RoboGuide Paint Pro Simulation by [ Ссылка ]: Software tool for increasing productivity.

Senior managers, paint engineers and operators often sense that their paint automation can become more efficient and productive. Sometimes however poor performance can critically affect the business.

In this simulation, a manufacturer had recently acquired new business that required a system upgrade for spraying 2 component base and clear coat paints. Graco ProMix 2KS, Sames gun and bell process controllers, and catalyst pumps were some of the equipment installed.

Immediately after the new 2K production began, it became clear that the new system configuration could not support production levels at all, much less support them efficiently.

The ProMix 2KS equipment quickly became clogged with paint build-up inside fluid tubing and passages. This rendered the flow control capability unreliable, color changes became extremely long and inefficient, and the solvent waste recovery system plugged and was unusable.

The Sames process equipment was also upgraded, This upgrade had the unfortunate effect of disabling the automatic selection of presets for Atomizing air, Fan air, Shape air, Bell Speed RPM, and KV (high volotage). All of these parameters had to be set manually at each robot.

NAPaint spent 1 day auditing paint operations and estimated significant improvements could be implemented.

The product is thermoplastic rocker panels. The automation utilizes 5 Fanuc P-145 (P145) robots with RJ3ib controllers and 2 Fanuc P-100 (P100) robots with RJ3 controllers. Mounted are Sames electrostatic bells and guns fed with Graco ProMix 2KS paint delivery systems. 5 conveyors include power and free and chain on edge, some indexing, some constant speed.

NAPaint made improvements. With existing equipment, we achieved significant paint savings and productivity gains thru 1.) efficient integration of equipment, 2) improved paint process control, 3) faster robot cycle times and higher yields, and 4) implementing a robust conveyor control method that reduced downtime greatly.

Paint production rates increased by 263%.
Total paint usage decreased by 78.3%.
System downtime was reduced by more than half.
Color changes became fast and efficient.
Solvent / Waste recovery system remained operational.
Manual spray was not required.
Finished quality improved by every measure.

More than half the paint used in the original production paint process formed paint overspray, contaminating the spray booth, flash tunnels, and ovens. Tons of solvent vapors including VOCs and HAPs were unnecessarily pumped into the skies above the plant.

NAPaint can review your current robotic paint automation, and develop an improved process using efficient and powerful tools like RoboGuide Paint Pro software.

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