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GROUP 1, GET2016
Aesthetic
appearance
Purpose of
painting:
Environmental
protection/corrosi
on prevention
Shop Insights:
Asias largest paint shop
Underbody PVC coating DFT (Dry Film Thickness): 300-400
m
There are currently 11 tank system used in pretreatment
system with around 98% yield in ED system and 68%
transfer efficiency in case of top coat system.
18 robots are in work.
Maximum possible output JPH (Jobs per hour) that can be
made from paint shop are 42 JPH due to the presence of
paint booth.
TAKT Time: 1.43 min
Two types of storage areas:
o PBS (Painted Body Storage)
o WBS (Weld Body Storage)
BAKING TEMPERATURE:
o Top Coat: 1800 C for 16-20 min
o CED: 1750 C for 15-30 min
o Sealer/PVC: 1150 C for 15 min
Parameters for controlling: Chemistry+
Mechanics+Time+Temp.
GROUP 1, GET2016
Techniques of Painting:
1C(Coat)+1 B(Baking) used for domestic vehicles
2C+1B (surfacer + top coat)
3C+1B (surfacer + Base coat + top coat/clear coat +1
Baking)
AUTOMOBILE
PAINTING SYSTEM
PT.CED Application
Corrosion Prevention
Primer/ Surfacer
Application
Corrosion Prevention,
UV Protection and
improve intercoat
adhesion
Top Coat
Application
Corrosion Prevention,
Aesthetic appearance
& UV Protection
GROUP 1, GET2016
Process flow:
PRETREATMENT
ELECTRODEP
OSITION
ED COAT
BAKING
SEALER/UND
ERBODY
APPLICATION
Top Coat
Baking
Top Coat
Application
ED SANDING
SEALER
BAKING
Inspection &
Polishing
Wax
Application
SEND TO TCF
PRE-TREATMENT:
An electro chemical conversion process, providing paint bonding
and corrosion resistance which is carried out prior to painting.
Function:
To provide
o Clean, oil & grease free surface
o Non conducting bond between the base metal & paint
o Fine & crystalline corrosion inhibiting base for paint
o Chemically inert surface to prevent the reaction
between the metal surface & paint ingredients
To improve the paint properties like adhesion, impact,
corrosion resistance
Types of conveyor system:
GROUP 1, GET2016
Pendulum System
RoDip Conveyor
Pre
Hot
wash
water rinse
(DIP)
Pre Degrease
(Spray)
Degreasing
Water
(DIP)
Rinse
Surface
conditioning
Phosphating
Water
DI
fresh
rinse
spray
ELECTRODEPOSITION:
o Voltage Potential is established and current flows
o Water decomposes at the electrodes (Electrolysis)
GROUP 1, GET2016
o Paint Particles move to the oppositely charged electrode
(Electrophoresis)
o Paint Particles deposit on substrate (Electrodeposition)
o Paint Particle become tightly packed (Endosmosis)
o Part becomes electrically insulated by paint and deposition
stops automatically
CED
SEALANT APPLICATION:
Functions:
Vibration dampening
Corrosion resistance
DRY SANDING
Improves topcoat adhesion between ED & I/C by providing a
rough surface.
GROUP 1, GET2016
Outside Painting :
TOTAL NO. OF ROBOTS: - 18
Inside Painting: