Dürr builds re­source-ef­fi­cient paint shop for ŠKODA

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Dürr, a lead­ing me­chan­i­cal and plant en­gi­neer­ing firm, has launched EcoInCure that of­fers best pos­si­ble top­coat qual­ity and max­i­mum process re­li­a­bil­ity by heat­ing the car bod­ies from the in­side in com­bi­na­tion with the in­no­va­tive trans­verse mode of op­er­a­tion. ŠKODA will use the ben­e­fits of the new Dürr oven in the fu­ture in the Mladá Boleslav main plant in the Czech Repub­lic. Dürr is sup­ply­ing all the sys­tem and ap­pli­ca­tion tech­nol­ogy, in­clud­ing the build­ing, for the new paint shop.

EcoInCure fea­tures noz­zles with long throw dis­tances that blow hot air into the in­side of the body through the open­ing for the wind­shield. The flow ve­loc­ity around the outer skin of the body dur­ing this process is min­i­mal. This re­sults in an undis­rupted paint ap­pear­ance with max­i­mum qual­ity. At the same time, op­ti­mum trans­fer of heat in­side the body en­ables ex­tremely ho­mo­ge­neous heat­ing of both thin sheet and mass parts. The re­sult is up to 30% shorter heat­ing times with min­i­mized ther­mal com­po­nent stresses, which is es­pe­cially im­por­tant for dry­ing elec­tric ve­hi­cles and mul­ti­sub­strate bod­ies.

The heat­ing con­cept of EcoInCure re­duces the elec­tri­cal en­ergy re­quire­ment by 25% and reg­u­lates the dry­ing tem­per­a­ture with pre­vi­ously im­pos­si­ble pre­ci­sion and speed. The ex­haust air from the ovens is pu­ri­fied via the in­te­grated Ecop­ure TAR af­ter­burn­ing sys­tem with heat re­cov­ery and then used for the oven heat­ing sys­tem. The en­tire plant, in­clud­ing data ac­qui­si­tion, data eval­u­a­tion, and plant mon­i­tor­ing, is con­trolled by the Dürr soft­ware so­lu­tion iTAC.MES.

Suite. The mod­u­lar MES sys­tem pro­vides de­tailed in­for­ma­tion on the pro­duc­tion work­flows and the con­sump­tion data.

For the first time, Dürr is us­ing the elec­tronic qual­ity card for the dry­ing process, which makes it pos­si­ble to track the dry­ing qual­ity of each body. This tried-and-tested tech­nol­ogy from Dürr is be­ing used to coat well over 10 mil­lion bod­ies world­wide each year.

The lat­est Dürr ro­botic gen­er­a­tion is used in all process steps in­volved in paint­ing. From the primer to the base coat and the clear coat line, a to­tal of 61 EcoRP third-gen­er­a­tion paint­ing ro­bots en­sure ef­fi­cient paint ap­pli­ca­tion. The ex­te­rior paint­ing is done by the EcoRP E043i, the first paint­ing ro­bot where the sev­enth axis is in­te­grated into the ro­bot’s kine­mat­ics. Two or four ro­bots are in­stalled in each of the ex­te­rior paint­ing cells. The stop-and-go paint­ing process means that they do not need a rail. This en­ables a much bet­ter view of the booth and elim­i­nates the po­si­tion­ing axis sig­nif­i­cantly re­duc­ing the main­te­nance ef­fort in the ro­bot cell.

The in­te­rior paint­ing sta­tions are equipped with the six-axis ro­bots of the type EcoRP L133i, which are mounted on a rail. The iden­ti­cally con­structed EcoRP L033i model with­out rail is used for open­ing the hoods. The ro­bots are as­sisted by Scara door open­ers. The lat­est Dürr ro­bot gen­er­a­tion has a mod­u­lar

struc­ture. The only dif­fer­ence be­tween the six-and seven-axis mod­els is the ad­di­tional axis of ro­ta­tion in the main arm. The oth­er­wise iden­ti­cal com­po­nents sim­plify spare parts man­age­ment, save stor­age costs, and make main­te­nance eas­ier.

The ro­bots are equipped with the lat­est Dürr ap­pli­ca­tion tech­nol­ogy. The EcoBell3 at­om­izer se­ries to­gether with the as­so­ci­ated EcoBell Cleaner D2 and the EcoLCC2 colour changer de­liv­ers low paint and sol­vent con­sump­tion as well as fast colour changes within the cy­cle time.

The third gen­er­a­tion of Dürr ro­bots is con­trolled by the new­ly­de­vel­oped EcoRCMP2 process and mo­tion con­troller. The con­trol plat­form com­bines a mul­ti­tude of sen­sors and ac­tu­a­tors in the paint­ing ro­bot and the higher-level main­te­nance or con­trol sys­tems. An in­te­grated in­ter­face makes the ro­bot “cloud ready” and pro­vides all rel­e­vant data for cur­rent and fu­ture re­quire­ments in the In­dus­try 4.0 land­scape.

Even be­fore the bod­ies get their layer of paint, the weld­ing and glu­ing seams are sealed fully au­to­mat­i­cally. This en­sures that no wa­ter can in­fil­trate into the ve­hi­cle in­te­rior later. Dürr is in­stalling a to­tal of 19 EcoRS seal­ing ro­bots with the lat­est ap­pli­ca­tion tech­nol­ogy at ŠKODA in Mladá Boleslav. These ro­bots un­der­take the task of seal­ing the seams from be­low, in­side the body as well as at the roof seams.

The EcoDryScrub­ber, a dry sep­a­ra­tion sys­tem with lime­stone pow­der as the binder, will take over the paint over­spray sep­a­ra­tion in the spray booth. This sys­tem re­quires no man­ual han­dling as it is fully au­to­mated, ro­bust, and easy to main­tain, and re­quires no adap­ta­tion to dif­fer­ent paint sys­temssys­tems. This makes it ideal for high-vol­ume plants such as at ŠKODA. An im­por­tant point is the en­ergy sav­ing of up to 60% in the spray booth. By elim­i­nat­ing wa­ter and chem­i­cals, up to 90% re­cir­cu­lated air can be used in pro­duc­tion. This re­duces the cost of con­di­tion­ing fresh air and is the de­cid­ing fac­tor in the out­stand­ing en­ergy ef­fi­ciency of the spray booth.

The per­for­mance of the

EcoDryScrub­ber is fur­ther im­proved through the new V5.X sys­tem soft­ware. It en­ables the sys­tem to be self-reg­u­lat­ing. As a di­rect re­sult, op­ti­mum use is made of the lime­stone pow­der for bind­ing the over­spray, thereby re­duc­ing con­sump­tion.

The dry sep­a­ra­tion sys­tem re­sults in highly con­cen­trated and es­pe­cially ef­fi­ciently fil­tered ex­haust air. This en­ables a very com­pact air pu­rifi­ca­tion sys­tem, con­sist­ing of a highly ef­fi­cient VOC ab­sorp­tive con­cen­tra­tion sys­tem ( Ecop­ure KPR) with down­stream ther­mal ex­haust air pu­rifi­ca­tion sys­tem ( Ecop­ure TAR). The en­ergy needed for the Ecop­ure KPR sys­tem’s des­orp­tion air is re­cov­ered from the pu­ri­fied gas of the ther­mal ex­haust air pu­rifi­ca­tion sys­tem. This re­duces the in­vest­ment costs for the ex­haust air sys­tem by 60%. The en­ergy re­quire­ment for ex­haust air pu­rifi­ca­tion is re­duced by 80% in this com­bi­na­tion.

The plant is de­signed for a through­put of 30 ve­hi­cles per hour and will be paint­ing ŠKODA’s mid-range mod­els from June 2019.

The Dürr Group has had a di­rect rep­re­sen­ta­tion in In­dia since 1997. Dürr In­dia, based in Chen­nai, of­fers paint­ing, ap­pli­ca­tion, fi­nal assem­bly and en­ergy ef­fi­ciency tech­nol­ogy prod­ucts as well as ex­haus­tair pu­rifi­ca­tion sys­tems. Since April 2015, Dürr In­dia has been of­fer­ing on-the-job as well as class­room train­ing in paint and ap­pli­ca­tion sys­tems to cus­tomers at its new train­ing cen­tre.

ŠKODA will use the new Dürr oven in the Mladá Boleslav main plant in the Czech Repub­lic.

Dürr EcoInCure

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