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Automation in Paint Shops: “Do not introduce too much technology”
Automation in coating technology has long been considered the domain of large operations. However, modular system solutions now enable smaller companies to enter the field. We spoke with Ulrich Tautz, Head of Sales – Industrial Products at Dürr, about flexible automation concepts and their practical implementation.
Mr Tautz, paint shop automation is often perceived as a solution for large-scale operations. What is the reality for smaller industrial coating companies?
The main challenges for small industrial operations are budget, know-how and the question of how flexible they can remain. With our product portfolio, we try to offer straightforward automation solutions. This already begins in the manual area, for instance with an automatic mixing system – that too is automation, because you’re no longer mixing manually. Building on this, we’ve developed the ready2integrate package, where you can decide which level of automation you want to enter at, how much of the process you want to handle yourself or have implemented by our partners.
With our technology package, we can cover all applications – from simple 1K processes to complex 2K processes with spray gun or with high-speed rotary atomiser and electrostatic charging. You can always decide which direction you want to go. Naturally, technology costs money, but you have to consider the cost-benefit ratio: quality assurance is important, skilled personnel are becoming scarcer.
The new concept for paint shop automation has replaced the previous “ready2spray” package. What are the differences?
The latter was the robot we sold as a complete solution at the time. But that product was discontinued. That’s why we’ve moved to the current solution, where we’re more open to all robot manufacturers. It doesn’t necessarily have to be a robot either – you can also use a lifting device or other automation systems.
The package is now considerably more flexible in application. If, for example, I have an existing system, a robot that I want to build on, or if I had a spray gun application and now want to convert to a rotary atomiser, it’s now very straightforward to install.
What does the package comprise specifically?
We focus on wet paint application, from paint supply through to application. We have the complete EcoSupply2 Core – a pre-assembled paint unit that can be placed in the paint mixing room. In our new project at Interstuhl, we were able to realise the installation in one week through our package with paint supply, “EcoAUC” and application technology. Everything is pre-assembled, easy to install – place it on site, connect it up and off you go. These are important advantages for operations with high utilisation that need to be productive again quickly.
What was the motivation behind developing this automation system? A deliberate diversification beyond the automotive industry?
People simply saw the potential. Dürr has a long history in application technology, superb know-how and excellent technology. With the Industrial Products division, we’re bringing the advantages and quality of the technology into industry. We don’t integrate ourselves, but work with partners, which makes it much more accessible for everyone.
What about integration into existing coating systems – the issue of control technology and communication between different suppliers?
With smaller operations, you need to communicate with the conveyor technology, but not like in large plants where you collect vast amounts of data. You keep it very clear: you try to automate the coating task and not introduce too much technology, because it quickly becomes complicated otherwise. Often it’s really just about: get the technology into the plant, get it running. You have interfaces, but they’re the standard ones.
How is programming handled?
For this, we have partners at various locations throughout Europe and in the USA. When there’s a customer there, they can provide quick service – if you need to adapt programming or change something in the application. We at Dürr don’t want to cover this ourselves, in order to remain more agile and faster. Coating isn’t simple, coating needs support – that’s why we have good service partners who help with integration and then also with commissioning.
Are there any innovations in the automation package?
Yes, we now have the “EcoAUC2”, which we presented for the first time at PaintExpo. We’ve integrated new features compared to the previous model: the control unit can now directly control the cleaning device – previously you had to do this via an external controller. There are additional functions that allow more precise coating, and a larger touchscreen. The new model can now also control the EcoPaintJet. We’ve incorporated the experience of recent years to create a compact control system.
From what company size does paint shop automation solution make sense?
You can’t say that categorically, but as soon as I have a painter in the spray booth all day coating repeated components, automation becomes worthwhile. The complex factor is component variety. If I don’t coat the same component twice in a day, it becomes more difficult. But if I coat the same component several times a day, it can quickly become interesting.
Programming is time-consuming. However, as soon as I have a main component proportion that I coat regularly, it’s worthwhile. We can manage colour changes quickly, so you’re unlimited in colour selection. If, for example, I coat the same parts every day, it’s worth considering, because you can programme that.
Further information:
Dürr Systems AG, Germany, Ulrich Tautz, Tel. +49 173 6853145, Ulrich.Tautz@durr.com, www.durr.com
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