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Space-saving Coating Equipment Technology For Electric Cars
Electric, fully networked, highly automated: a number of new car manufacturer is consistently designed for the mobility of the future. We also insist on state-of-the-art standards for manufacturing and commissioned to construct a complete painting line. Distinguishing features are a 20% reduction in footprint and the use of pioneering technologies. An example of this is the our new design coating equipment, which is ideal for electric vehicles. Our new solution is initially designed for 150,000 vehicles per year – equivalent to 30 units per hour. Growth has already been factored in, since the capacity can easily be doubled. Electric mobility goes hand in hand with modified body concepts that use new materials or combine materials in new ways. Conventional coating equipment reach their limits when steel, aluminum, and composite materials are used together. This is because it is vital that all body parts are heated uniformly, otherwise thermal stresses occur. For this challenge, we developed a fundamentally new concept in vehicle drying with new technology: bodies are heated from the inside out by two jet nozzles through the opening for the windshield and two nozzles directed into the engine compartment opening. This enables unprecedented uniformity of heating. Compared with conventional coating equipment, there is also a significant improvement in top-coat quality and process performance - because heating from the inside out reduces the risk of pin holing. In addition, minimized flow velocities along the freshly painted surfaces ensure a completely undisrupted top coat appearance.
Our scope of delivery for the new painting line includes the rotational dip process for pretreatment and electrocoating – already equipped for 60 units per hour – as well as all the robotic and application technology for the sealing and painting processes. The electrocoating stage uses the energy-saving and fail-safe system . This technology uses its modular anode control to create a voltage profile in the tank that moves with the body. The robots in the spray booths are equipped with the latest atomizer generation. The semi-automatic dry separation system, which separates the overspray in the coating equipment for primer and top coat, requires absolutely no water or chemicals. This simple and robust technology works on the basis of cardboard filters. In addition, we are designing a downstream exhaust air purification system made up of the highly efficient adsorptive concentration system with combined thermal exhaust air purification.
The scope of delivery of the order placed at the beginning of 2018 includes material feeding for PVC and paint, coating equipment ventilation, fire protection for the process systems, and a reverse-osmosis plant to reduce the water hardness. The exhaust air from the ovens is purified via the recuperative thermal process, which also provides all the heat for heating the oven in an energy-efficient way. Despite the extensive equipment, the design of the painting line will be very compact and space saving .This is because related equipment transports bodies transversely, halving its length compared to conventional systems. In addition, a central high-bay warehouse saves the space required for multiple intermediate buffers and enables intelligent material flow control.
All in all, our design layout reduces the paint line’s footprint by 20 percent.