Spray painting with robots

Clemco Denmark specializes in heavy duty protective coating application with robots. Our long term experience comes from the wind turbine industry and from off shore oil and gas.

ROBOTIC SPRAY PAINTING

QUICK FACTS

  1. Clemco Denmark specializes in heavy duty protective coating application with robots
  2. We always estimate the potential savings in paint consumption prior to any project.
  3. For our robotic painting systems we recommend using the Wiwa Fleximix system with necessary I/O facilities
  4. The robotic spray program can be simulated using the Motosim software in order to plan the spray patterns and overlaps.
  5. Our robotic paint systems can be integrated with conveyor lines
  6. We offer 3K systems for controlling the paint viscosity.  

Airless spray painting with robot

When considering using a plural component paint system for robotic spraying there are a number of parameters you have to consider before purchase. The big advantage of using a paint system that can automatically mix the components (base, hardener and process thinner) is to mix the components just before the paint is to be used. This means that it is not going to mix more than the amount of paint which can be applied, and it can be measured how much less waste is generated compared to mixing base and hardener in separate tanks. Wiwa multicomponent airless systems are all equipped with surveillance of pot-life that allows an alarm before the paint hardens in the mixer unit and high-pressure hoses etc.

Wiwa has two types of multicomponent systems called Wiwa FlexMix and Wiwa Duomix. The difference between the two painting systems is that Wiwa Duomix has a fixed mixing ratio of hardener and base compared to a Wiwa Fleximix painting system with adjustable mixing ratio. Wiwa Fleximix has a built-in Omron PLC which can be programmed for the robot control and can be programmed to, for example, adding a thinner before the painting program is completed in order to utilize the paint that is already in the high-pressure hoses. This can generate significant cost savings in the long run.

There are several advantages in using a Wiwa Duomix airless painting system with fixed mixing ratio because then you are always sure that the mixing ratio of hardener and base is correctly adjusted. Wiwa Duomix is ​​a 2-component mixing unit known for its extremely high reliability and a relatively simple configuration with an air motor which controls the two pistons for base and hardener. The two components are mixed in a static mixing chamber that provides the complete mixing of the curing agent and the base.

The Wiwa Duomix 270 application unit is a great and dynamic addition to the Wiwa Duomix Series, as it combines the advantages of continuous production and accurate, stable dosing with easy electronic operation and monitoring. The Wiwa Duomixer is specifically suited for highly viscous materials and applications on large surface areas.

This painting system is equipped with the latest, low-noise, oil free, anti-icing air motor. The system allows the use of multiple guns and long hoses while the anti-icing design provides for continuous application and minimizes downtime. For what concerns the mixing ratio it can be changed in a matter of minutes by exchanging the material pumps. Furthermore the mixing block can be located directly on the unit or, for products with a short pot life, in an external mixing block connected by a heated hose package up to 100 m long.

All parts that are in contact with the material are made of stainless steel and are crafted to require the lowest possible maintenance. They are easy to clean and will reduce material waste and solvent use, which makes the Duomix series highly durable and very economical.

The material feed is possible either via, various sized, feed hoppers (with optional heating/agitator) or by using feed pumps for either small or large drums. If necessary the Wiwa material fluid heaters are easy to add to warm up the material to the required processing temperature. Available electronic features include; pot life monitoring, flush program execution, gear flow metering, mixing ratio memory and data recording and downloading with the Wiwa datalogger.

Wiwa FlexiMix II Herkules


A Wiwa Fleximix airless painting system has the advantage that you can set the mixing ratio of hardener and base so you do not need to change piston pump if you use paint systems with many different mixing ratios between base and hardener. The mixing ratio can be adjusted directly in the control display and mixing ratio is constantly monitored by an alarm system that reports an error if the mixing ratio does not comply with a very narrow tolerance. For robotic spraying system you will be able to control parameters such as paint temperature, mixing ratio, thinner consumption, adding process thinner to reduce the viscosity etc. This means that you are able to apply the paint much more even and with higher savings compared to a normal mixing system.

Clemco Denmark has a long experience in using Wiwa Fleximix for a 3-component system; you can add thinner directly into the paint to adjust the viscosity of the paint, for example for what concerns mist coating which is widely used on zinc/aluminum metallized surfaces. The thinner is applied at a given mixing ratio and the thinner is pumped directly to the mixer pipe where it is mixed with the base and hardener. In this way you can achieve a very accurate control of the paint's viscosity and spraying characteristics.

For our robotic painting systems, we recommend using a Wiwa Fleximix as its Omron PLC has the necessary I/O facilities that controls the mixer system very precisely to achieve a highly accurate coating thickness without pulsation in the spray fan.

  1. We perform quality control and "wet" testing of the equipment before delivering on site

  2. We set up the complete line with our own supervisors and project managers

  3. We establish a project plan prepared to include the clients' overall project management

  4. We introduce the specific procedures to respect the agreed transfer efficiency rates and process times

  5. We have the necessary insurance and permits for the installation of epoxy and polyurethane systems and we are able to accommodate most HSSE requirements during the work

  6. We offer a full CE approval of the entire solution

Robot for automatic spray painting

For robotic painting we can recommend the Motoman MPX 3500 6-axis painting robot with high performance within painting automobile bodies, bumpers and construction equipment. The robot is approved for installation in an Atex zone 1.

A high-density layout saves space by reducing the size of the painting booth. The L-axis is designed with no offset to enabled installation of the manipulator closer to a work piece, which saves space.

 

Spray fan for robotic spray painting:

 

A track measuring the full length of the booth is mounted on the wall of the booth so that the robot is able to move in the longitudinal direction of the booth. The movement of the longitudinal axis is fully incorporated in the control system of the robot.

The MPX model has a payload up to 15 kg and a working envelope of 3.500 mm. The robot will be covered in a protection suit to protect the robot from overspray and spray dust.

 

Robot Control

The robot uses the dynamic DX200 controller which includes patented multiple robot control technology for easy handling of multiple tasks and for controlling up to eight robots (72 axes), I/O devices and communication protocols. Featuring a robust PC architecture with unmatched memory capacity, the DX200 uses a Windows® CE programming pendant with color touch screen.

The energy-saving DX200 controller features faster processing speeds for smoother interpolation, advanced robot arm motion, built-in collision avoidance, quicker I/O response and accelerated Ethernet communication. Its extensive I/O suite includes integral PLC and HMI pendant displays, 4,096 I/O and a graphical ladder editor that can provide system level control. The DX200 supports all major fieldbus networks. It is compliant to ANSI/RIA R15.06-2012 and other relevant ISO and CSA safety standards.

         DX 200 Controller                       Hand controller with touch screen

The WIWA 400 Airless Automatic spray gun

The WIWA 400 Airless Automatic spray gun is designed with a pneumatic controlled needle. The ATEX approved solenoid valve controls this open/close function. In addition, a pressure sensor is installed outside the spray booth to provide data for checking for an even spray pattern. The spray gun is equipped with a tungsten carbide spray tip. We expect the spray tip’s orifice to be between 0,013” – 0,021”.

The WIWA 400 automatic gun is equipped with a material return flow connection and can be used either with or without circulation. In order to ensure that the robot spray gun can be flushed safely we will install a service dump pot. This dump pot will be made in stainless steel and is ground wired to eliminate static electricity.

Frederik Nielsen

"Need more information about spray painting with robot? Call me."

Frederik Nielsen CEO, Clemco Denmark

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