What kind of issues from existing paint shop?
Paint shop is a crucial system since from many decades before. That means there’re still many installations maybe from 10 or 20 or even earlier ages. Due to the technology development on both mechanical and coatings, there’s huge difference between old age and new requirements. Thus, when we need to work with the modern products, the painting system might not be capable of handling. We either need to make a new shop or probably considerring modification and upgrade the existing one to make it working better.
Even from the new installations, there’re also various issues if it’s not well calculated and constructed. Considerring the problems on the market, robotic paint group offers a service to modify and upgrade customer existing paint shops to meet with higher production requirements. Especially for those ones that make pretty low fine rate and onsite technicians can not solve issues by any way, our professionals will deal with such problems seriously with guaranteed agreement until customer satisfication.
How robotic paint group help optimize customer paint shop?
It’s not an easy job to apply modification to existing production line because many items can not touch directly after long time working. Such as dusts /sludge and many dangerious contacts inside chamber or pipes. However, our professionals will inspect each part carefully in professional way then provide a workable solution. For paint shop performance issues, there’s a variety of checks to be processed including the following:
General mechanical structure
It’s a basic but important part of the paint shop, its the backbone to ensure the system stability in long run. Unfortunately there’s huge difference from each manufacturer due to various reasons like material selection /engineers’ work concept or the final setup costs etc will greatly result in different structures. But for most of the cases, we can not observe this after clean room configuration as everything will be hidden by various panels.
For a durable and high end setup, the mechanical support structure must have setup with national standard profiles and connected in professional way. The pipe thickness and surface treatment is crucial to ensure problem free working in long run after warranty time. All connection part must be reinforced by sufficient pipes (It’s common issue many manufacturers just make it be able to stand up. The potential issue is conveyor system will be pulse moving with extra noise and the products on holders will easily fall off.)
Our professionals will inspect each unit from backend then provide a fix solution.
Spray method
The direct and most crucial device of spraying quality control. The type of spray nozzle, paint supply and fluid control must be all compatible and adjusted properly as spray requirements. Factory always have to paint various objects with different sizes and appearance designs. That means a single spray system might not be sufficient to deal with all spray needs, or spraying program has to be precisely made for each model.
Due to limited time frame or any other onsite condition, training engineer may just provide a general concept but not able to offer a detailed instruction to operators. A not well trained operator won’t be able to handle the spray system for sure.
At robotic paint group, our professionals will study all the models to be processed in paint shop then suggest a suitable sprayer or how to adjust existing devices properly without a big change.
Fine rate issue
This is probably the biggest issue among all issues from production site. Regardless the production line investment, it’s nothing if we can not produce a well accepted product. But it’s not a single point fix as learned from all above tips. Fine rate can be from conveyor, painting booth or curing furnace or the installation environment. It’s the biggest challenge among all other fixes. In order to fix or improve the fine rate, there’s a list of checks by our professionals when they arrived at the production site.
Energy consumption
Energy refers to either elctricity or gas consumption for paint shop operation. Not to mention the economy, the numorous competitors forced all manufacturers to save on every side in order to give a competitive offer. Energy consumption is in top list in daily expense, thus any improvement on this is valuable.
Curing oven is the main part either for electric or gas. If the oven energy consumption is abnormal from original design properties, we have to pay extra attention to it’s functionality like heater damaging or sealer broken or leakage etc. It’s always wise to follow up to date oven technologies either on it’s design or the type of energy supply.
Because each oven is built through onsite conditions, our professionals will have to inspect side by side in order to improve the energy efficiency.
Waste air treatment
Most early age paint shops were not configured for waste air filtration which is a must for modern production. It’s easy to attach a new filtration unit once the installation position confirmed. We will follow up local environment policy and exhaust rules then propose a suitable filter unit to fit the existing painting line system. Some popular solutions like water filtration, active carbon, RCO/RTO etc are ready units for quick application.
If you’re running a paint shop and experiencing any above issues, feel free to contact with us. Our professionals will get in touch with you shortly and follow up.
