor-based paint pressure control system also ensures minimal mechanical load on the pump, as well as a constant discharge rate and therefore constant process quality. The robot controllers can be easily incorporated into a centralized data network for the smart factory of the future, and have the capability to transmit all process-related information from the sensors and actuators as data stream to higher-level maintenance and control systems at the customer’s site or to the supplier”s Service Cloud.