This document discusses automating the coating process and different applicator technologies. It covers spray characteristics like air atomization, hydraulic atomization, centrifugal atomization, and electrostatics. Air atomization includes conventional, HVLP, and LVMP technologies. Hydraulic atomization includes airless and air assisted airless. Centrifugal atomization uses high-speed rotation to atomize coatings. Electrostatics increases transfer efficiency by applying a charge to coatings. The document also discusses automation options like reciprocators and robotics, and factors to consider like production requirements and cycle times when selecting an automation solution.
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Precision engineering was first published in January 1979; since 1986 it has also been known to many of its readers as the Journal of the American Society of Precision Engineering. Now with effect from 2000, it assumes a new look, proudly proclaiming itself the Journal of the International Societies of Precision Engineering and nanotechnology.
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automating coating process
1. Automating the Coating Process
Presented by:
Nguyen Quang Vu
Business Development Manager
Finishing Brands UK
2. Automating the Coating Process
• Applicator Technologies
• Spray Characteristics
• Automation: Reciprocators & Robotics
• Product Presentation
• Production Requirements & Cycle Time
• Calculating Coating Volume Needs
• Selecting Automation
3. Applicator Technologies
Air Atomization
Hydraulic Atomization
Centrifugal (Rotary) Atomization
Electrostatics
Automating the Coating Process
4. Air Atomization Technology
Conventional Air Spray
• Low Volume High Pressure
HVLP
• High Volume Low Pressure
LVMP (TransTech Compliant)
• Low Volume Medium Pressure
5. Applicator Technologies
Conventional, HVLP, LVMP
• Functional mechanics are all the same
• Air impinging on fluid stream to create droplets
Atomization air exits
from center holes of
air cap and creates
droplets
Fan (Pattern) air
exits from horns of
air cap and shapes
pattern into elliptical
shape
6. Conventional “Air Spray”
• The most established method of air
atomizing used on spray guns
• Uses high pressure and low volume of air
to provide good atomization of the
material
• This process creates a high particle velocity
resulting in lower paint transfer efficiencies
due to “bounce-back” and “overspray”
generated.
Applicator Technologies
7. Applicator Technologies
HVLP (High Volume Low Pressure)
• Compliant technology developed in the 80’s
when environmental legislation was first
introduced.
• Uses larger compressed air volumes at lower
pressures to atomize coating materials.
• Can yield higher transfer efficiency than
conventional air spray, however, quality of
finish may be negatively impacted.
8. LVMP (Trans-Tech Compliant)
• Introduced in the 90’s and is a combination
of Conventional and HVLP atomization
methods.
• Trans-Tech utilizes more compressed air for
the atomization process producing smaller
droplet than HVLP.
• Can yield higher transfer efficiency than
conventional air spray, with better quality
than HVLP.
Applicator Technologies
9. Conventional
• Spray at Any Pressure / CFM
• Air cap pressures typically 30 – 60 psi
HVLP
• Meets USA Regulatory Requirements
• Air cap pressure less than 10 PSI
• Requires air cap test kit
LVMP (TransTech, Compliant)
• Meets European Requirements
• Air cap pressures typically 20 – 40 psi
Applicator Technologies
10. Conventional, HVLP, LVMP
• Comparison of air consumption, efficiency and particle size
Particle Size
150
300
450
600
750
900
20 40 60 80 100
HVLP
LVMP
Air
AirConsumption(l/min)
Transfer Efficiency %
Applicator Technologies
12. Applicator Technologies
Hydraulic Atomization
• Material at a high pressure is forced
through a fixed orifice.
• The material is atomized by shear
• Spray pattern size is based on angle
ground into tip
• Flow rate is based on fluid
pressure developed by pump
17. Applicator Technologies
Centrifugal (Rotary) Atomization
• Rotary atomizers were developed
by Harold Ransburg in the 1940’s.
• The term “Bell” comes from
the shape of the original
atomizers that were driven at
low speeds 900 -1800 rpm
with electric motors.
• The rotation was used to distribute coating
evenly around the perimeter and the
atomization process was purely due to the
electrostatic charge applied to the “bell”.
18. Applicator Technologies
Centrifugal (Rotary) Atomization
• High speed rotary atomizers, utilize mechanical
shearing action to atomize coatings materials.
• Rotational speeds vary from 15,000 – 100,000 rpm
19. Applicator Technologies
Centrifugal (Rotary) Atomization
• Atomized droplet size is
based on bell cup diameter
and rotational speed.
• Various diameters used
based on flow rate and
coating materials
• Bell cup design vary
Serrated edge
Non-serrated edge
20. Applicator Technologies
Centrifugal (Rotary) Atomization
• Shaping air is used to provide forward
direction to the spray pattern
• Various shape air technologies used
Single shape function
Dual shape function
Vortex style
Combinations
• lower particle velocities associated
with higher transfer efficiencies
when compared to air atomization
22. Applicator Technologies
Centrifugal (Rotary) Atomization
• TurboDisk operates at speeds of
6,000 - 40,000 rpm
• Various disk platters available
Serrated edge conical available in
6, 9 or 12”
Smooth edge uni-disk available in
6, 8, 10 & 12”
• lower particle velocities associated
with higher transfer efficiencies
when compared to air atomization
23. Applicator Technologies
Centrifugal (Rotary) Atomization
• TurboDisk is a specialized applicator
that works well with
High production systems
Minimal color changes
Batch run parts
• Markets used in:
Aluminum Extrusion Industry
Door manufacturers
Propane or cylinder manufacturers
Car or truck filter
Shock absorbers
Sporting equipment
25. Applicator Technologies
Electrostatics
Definition: Method of paint application in which a
high voltage charge is used to dramatically increase
transfer efficiency.
• Coating is negatively charged
as it is atomized
• Product coated is at ground
potential, and appears to be
opposite charge
• Opposites attract - coating is
drawn to grounded product.
-
-
-
-
-
- -
-
-
-
-
-
-
-
- -
-
26. Applicator Technologies
Electrostatic: Two Methods
• # 1 Process: External or Indirect Charge
Fluid supply and
application
equipment at
ground potential
Wire grid is
electrically charged
Product coated
is grounded
through
conveyor system
28. Applicator Technologies
Electrostatic: Two Methods
• # 2 Process: Direct Charge
When first developed, atomization
process was based on electrostatic
repulsion, like particles repel.
Optimal atomization was obtained at a
maximum fluid flow rate of 10 ml/inch of
circumference
Today atomization process is either
mechanical shearing action (rotary and
hydraulic atomizers) or air impingement.
29. Applicator Technologies
Electrostatic: Two Methods
• # 2 Process: Direct Charge
With disk and bell applicators, charge is
transferred from disk platter or bell cup.
Air atomized applicators utilize an
electrode in the fluid stream
31. Non - Electrostatic applicator applying coating
material to tubular target.
Back side of tube targets
after being coated
Fluid flow rate set at 200 cc/min
Applicator Technologies
Non-Electrostatics Application
32. Electrostatic air atomized applicator applying
coating material to tubular target.
Fluid flow rate set at 200 cc/min Back side of tube targets
after being coated
Applicator Technologies
Electrostatics Application
33. Electrostatic rotary atomizer applying coating
material to tubular target.
Fluid flow rate set at 200 cc/min Back side of tube targets
after being coated
Applicator Technologies
Electrostatics Application
35. 0
20
40
60
80
100
Bells Air Elec. Air Conv.
Min
Max
0
20
40
60
80
100
Bells Air Elec. Air Conv.
Typical Transfer Efficiency
on Metal Substrate
Typical Transfer Efficiency
on Plastic Substrate
Applicator Technologies
Electrostatics
36. • Increased transfer efficiency
• The best way to reduce coating usage is to minimize
the volume of material that is sprayed.
Applicator Technologies
Electrostatics
• You pay for paint 4 times!
You pay somebody to buy it
You pay somebody to apply it
You pay somebody to clean it up
You pay somebody to dispose of it
38. 1. Conductive Sensitizers
2. Conductive Primers
3. Conductive Adhesion Promoters
4. Inherent Conductivity (moisture content)
5. Misting
6. Imaging Techniques
7. Conductive Additives
8. Metal Deposition
Applicator Technologies
Electrostatics: Eight techniques used to
make non-conductors conductive:
39. Spray Characteristics
Applicator technologies can be used across a
wide range of markets and applications
TransportationWoodMetal Special Coatings
Urethanes
Latex
Two-Component
Epoxies
Toners
Stains
NGR Stains
Topcoats
UV Materials
Primers
Base Coats
Clear Coats
Aerospace
specific coatings
Waterborne
Adhesives
Mold release
Ceramics
Enamels
40. Spray Characteristics
Classification of Atomization Technologies:
• Finish Quality
Rough------------Fine
Large -------------------------------------------- Small
FinishQuality
Atomized Droplet Size
Airless
Air Assist
HVLP
LVMP
Conventional
Disk
Bell
41. Spray Characteristics
Classification of Atomization Technologies:
• Transfer Efficiency
Low---------------High
Conventional -------------------------------- Rotary
TransferEfficiency
Applicator Technology
Airless
Air Assist
HVLP
LVMP
Conventional
Disk Bell
E-Stat Gun
Note:
42. Spray Characteristics
Classification of Atomization Technologies:
• Speed of Application
Slow----------------Fast
HVLP ------------------------------------------ Airless
SpeedofApplication
Airless
Air Assist
HVLP
LVMP
Conventional
Disk
Bell
Applicator Technology
44. Normal: 200 – 250mm
Normal Spray PatternCut-in Areas
44
Dual Shaping Air Spray Pattern - can be optimized for coverage
into deep recessed areas or larger surfaces.
Cut-in: 75 – 100mm
Spray Characteristics
45. Automation: Reciprocators and Robots
Machines and robots installed in spray booths
must be approved for operation in hazardous
area (Class 1, Division 1).
• Machines Hard Automation
Short Stroke Reciprocators
Long Stroke Reciprocators
Smart Reciprocators
Special Machines (Rotary Spray)
• Robots Flexible Automation
Electric robots, highly reliable
46. Automation: Reciprocators and Robots
• Short Stroke Reciprocators
A reciprocator increase the effective
coating area of the applicator.
Typical stroke range 7 – 14”
Blends round spray patterns together
providing very good coating uniformity.
Improves coverage by changing
presentation of the applicator to
the part.
Rotary atomizer, 30 cycles per
minute
Air atomizers, 60 cycles per
minute
47. Automation: Reciprocators and Robots
• Long Stroke Reciprocators
A reciprocator increase the effective
coating area of the applicator.
Typical stroke length 3’ – 14’
May be equipped with “toeing”
feature that angles applicators in
direction of travel.
Rotary atomizer, 180 ft/min
maximum
Air atomizers, 280 ft/min
maximum
48. 12 cyc
1 min
50% Spray Pattern Overlap
Automation: Reciprocators and Robots
• Long Stroke Reciprocators
Machine must be
synchronized with conveyor
to get uniform finish
50% or 75% spray pattern
overlap most commonly used
50% overlap: conveyor speed
(in) / pattern width (in) =
machine cycle rate
75% overlap = above X 2
Assume:
• 14 ft/min
• 12 in spray pattern
Conveyor TravelApplicatorTravel
14 ft
1min
12in
1 ft
1 cyc
12 in
XX @ 50% Overlap
49. Automation: Reciprocators and Robots
• Long Stroke Reciprocators
Used with disk system
Typical stroke range 3’ – 24’
Recommend a minimum of
4 strokes on part while in
disk loop
Maximum speed 4ft/sec,
recommend slower.
50. Automation: Reciprocators and Robots
• Long Stroke Reciprocators
“S” loop conveyor configuration
Allows access to both sides of part
51. Automation: Reciprocators and Robots
• Smart Reciprocators
• Special Machines (Rotary Spray)
Similar to long stroke style reciprocator
Additional axis of movement incorporated
Variable stroke length
Multiple atomizer mounted
on rotary axis
Product coated conveyed
on belt beneath atomizers
Integrated system to
reclaim material
52. Automation: Reciprocators and Robots
• Robots
Flexible automation, programmed to accommodate product
coated.
Ability to maintain optimal distance
between applicator and substrate.
In most cases more cost effective
than designing custom “hardware”
solution
Robot selection made based on
work envelope “reach” and payload
capability
57. Product Presentation
Product presentation is most often dictated by
• Manufacturing process
• Size or weight of the product coated
• Desire to coat new product in existing system
Conveyor Systems
• Overhead
• Floor mounted
• Chain on edge
• Power and Free (indexing)
• Horizontal belt or web
58. Product Presentation
Part Presentation
• Single or multiple parts per fixture
• Fixture may index on 90˚ or 180˚
increments
• Fixture may continuously rotate
• Rotation may be reversed in each
spray zone
61. Production Requirements
• Following information is need to make
equipment recommendations
Conveyor speed (ft/min)
Rack centers (ft)
Parts per rack
Hours per shift
Shifts per day
Days per week
Weeks per year of operation
2’
66. Evaluate the “Givens”
• Greenfield project?
• New program in existing finishing system
• Production requirements
Selecting Automation
Prioritize the requirements
• Finish quality
• Production level
• Coverage
• Transfer efficiency
• Environmental
67. Bring in the Experts
• Use equipment suppliers applications labs
Selecting Automation