EISENMANN€¦ · Photo right: Indexing dip coating system for the farm implement industry. 4....
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Dip Painting EISENMANN
Transcript of EISENMANN€¦ · Photo right: Indexing dip coating system for the farm implement industry. 4....
Dip Painting
EISENMANN
Competence and Know-How:Dip Painting Systems by EISENMANN
Contents:
Electro Deposition 2
Bath Maintenance and Recycling 3
Indexing Lines with Power & Free 6
Continuous Systems 8
Cleaning and Pretreatment 10
Paint Cure Ovens 11
Conveyors and Controls 12
Service and Maintenance 13
Programmable hoist dip lines allow individual processes for smallbatches and large work pieces.
EISENMANN is one of the leading suppliers in the worldfor turnkey automotive paintlines. We employ the newesttechnologies and expertise gained from years of experi-ence having built several hundred systems.
For all areas of industrial pain-ting, from the contract coaterto the automobile industry,EISENMANN is an able partnerfor advanced surface finishingtechnologies.
Small teams of engineers, working with specialists inenvironmental, material handling and control techno-logies, develop individualsystem concepts.
EISENMANN’s ability does notstop with the manufacture ofpaint lines. As operators ofcomplete automotive paintingfacilities, our personnel is re-sponsible for running a systemeconomically and achieving thehighest surface quality.
Photo left: Continuous E-coatsystem using a pendulum con-veyor in the automotive industry.
Photo right: Heating elements andradiators nowadays are primed byE-coat and then powder-coated.
The Benefits of Tailor-Made Concepts:
Waterborne, Conventional or E-Coat
Know-How from aSingle Source
EISENMANN offers a completeline of dip painting conceptsincluding indexing systems forconventional or waterbornepaint and continuous flow electrophoretic systems (anodic/cathodic E-coat). This is whyEISENMANN is considered one of the leading international manufacturers in this area.
Dip coating is an economicaland environmentally-friendlypainting process. The key areasof application are automotivecomponents, agricultural machi-nery, household appliances,metal furniture, constructionequipment, electrical devices,automobiles and many others.
Perfect Coordination
A turnkey facility. Your newEISENMANN dip-coating line hasall components in the plant perfectly coordinated with oneanother: water-saving pretreat-ment, indexing and continuousdip-coating systems, energy-conserving ovens, rationalmaterial flow systems, and comprehensive PC controls aswell as all-inclusive service oroperation of the entire systemby EISENMANN personnel.
To help protect the environ-ment, exhaust air and waste-water purification programs areeconomically integrated intothe design.
EISENMANN has specialists forall of these disciplines underone roof. You need only onepartner to answer all of your questions regarding the implementation of your newcoating facility.
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For the Best in Corrosion Protection:
E-Coat
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Photo right: Cathodic E-coatsystem for automotive parts usinga 10-stage pretreatment.
The Benefits of E-Coat
• Highest quality with best corrosion protection.
• Uniform, controllable coating thicknesses.
• Excellent coverage in corners and on edges or in difficult to reach areas due to good throw power.
• No runs or drips; rework not required.
• Highly cost effective through practically loss-freecoating in a closed loop system using ultrafiltration.
• Can be fully automated for medium or large production runs.
• Environmentally friendly because paint is practically solvent-free and no paint sludge forms.
Diagram of an anaphoretic E-coat system. Diagram of cataphoretic E-coat system.
Depending on your require-ments, EISENMANN recommendseither a continuous flow orindexing systems for anodic orcathodic dip-coating.
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Cathodic E-coat is outstandingfor providing excellent cover-age in cavities as well as forwrap-around edges. Today it isconsidered the standard forhigh quality products, otherthan within the automotiveindustry.
Workpieces to be coated aredipped into a water-solublepaint using a low concentrati-on of paint solids.
By applying a DC power fieldbetween the workpiece and thecounter electrode, the solidparticles in the paint depositon the workpiece.
In the process, an extraordina-rily uniform film of paint withoutstanding adhesion forms incorners, on edges, and in hardto get to areas.
Anodic or Cathodic E-coat: For Every Application, The Appropriate Process.
anode
cathode cathode
anode
A partial stream of the paintis continuously removed fromthe E-coat tank and fedthrough the ultrafiltrationsystem. There the solids areretained and returned to bemixed into the bath again.The pigment-free ultrafiltrateis used for rinsing loose paintmaterial, still present aftercoating, from the workpiece.UF rinsing typically is a multi-stage counter-flow process.
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Ultrafiltration:
Bath Maintenance and Paint Recycling
Cathodic E-coat with programmable hoist for automotive components.
Multi-stage rinse with final DI-rinse.
Continuous flow E-coat system for control panels.
DI-rinseUF counter-flow
Recycling orwaste watertreatment
Ultrafiltration
Material flow
E-coat bath
DI-water
Permeate
Bag filter
Overflowtank
E-coat paint
UF-module
Economical and Flexible, also for Small Production Runs:
Indexing Systems with Power & Free Conveyor
When selecting a dip coatingprocess for specific applica-tions, a series of importantparameters have to be considered, all of which areimportant in terms of economyand surface quality.
EISENMANN builds all types of paint dip systems, andbased on our experience canalways recommend the mostapplicable one.
Indexing systems are used forrelatively low overall through-put as well as for larger work-pieces of the same type. Theyare characterized by a compactdesign with small dip tankvolumes.
This type of system is particu-larly economical because thelift and lowering stations canbe integrated into the other-wise continuous material flowsystem (overhead power & freeor chain conveyor) and transferto other conveyors is not required.
Diagram of an indexing system with power & free conveyor.
Photo right: Indexing dip coatingsystem for the farm implementindustry.
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Photo right: Side rails for trucks aslong as 12 meters are handled by apower & free conveyor through thezinc phosphate process and arethen lowered into the E-coat tankby a lift station.
Photo above: This custom coatingbusiness uses the advantages of anindexing cathodic E-coat system forindividual batches.
Photo left: Cathodic E-coatsystem with overhead chain conveyor and special lift stationfor truck cabins.
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Variable and Versatile for all Shapes and Sizes:
Programmable Hoist Systems
Diagram of a programmable hoist system.
Programmable hoist systems are especially useful for large workpieces with relatively low production volumes such as the truck frames in a dip painting line as shown.
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Programmable hoist systemsare used whenever workpiecesof varying materials, shapesand sizes are to be painted.These systems are valued fortheir high flexibility and multi-task programming possibilities.
The cleaning, pretreatment andE-coat stages are serviced byone or more programmablehoists. Computer controls allowflexible sequences and treat-ment times in the tanks depen-ding on workpiece and mate-rial.
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Cathodic E-coat with programmable hoistfor automotive parts.
Cathodic E-coat system with flexibleprogramming at a custom coatinghouse.
A variety of automotive components are cleaned, pretrea-ted and painted in this cathodic one-coat E-coat system.
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Economic and compact:
The „Easy Coater“ Square Transfer System
Easy Coater systems are usedfor the electro coating of a variety of work pieces where anall-immersion process is desira-ble and space is at a premium.
All work pieces are processedin a synchronized square trans-fer pattern based on a fixedcycle. The paint curing oven is arranged above the processtanks reducing the floor spacerequirements substantially.
Loading and unloading theEasy Coater is usually perfor-med by a Power&Free conveyor.The Power&Free conveyor canalso transport parts throughthe cure oven in plants nothigh enough to accept a topmounted oven. Another featureof the Power&Free conveyor isthe integration of your coatingprocess into other processesand your overall plant operat-ion.
Easy Coater System E-coating parts for a heavy truckmanufacturer
Cooling zone
Curing oven ( may be above or next to the Easy Coater )
Lift carriage
Drive carriage
Power&Free-conveyor
Automatictransfer
Automatictransfer
Work piece
Dip tank
High Volume Production with Uniform Workpieces:
Continuous Dip Coating Systems
Continuous systems are wellsuited for high rates of produc-tion and uniform loads; but not for oversized workpiecedimensions.
Required dwell times in pre-treatment, dip tanks and curingovens result at times in a largersystem layout than is commonwith indexing systems withhoist technology.
However, they have the relativeadvantage that workpieces flowdirectly through the system on overhead or power & freeconveyors without having to be transferred to lifting andlowering stations.
This saves on transfer equip-ment and related control costs.
Continuous dip painting is themost frequently used painting process for radiators.
Diagram of a continuous dip-coating system.
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Even very large or heavy work-pieces, such as this machineassembly, are no problem for acontinuous dip painting system.
Cleaner Processing Technology:
Cleaning and Pretreatment
Photo above: The cleaningand pretreatment bathsare completely integratedinto the painting processwith a programmablehoist system.
Wastewater-free evapo-ration for the recycling of rinse water.
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Highly effective cleanerbath recycling throughultrafiltration.
Pretreatment systems operatesolvent-free with wet chemi-cals and integrate advancedenvironmental technology.
Bath maintenance and increa-sed bath life for rinse and pro-cess baths are not only econo-mical, but are also required bycurrent government regulati-ons. Rinse water is cascadedrepeatedly or recirculatedthrough a filtration system.
The life of cleaner baths canbe increased relatively easilyby a multi-stage approach orthrough the use of continuousseparation of oil and sludge.Still more effective for highconcentration is the use of"Carbosep Ultrafiltration” inthe cleaner bath recirculation.
Rinse
RinseCleaning bath
UltrafiltrationOil concentrate
Waste water Water
Active bath
DistillateEvaporatorConcentrate
Designs range from simplestraight-through ovens toelevated multiple pass ovenswith energy saving bottomentry and exit and optimizedheat energy concept. Indexingsystems with programmablehoist utilize a top-loading orcontinuous oven.
EISENMANN builds custompaint curing ovens adapted totechnical specifications andeconomical feasibility withdirect and indirect heatingusing oil, gas, electric or reco-vered energy in the form ofthermal oil, hot water orsteam.
Energy-Efficient and Clean:
Paint Curing Ovens and Exhaust Air Purification
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Picture left: Cathodic top coatcuring oven with bottom entry/exitfor heat loss prevention.
Picture above: Thermal oxidizerwith heat recovery for purifyingexhaust air from the E-coat curingoven.
Heat recovery concept when curing paint: Thermal oxidation as exhaustpurification and energy supply.
Thermal oxidation
Exhaust air
Bottom entry
Intelligent Controls:
Handling and Controls
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Microprocessor-based controlsare also being used more frequently for smaller systems.They profit from powerful, yet economic hardware and our software experience gainedwith large and complex paintlines. We have been able toachieve a technological edgethrough constant updating ofthe synergy potential of ourconveyor and handling techno-logies.
Above: Indexing system with programmable hoist and roller conveyors connecting load and unload stations.
Control center for an automotive paint line.
EISENMANN designs and buildscustomer-specific material-flow systems such as chainconveyors, power & free, skidconveyors, hoist systems, lifting and lowering stations aswell as tailor-made special con-veyors. Combined with intelli-gent computer systems andsoftware developed solely forthis purpose, they form the basis for fully automatedproduction in your company.
Transport to unloadUnload withfork lift
Load
Lift tableTransfer
Waste watertreatment Pretreatment Programmable hoists E-coat tank UF-rinse
UF-
rins
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UF-
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DI-r
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Pass
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Rins
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Rins
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Rins
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Zn-
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Acti
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Rins
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Rins
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Degr
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Degr
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Tran
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Shuttle cartwith lift
table
Thermal oxidizer
E-coat curing oven withcooling zone below
Remote service is possible with the transfer of digital images and data over telephone lines or the Internet. With this option, servicespecialists can immediately help maintenancepersonnel by sending them instructions.
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Within a manufacturing areavarious conveying methods are available, such as electricmonorail systems (EMS), rolleror skid conveyors.
Service and MaintenancePreventive maintenance and continuous system improvements are the basis for lasting operational readiness and trouble-free operation of your facility.
EISENMANN offers an extensive package of service programs:
1. Periodic service
2. Full-time service
3. Complete service
Facility telemaintenance per PC and modem is the latest trend. Our service technicians remotely monitor your facility per PC from their workstation and, in many cases, re-establish system operations after a malfunction without makingan on-site service call.
Long term monitoring with alarm data analysis support preventive maintenance.
EISENMANN Corporation150 East Dartmoor DriveCrystal Lake . Illinois 60014 . USAPhone +1 815 4554100Fax +1 815 [email protected]
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OOO EISENMANNUl. Pyatnitskaya 47-1119017 MoscowRussian FederationPhone +7 495 951-6824Fax +7 495 [email protected]
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Daimlerstrasse 571088 Holzgerlingen . Germany
Phone +49 7031 78-0Fax +49 7031 [email protected]
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