Plasma processes reduce costs in automotive manufacturing

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Developing Paints with the Help of a Robot

Dürr Systems AG

A paint manufacturer found that its conventional manual application system was no longer an adequate aid for developing new specialist coatings. The company's newly installed compact painting robot enables it to apply coatings at a reproducible thickness in the micrometre-range. This is an essential feature of the development process for chrome-effect paint systems, for example. PDF-Download

Dry Separation as a Long-Term Solution

brainflash GmbH

The construction machinery manufacturer Liebherr has been using a dry separation system in the paint shop at its plant in the Austrian town of Nenzing since 2009. The box system functions without problems and has proved to be cost-effective, environmentally friendly and ergonomic in long-term operation. PDF-Download

Increasing Productivity and Reducing Emissions

Emil Frei GmbH & Co. KG

UV paint systems cure particularly quickly and have excellent mechanical properties. As well as protecting the substrate, these coatings can also function as adhesion primers before a surface is printed. PDF-Download

Good Prospects for UV LEDs

IST Metz GmbH

Energy-saving UV LEDs can now be used to cure coatings on three-dimensional parts. The technology has found its way into the cosmetics industry where it is used, for example, when a high-quality appearance is needed for cosmetics containers. This article sheds a light on how lipstick tubes made from ABS are coated and painted. PDF-Download

Zero-Emission Pre-Treatment and Electrocoating

Pashalis Simos

The automotive industry supplier Tenneco has installed an efficient zinc phosphating and electrocoating system based on the zero-liquid-discharge principle to coat shock absorbers at its Chinese plant. The zero-wastewater concept complies fully with the strict environmental regulations in the city of Changzhou. PDF-Download

End-to-End Automation for a Highly Reliable Process

Gema Switzerland

In the past, Scandinavian companies have often played a pioneering role in the automation of surface technology processes. A foundry in Denmark is continuing this tradition by fully automating both its electrocoating line and its new powder coating shop. The result is a highly efficient and cost-effective process. PDF-Download

Dense Phase Technology Combined with Robot Precision

Nordson Deutschland GmbH

Automotive and motorcycle exteriors are exposed to extreme conditions, including heat, cold, moisture, stone chips, salt, UV radiation and other environmental influences, over long periods. At the same time, they have to meet high standards in terms of their appearance and finish. Since 2016 after many years of manual powder coating, the German coating company Welco invested in the combination of robot coating and a dense phase application system. This is a report on its experiences. PDF-Download

Intelligent visualization of coating systems

Mario Oesterle

Successful lloT solutions must allow several coating systems in a company to be easily linked. This also includes clear system visualization and intuitive user guidance. PDF-Download

Deburring and Cleaning in a Single Process

Weber Ultrasonics AG

Reliable deburring and cleaning are essential features of the manufacturing process for high-quality, precision components. An immersion machine with multiple tanks has been designed for these stages of the production process where parts can undergo preliminary cleaning, deburring and precision cleaning using ultrasound in a single process. PDF-Download

Eco-Friendly Cleaning of Metal Parts

MicroCare Europe BVBA

Increasingly strict environmental regulations require the development of eco-friendly cleaning agents. Numerous ecological cleaners that emit hardly any greenhouse gases and which do not harm the ozone layer are already available. What is more, when used in a vapor degreaser, environmentally friendly metal cleaning fluids achieve maximum performance. PDF-Download

Chrome (III) - From Planning to Mass Production

Willy Remscheid Galvanische Anstalt GmbH

Decorative chrome coatings using trivalent chrome are a valuable alternative to hexavalent chrome compounds in terms of both appearance and corrosion protection, as this current example from industry shows. PDF-Download

Working with Robots

Blastman Robotics Ltd

Outsize cast components weighing up to 200 tonnes can be blasted by a robot in the new blasting chamber of a foundry using a fully automated process. As a result, the work can be carried out not only more quickly and safely, but also at a lower cost and to a higher standard of quality. PDF-Download

Integrated Production Concept with Power-and-Free Conveyor

Caldan Deutschland

The German company Strautmann Hydraulik invested in a new manufacturing building and a new paint shop for the production of a variety of different hydraulic cylinders. A power-and-free conveyor system is responsible for transporting the components through the paint shop and for the loading and unloading process which takes place in a separate building. PDF-Download

Reliable Measurements of Textured Surfaces

Andor Bariska

Until now it has only been possible to measure the thickness of coatings at the edges of perforated metal baking sheets. As a result, the layer of coating around the perforations is sometimes too thick and this in turn can cause cracks to form. For the first time, a non-contact measurement process is available which allows the coating thickness in the area of the holes to be measured quickly, non-destructively and with high precision. PDF-Download

Efficient Waste Water Treatment Improves Rinsing Water Quality

Thomas Nadler

An Austrian manufacturer of shopfitting solutions extended its powder coating shop and, at the same time, invested in a new vacuum evaporator with an annual capacity of 1500 cubic metres. The evaporator provides rinsing water with a conductivity of 3 µS/cm that can be used directly in the production process. PDF-Download

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