Automobile body painting is most representative in automotive painting due to its complicated process, many processes and high coating quality requirements. Germany's newly developed rotary impregnation conveyor technology and robotic cup electrostatic spray technology are two of the highlights of the body coating process/technical advancement in the past five years.
In order to meet the needs of environmental protection and enhance market competitiveness, people continue to develop new equipment and new technologies that are more environmentally friendly, improve coating quality, improve material utilization, and reduce coating costs. In terms of body painting, in the past five years, Germany has developed a new rotary impregnation conveyor technology and a robotic cup electrostatic sprayer to replace the 9-cup electrostatic sprayer technology. There are two types of rotary impregnation conveyor technology: RoDip-3 conveyor and multi-function shuttle (Vario-Shuttle).
The rotary impregnation conveyor body technology completely solves the problems in the pre-painting and electrophoresis body transport process with a new concept. The characteristics and advantages of this technology are very obvious, far superior to the push rod catenary and swing chain transport body mode, with small processing tank capacity, low running cost, excellent electrophoretic coating quality, and greatly reduced grinding workload. The material utilization rate is improved, the amount of cleaning water is saved, and environmental protection is beneficial.
RoDip-3 conveyors and multi-function shuttles are technically advanced in both rotary impregnation conveyors. The multi-function shuttle has the function of adjusting the running mode of the vehicle body during the process, and has good flexibility. Regardless of whether the roof is facing up or down, different angles of the access slot can be adjusted according to the structure and process requirements of the vehicle body. However, there is a certain gap between the treatment tank volume, the running cost, the electromechanical maintenance workload and the influence of the hanger on the electrophoresis electric field compared with the RoDip-3 conveyor. Taking the electrophoretic coating process as an example, the RoDip-3 conveying method can initially reduce the tank volume by 36m3, the cycle of the bath liquid can be shortened by 20%, the circulation amount of the bath liquid can be reduced by 20% to 25%, and the pole pitch is shortened. The electrophoresis voltage can be appropriately reduced, the energy consumption is reduced, the maintenance workload of the conveyor is reduced, and the relative cost can be reduced by about 20%. In addition, RoDip-3 also has a single-chain single-arm rotary type (RoDip-3+), which is suitable for body handling of pre-treatment and cathodic electrophoresis lines of 20 units/h or less.
From the perspective of painting process, the rotating impregnated conveying body technology eliminates the problems encountered in the pre-treatment and electrophoresis process of the car body, and is an ideal advanced practical technology in terms of technology, economy and environmental protection. At present, two domestic car body pretreatments and cathodic electrophoresis lines with an annual output of more than 120,000 cars of RoDip-3 technology have been put into production.
More than 10 years ago, the economical scale of the annual production of 200,000 to 300,000 vehicles in the body coating line and the annual production of 12 to 150,000 sets of topcoat spraying line equipment automatic electrostatic spraying equipment with 9 high-speed cup electrostatic spraying station (ESTA , consisting of a reciprocating side sprayer and a top sprayer). With the advancement and development of robotics and electronic control technology, the degree of intelligence is constantly improving. People have successfully developed a small and lightweight high-speed cup-type electrostatic spray gun. Now, ESTA consists of 3 to 4 robots instead of 9 cups of static electricity. The situation of the spraying station is mainly due to the following advantages of the robot spraying machine:
1. The painting efficiency is high, and 3 robots can undertake the spraying task of 9 cups of ESTA;
2. It is suitable for multi-varietal mixed-flow production and medium and small-volume body painting lines;
3, small investment, low operating costs, 3 cups of ESTA consisting of 3 robots in addition to 2.7 times increase in power, compressed air and cleaning solvent consumption, maintenance workload is only about 35% of 9 cups of reciprocating spray station ESTA .
The freedom and reproducibility of the coating path of the robot spraying machine are very high, and the coating efficiency is not only affected by the spraying distance, but also affected by the moving speed of the spraying machine related to the recoating interval and the spray width. We can optimize these factors by performing a film thickness simulation test to set the optimum coating trajectory and coating conditions for the coating efficiency.
For the robot configuration of the automatic electrostatic spraying station (ESTA), it is generally believed that under the premise of ensuring the production program and the quality of the spraying, the fewer robots (spray cups) per station are configured, so as to reduce the investment, running costs and maintenance workload. .
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