Robotic Paint Applications

ROBOT PAINT APPLICATION
Innovative, Efficient and Low complexity technologies / solutions in Paint Application
Hirenkumar Parmar, APT DSIN
Chennai, September 2, 2018
www.durr.com
DÜRR PAINTING ROBOTS
A success story
1984 1998 2005 2016
EcoRP E043i
Behr3/6 EcoRP6/7 EcoRPL/E 033/133
EcoRP L/E 033i/133i
Hydraulic drives Servo drives Modular robot family with Modular robot family with
Air for interiors Air & ESTA 6 axis base kinematics 6 or 7 axis base kinematics
Stop & go Interiors & exteriors Pedestal & elevated “Without rail” solutions
Glass fiber process arm 8/9 axis van painter Improved MTBF / MTTR
EcoScreen 3D-onsite Best hose & cable routing Integrated safety

Integrated application “Cloud ready”
© Dürr India Private Limited, Robot paint application, September 2, 2018 2

ECOPAINT APPLICATION – INSTALLATION CONFIGURATION
Ecopaint Checker
Ecopaint Air BC
Ecopaint ESTA BC
Ecopaint Robot BC
Ecopaint Clean
Ecopaint Blow-Off Ecopaint Quality
Ecopaint ESTA CC
Ecopaint Robot CC

ECOBELL CAR BODY PAINTING INSTALLATION CONCEPT
 Exterior painting
 Interior painting
 Epoxy parts; add-on pieces
 Solventbased and waterbased
paint systems
 Direct charging
 Exterior charging
 Without high voltage

COMPARISON OF A ROBOT AND MACHINE CONCEPT
Product Machines Robots
• Flexibility conc. vehicle design + variety of models - +
• Accessibility of problem zones -- +
• Product modification time o +
Installation
• Necessary zone length o --
• Assembly and commissioning expenditure o +
• Innovation, prestige -- +
Efficiency
• Invest, running costs -- +
• Personnel requirement o +
• Availability o +
• Extent of touch-up o +
• Material consumption -- +
• Total paint transfer efficiency o +
• Paint and solvent losses during the colour change -- +

Operation, Maintenance, Repair Machines Robots

• Operation + o
• Programming path and process o +
• Maintenance, repair o +
• Cleaning o +
Process / Quality
• Availability o +
• Process safety / backup concept -- +
• Painting extent 100% -- +
• Number of necessary atomizers -- +
• Conveyor dependence, for example: conveyor stop -- +
• Electrostatic paint charging + +
• Colour shade variety, special colours + +
• Film thickness distribution -- +
• Formation of stripes, cloudiness o +

Machines Robots
Flexibility concerning vehicle design and problem zones - +

Availability o +
Number of necessary atomizers - +
Conveyor dependence, for ex. in case of conveyor stop - +
Film thickness distribution - +
Invest, current costs - +
Material consumption / paint colour change losses - +
Programming path and process o +
Service, maintenance o +
Assembly and commissioning expenditure o o (+)

BASICS FOR PAINTING
Overspray without HT

BASICS FOR PAINTING
Electrostatic Wrap-Around

BASICS FOR PAINTING
Electrostatic Field

BASICS FOR PAINTING
Electrostatic Field
Paint accumulation
Faraday cage effect
Electrostatic field concentration

BASICS FOR PAINTING
EcoBell – Internal or Direct Charging

BASICS FOR PAINTING
EcoBell – External Charging

BASICS FOR PAINTING
Air Spray Jet on Target
Air cushion
Small droplets captured
by electrostatic force
Air stream lines

Deflected small droplets
(overspray)
Due to inertia, larger droplets

deflected less
Paint droplets
Paint droplets paths

BASICS FOR PAINTING
Ecopaint ESTA High Speed Rotation Direct Charging System

STRUCTURE OF PAINT FILM PAINTING QUALITY
Standard Paint Film Structure For Automobile Car Bodies
Paint film film thickness paint baking process

20 minutes
top coat oven
clear coat
Top coat
base coat primer oven
Primer
dip-coating oven
Electro
dipcoat
Pre-treatment Corrosion protection measures
(phosphatizing) - galvanizing
- seam sealing
- application of underbody protection
- cavity preservation (waxing)

STRUCTURE OF PAINT FILM PAINTING QUALITY
Colour Effects

SPRAY PATTERN CALCULATION SB 50 %
SB50 = Brush jet width measured at 50 % of the max. film thickness) Example for SB 50 / 470

Evaluating SB 50
Result: SB 50 470 mm;
max. film 18.8 µm;
Dünnschichtfüller
Film primer
film by 10% too
high, and SB by
20
5% too wide 18
16
µm
film ininµm
Upshot: Reduce paint 14
volume by 12
10
Schicht
approx.10%; 8
Increase shaping 6
air by approx. 5%; 4
2
create new brush
0
steel sheet with 0 10 20 30 40 50 60 70 80 90 100
changed painting
parameters, if ok Sprayjet width
Spritzstrahlbreite
start car body trials

with this basic
setting.
Evaluating SB 50
Result: SB 50 470 mm;
max. film 18.8 µm;
Dünnschichtfüller
Film primer
film by 10% too
high, and SB by
20
5% too wide 18
16
µm
film ininµm
Upshot: Reduce paint 14
volume by 12
10
Schicht
approx.10%; 8
Increase shaping 6
air by approx. 5%; 4
2
create new brush
0
steel sheet with 0 10 20 30 40 50 60 70 80 90 100
changed painting
parameters, if ok Sprayjet width
Spritzstrahlbreite
start car body trials

with this basic
setting.
ECOBELL ATOMIZER
EcoBell High Speed Rotating Atomizer
For all paint materials
 waterbased paints
 solventbased paints
 powder
 powder slurry
 1K + 2K paints

ECOBELL ATOMIZER
EcoBell High Speed Rotating Atomizer
 Commonly used for primer surfacer and clear coat painting
 Atomization by centrifugal force
 Spray pattern control by shaping air
 Charging by conduction and corona
 Droplets transportation/deposition primarily by electrostatic force
 High transfer efficiency due to low air volume used

ECOBELL ATOMIZER
EcoBell / EcoGun Spray Pattern Comparison

ECOBELL ATOMIZER
EcoBell – Direct charging
connection
flange
control valve
bearing unit/turbine
shaping air ring
union nut
atomizer housing

ECOBELL ATOMIZER
EcoBell – External charging
connection
flange
electrode ring
control valve
bearing unit
/turbine
union nut
atomizer housing with integrated

shaping air ring

ECOBELL ATOMIZER

ECOBELL ATOMIZER

ECOBELL ATOMIZER
Bell Cup with Paint Nozzle

ECOPAINT MACHINE
Ecopaint Machines

DÜRR PAINTING ROBOTS
A success story
1984 1998 2005 2016
EcoRP E043i
Behr3/6 EcoRP6/7 EcoRPL/E 033/133
EcoRP L/E 033i/133i
Hydraulic drives Servo drives Modular robot family with Modular robot family with
Air for interiors Air & ESTA 6 axis base kinematics 6 or 7 axis base kinematics
Stop & go Interiors & exteriors Pedestal & elevated “Without rail” solutions
Glass fiber process arm 8/9 axis van painter Improved MTBF / MTTR
EcoScreen 3D-onsite Best hose & cable routing Integrated safety

Integrated application “Cloud ready”

DÜRR PAINTING & SEALING ROBOTS WORLDWIDE
Total 10.552 Painting Robots*
Total 2.002 Sealing Robots*
* As of July 2016

ECOPAINT ROBOT – THE LATEST GENERATION IN ROBOTS
The new 6- and 7-axis painting robots
Full modularity for 6 and 7 axis kinematics:

Same housing, gear boxes, motors ...
… only arm 1 is different
Same basic kinematics and dimensions
Identical application integration
Identical assembly interface
Improved MTBF and MTTR
New modular Robot Controller
EcoRP E043i New drives and motors
Integrated safety
EcoRP E/L033i

ROBOT PAINTING CELL FOR 2 WHEELER, PLASTICS

‘READYTOSPRAY’ ROBOT
Robot

‘READYTOSPRAY’ ROBOT

ECOPAINT ROBOT
Kinematics

ECOPAINT ROBOT
EcoRP E 32

ECOPAINT ROBOT
EcoRP E 32

ECOPAINT ROBOT
EcoRP E 32

ECOPAINT QUALITY
 Ecopaint Checker:
Contactless film thickness
measurement
 Ecopaint CarFlash:
Ecopaint Checker
Fully-automatic quality measurement
 Ecopaint Expert:
Online process control
Ecopaint CarFlash

ECOPAINT SUPPLY SYSTEMS
EcoSupply P Special Paint Supply Systems

ECOPAINT CONTROL

NEW CONTROL PANEL DESIGN
Modular control panel family for paint and sealing: EcoRCMP2, EcoSCMP2, EcoPSMP2
New design with easy access to all components

Cold plate technology for robot control panel:
No cooling device for ambient temperatures up to 38 °C
Airflow between cooling plate and cabinet back side only
No airflow inside panel, no filters
25% to 35% less space required
40% smaller motor cable profile to robot
Operator panel
(3 types)
+ +
SMART FACTORY
EcoScreen 3D-Onsite
Features
Perfectly designed software package for
Ecopaint robots
Parameterization
Programming
Simulation
Customer benefits
User-friendly interface
High performance for graphics and simulation
Interface for all important CAD formats
Start paint shop Start other shops

SMART PRODUCT
Intelligent pump control
Features
Flushing programs with slide control
Synchronization of main needle and dosing pump
Automatic adjustment of differential pressure
Customer benefits
Easy setting of cleaning intensity
No manual gauging required
Consistent dosing accuracy
Extends the service life of the pump
EcoPump9 with integrated pressure sensors
Start paint shop Start other shops

NEW COMPACT DOSING PUMP GENERATION
EcoPump9
Optimized for robot installation
Increase of lifetime
Maintenance-free
Compact dosing pump design
One pump size for paint metering: 4,5cc/rev
Advanced paint flow: 90 - 900 ml/min
Adaption on the EcoRP E/L and EcoRP F Comparison of size: EcoPump8 vs. EcoPump9
Speed max. 200 rpm
Installed at 3 customers in India so far

Reduction of paint loss up to 25% EcoPump9
Reduction of flushing time up to 10%

ECOPUMP 9 PURGE CYCLE REDUCTION : CASE STUDY :
Thinner / Paint Consumption Cycle Time

Description
Cycle No Before After % reduction Before After % reduction
1 Long purge cycle 230 ml 155 ml 33% 9.8 9 8%
Paint Load
11 Cycle 25 ml 19 ml 24% 3.8 3.6 5%
Initial investment = INR 600,000 per pump including installation, excluding taxes.
ROI to be calculated based on Paint Costs and number of colour changes / long purge cycles.

CURRENT & OPTIMIZED NEW TURBINE
TECHNICAL DATA

NEW TURBINE VALIDATION : CASE STUDY
ACTUAL VALIDATION REPORT AT ONE CUSTOMER IN INDIA
Installed at 7 customers in India so far.

Initial investment = INR 571,000 per turbine excluding taxes. Same as old turbine.
ROI : Compressed air savings + One Bell Disc is free with each new turbine.

LINEAR COLOR CHANGER
EcoLCC
Simple technique
Color changer without main paint duct
No paint carryover possible
Number of colors: 36 water-based colors without paint
circulation, at the most 24 colors with paint circulation
Only 5 magnetic valves needed for excitation of color
changer
(formerly one magnetic valve per color)
Suited for exterior and interior painting
Installed at 2 customers in India so far.

Reduced color loss from 45-120ml to 10-15ml per color change
Color change time <10s with push out
ROI to be calculated based on customer requirements

HIGH PERFORMANCE - LESS COMPLEXITY
Rotating atomizer EcoBell3
Compact external charge
- reduced invest
- most simple technology
no voltage blocks necessary
2 main needles
- different paint systems applicable
- 1K&2K possible
Paint stop valve
- no paint loss at preload process
New small valve technology
- more functions possible
Modular atomizer family
Flexible spray pattern for details and surfaces
Lowest color change loss

ECOBELL ON RECIPROCATOR

INNOVATIONS IN APPLICATION
EcoBell3 Ci: Application systems, new high speed atomizer for interior painting
Application area Water based paint 1K, 2K Solvent based paint 1K, 2K
with high tension without high tension with high tension
Interior painting
SB50%: 50-220 mm
EcoBell3 Ci EcoBell3 EcoBell3
Exterior painting
SB50%: 180-600 mm
EcoBell3 E
- EcoBell3
Combined zone (interior & exterior), plastic

parts & bumper painting
SB50%: up to 600 mm
EcoBell3 C
- EcoBell3

ECOBELL CLEANER D2
01. Application Area
The EcoBell Cleaner D2 is a cleaning device for rotary
atomizers, especially EcoBell3 and EcoBell2 (planned)
Cleaning is carried out within the usual cycle time and with
very low flushing agent consumption
Usable for waterborne and solventborne 1K and 2K paints
Can be attached in a stationary position or moving with the
robot
EcoBell Cleaner D2

ECOBELL CLEANER D2
02. Design and Functional Principle - Cleaning area
In the cleaner, the shaping air ring and the tube are
cleaned up to the contact seal
This is in keeping with the area important to the process
2h production activities are usually feasible without
manual cleaning of the atomizer with dirt varying
according to the system
Cleaning area
Illustration of cleaning area

ECOBELL CLEANER D2
03. Advantages
Low flushing agent consumption: less than 50 ml
Short cleaning time usually without cycle time loss
Simultaneous color change and short flushing possible during cleaning
No hoppers, pans or separator additionally necessary
Less space occupied in the booth
Suitable for a 6 bar dynamic supply network
Can be attached in a stationary position or can be attached to move with the robot
EcoBell Cleaner D2

ECOBELL CLEANER D2
04. Customer Benefits
No cycle time loss when cleaning the atomizer
Savings of up to 91 % of cleaning medium compared to EcoBell Cleaner D
Reduction in the manual cleaning interval of up to 50 % compared to EcoBell Cleaner D
Low and simple maintenance
Disposal of all fluid media in return pipes
VOC reduction of 94 % compared to EcoBell Cleaner D
Less use of chemicals and waste disposal in wet scrubber systems since
99 % of complete media is disposed via the return pipe
Less waste disposal and higher endurance of dry scrubber systems
Emissions are almost only produced by the painting process
Concentration of solvents in the air recirculation area is reduced

ECOBELL PARTS CLEANER
Product Features
Cleaner for bell disks and shaping air rings (also integrated
in housing)
Automated and reproducible cleaning processes
Simultaneous cleaning of up to six bell disks and six shaping
air rings
Three cleaning programs for different degrees of soiling

ECOTESTER SHAPING AIR
Product Features
Tester for shaping air rings (also integrated in housing)
Visual quality inspection of the shaping air bores by
means of water jet test Test object
Higher production reliability Pressure regulator for

Ideal supplement for EcoBell Parts Cleaner EcoPump AD
Switch EcoPump AD on/off
Switch for:
• Shaping air 1
• Shaping air 2
• Dry air
Supply unit:
• Tank with DI water
• EcoPump AD
• Rack for additional adapter
• Maintenance unit and control
valves

ECOPUMP HP (PNEUMATIC)
Unique 4-ball Pneumatic horizontal pump technology for paint circulation.
Less wear parts in comparison to vertical pneumatic piston pumps.
Modular pump design, easy to maintain and repair.

ECOPUMP HP (PNEUMATIC)
TYPICAL INSTALLATION

ECOPUMP HPE (ELECTRIC)
4 ball pump design with electric drive offers lower operating costs
Complete surge free operation

ECOPUMP HPE (ELECTRIC)
TYPICAL INSTALLATION

ADVANTAGES – DURR HP (E) V/S BINKS
Competitive in price.
Prompt service available through Durr legal entity.
Life of piston seals & better by 15%.
More robust in terms of construction.
Paint delivery of Durr pump better by 6.5%

ROBOT TRAINING CENTRE AT DSIN, CHENNAI, INDIA
TRAINING ROBOT DETAILS

RPL 033 with EcoBell 2 atomizer
EcoLCC : Colour Changer
RPC V3 : Robot Controller
RW GuardLogix L73S : PLC
EcoPump 9 : Dosing Pump
8 bar compressed air booster with dryer
© Dürr India Private Limited, Robot Training Centre, Chennai

ROBOT TRAINING CENTRE AT DSIN, CHENNAI, INDIA
TRAINING CONCEPT & TOPICS

Duration : 5 days (Mon to Fri, 9 am to 5 pm )
No. of participants : 08 max.
Type of training : Classroom + On the job
Agenda : Basic operation of robots ( Mech + Elec ), Maintenance, Troubleshooting, Teaching.
BROAD TOPICS COVERED

Brief details about Durr Paint Robots.
Mechanical construction
Electrical panels – Brief details including RPC V3.
Robots Axes & Drives
Axes mastering
Air Purging system
Paint Application Equipment including Eco-Pump 9, LCC.
Feedback system & diagnosis
Dismantling & assembly of main components
Basics of Eco-Screen, Teach Pendant, Profiling, Parameter Setting & effects on quality.
© Dürr India Private Limited, Robot Training Centre, Chennai
SMART SERVICES ON SITE

SMART SERVICES ON SITE

STOP BY BOOTH NO 124, HALL NO 3
Meet our experts

Hirenkumar Parmar, APT DSIN
Address: Dürr India Private Limited

804, 8th Floor, Earth Arise, Near YMCA International Club, S G Highway,
Ahmedabad - 380051
Gujarat, India.
Phone: +91 75500 84222
Email: hirenkumar.parmar@durr.com
Web: www.durr.com
“Subject to change. The information in this presentation contains only general descriptions or performance characteristics, which may vary
in different cases. The requested performance characteristics are only binding if they are expressly agreed in the contract.”

Robotic Paint Applications

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Robotic Paint Applications

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ROBOT PAINT APPLICATION

Innovative, Efficient and Low complexity technologies / solutions in Paint Application

Hirenkumar Parmar, APT DSIN

Chennai, September 2, 2018

1984 1998 2005 2016

EcoScreen 3D-onsite Best hose & cable routing Integrated safety

© Dürr India Private Limited, Robot paint application, September 2, 2018 2

Ecopaint Blow-Off Ecopaint Quality

© Dürr India Private Limited, Robot paint application, September 2, 2018 3

© Dürr India Private Limited, Robot paint application, September 2, 2018 4

© Dürr India Private Limited, Robot paint application, September 2, 2018 5

Operation, Maintenance, Repair Machines Robots

© Dürr India Private Limited, Robot paint application, September 2, 2018 6

Flexibility concerning vehicle design and problem zones - +

© Dürr India Private Limited, Robot paint application, September 2, 2018 7

© Dürr India Private Limited, Robot paint application, September 2, 2018 8

© Dürr India Private Limited, Robot paint application, September 2, 2018 9

© Dürr India Private Limited, Robot paint application, September 2, 2018 10

Faraday cage effect

Electrostatic field concentration

© Dürr India Private Limited, Robot paint application, September 2, 2018 11

© Dürr India Private Limited, Robot paint application, September 2, 2018 12

© Dürr India Private Limited, Robot paint application, September 2, 2018 13

Air stream lines

Due to inertia, larger droplets

© Dürr India Private Limited, Robot paint application, September 2, 2018 14

© Dürr India Private Limited, Robot paint application, September 2, 2018 15

Paint film film thickness paint baking process

© Dürr India Private Limited, Robot paint application, September 2, 2018 16

© Dürr India Private Limited, Robot paint application, September 2, 2018 17

© Dürr India Private Limited, Robot paint application, September 2, 2018 18

start car body trials

start car body trials

For all paint materials

© Dürr India Private Limited, Robot paint application, September 2, 2018 21

 Commonly used for primer surfacer and clear coat painting

 Atomization by centrifugal force

 Spray pattern control by shaping air

 Charging by conduction and corona

 Droplets transportation/deposition primarily by electrostatic force

 High transfer efficiency due to low air volume used

© Dürr India Private Limited, Robot paint application, September 2, 2018 22

© Dürr India Private Limited, Robot paint application, September 2, 2018 23

shaping air ring

© Dürr India Private Limited, Robot paint application, September 2, 2018 24

atomizer housing with integrated

© Dürr India Private Limited, Robot paint application, September 2, 2018 25

© Dürr India Private Limited, Robot paint application, September 2, 2018 26

© Dürr India Private Limited, Robot paint application, September 2, 2018 27

© Dürr India Private Limited, Robot paint application, September 2, 2018 28

© Dürr India Private Limited, Robot paint application, September 2, 2018 29

1984 1998 2005 2016

EcoScreen 3D-onsite Best hose & cable routing Integrated safety

© Dürr India Private Limited, Robot paint application, September 2, 2018 30

Total 10.552 Painting Robots*

Total 2.002 Sealing Robots*

© Dürr India Private Limited, Robot paint application, September 2, 2018 31

Full modularity for 6 and 7 axis kinematics:

© Dürr India Private Limited, Robot paint application, September 2, 2018 32

© Dürr India Private Limited, Robot paint application, September 2, 2018 33

© Dürr India Private Limited, Robot paint application, September 2, 2018 34

© Dürr India Private Limited, Robot paint application, September 2, 2018 35

© Dürr India Private Limited, Robot paint application, September 2, 2018 36

© Dürr India Private Limited, Robot paint application, September 2, 2018 37