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We
design and install the most efficient robotic paint
application systems available. We can significantly
improve the performance of most existing systems. If
your business includes robotic, semi-automated, or fully
automated production line painting processes incorporating
ABB, Fanuc, Kawasaki,
Motoman or other robots, NA Paint encourages you to examine your process
using the following guidelines. We can
support you at any level in this and can suggest and
implement methods to significantly improve the efficiency of your
automation. |
THE
PAINTING ROBOT
Painting
robots can have a tremendous impact on the efficiency of paint
application processes. Like any tool, however, it is only as
efficient as the person using it. Robots helpful
characteristics are their strength, speed, accuracy,
repeatability, and endurance. If the owner can utilize these
advantages in an efficient method
of paint application, his or her system can often be dramatically more
productive and economical, with less environmental impact than
other types of automation.
Often
though, programmers are not painters and visa versa. Or,
with time, the system has experienced a decline in operational
efficiency. Whatever the reasons, North
American Paint Applications can help you get out of your existing
robots the highest levels of productivity, quality, and
consistency that are attainable. We can likely make your
system considerably more efficient than the day it was
installed.
Robot
Support Requirements
A
robot can move from Point A to Point B at the same speed
repeatedly. To apply paint efficiently and consistently,
more is required. First, the target, including its style, movement,
and location, must be known. Second, the flow rate control of paint
should be accurate, adjustable, and responsive to the application
process. Third, the size and shape
of the spray pattern should be controllable, adjustable, and
responsive to the application process. Fourth, on/off
trigger time for the applicator should be very fast and
repeatable. Fifth, transfer efficiency should be consistent. Lastly,
spray booth conditions ought to remain relatively consistent.
Variations
in any of these support systems reduce the overall efficiency of
the paint application process to the extent that it affects the
worst case condition. For example, suppose the flow rate of
dispensed paint cannot be controlled with accuracy. To
prevent light sprays, flow rates must be increased to a level for worst
case. This increase then affects the entire cycle, resulting
in the use of more paint, variations in spray patterns that affect transfer efficiency and quality, and an increase in
overspray.
Discussions
regarding color
change, overspray,
finish quality,
and paint
supply systems can be found on other
pages of this site.
System Integration
Robotic
or other paint application automation requires efficient
integration with every other supporting paint process system to
achieve good performance. To achieve the highest quality
finish in the most economical and productive way requires a broad
and special knowledge of paint process control that typical
control companies and engineers do not possess. All systems
must be inter-supporting and set-up for best performance.
Despite
owning and using the best equipment available, without good system
engineering and integration, you may not achieve even an
acceptable level of paint application performance at any cost, and
your system will certainly never achieve the highest level of
performance or productivity.
If
for any multitude of reasons your robots do not achieve first time
yields and up time in the high ninety percentile range, then your
process can be improved.
Robot
Path Economy
Whether
your automation support systems are reliable or not, there is much
that can be done in the programming and set-up of the robot to
increase overall system efficiency. Triggering
paint off the part or triggering when no part is present, improper head to target
distances, improper
angles of application, excessive mechanical force in abrupt turn around
points, excessive atomization, and large spray patterns are some
of the control variables that affect the application efficiency of
automated systems.
A
robot fault, for any reason, can often severely impact both
up-time and first time yields. Robot faults associated with
any movements, singularities, line stops, or applicator operation
are preventable.
In
addition to poor transfer efficiency, throughput and cycle times
are adversely affected by needless wait commands and movements of
the robot when it is not painting the target. These should
be minimized.
When
two or more robots paint the same target, with perhaps door
openers incorporated, a well conceived and orchestrated
application program can have a dramatic impact on overall process
efficiency and quality.
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