Smart solutions paint shop 4.0

Smart solutions for paint shop 4.0

6:34 AM, 21st June 2018
Automated software for paint shop 4.0. © Eisenmann
Automated software for paint shop 4.0. © Eisenmann

The optimal link-up of flexible hardware with intelligent software, complemented with innovative digital services, maximizing customer benefits – with this in mind, the German painting plant manufacturer Eisenmann is tackling the challenges of the future. The aim is to build the “Paint Shop 4.0” for the automotive industry and other sectors.

How far the possibilities of digitization in surface treatment have developed in the meantime was shown to the visitors at several trade fairs with Eisenmann participation. Around 1,000 guests from 34 nations, mainly from the automotive industry, came to the Eisenmann Technology Days at the Technology Center in Holzgerlingen near Stuttgart to see the latest solutions for surface treatment in Industry 4.0. Innovations in the areas of engineering, application technology, paint shop solutions, service and production control systems were also in the spotlight at the PaintExpo in Karlsruhe and at the Hanover Fair.

Efficiency and flexibility

Eisenmann solutions for paint shops arouse great interest. VarioLoc, the skidless paint shop transport system for car chassis, revolutionizes the painting process by replacing expensive skids, thus drastically reducing investment costs by up to 38 percent. Users also benefit from higher system availability and a significant reduction in operating costs. In combination with the dryer concept Smart Oven, which is skidless and has swivel nozzles, energy savings of up to 37 percent are possible compared to conventional dryers. Eisenmann is also a leader in application technology. New developments of high rotation atomizers such as the compact VarioBell, available with direct charging as well as with external charging, enable efficient painting through fast color change with minimal paint loss. Other highlights are current technologies in the fields of sealing and gluing.

Networking flexible hardware components into an intelligent factory has been a major challenge to date. With the modular Manufacturing Execution System E-MES from Enisco (Eisenmann Industrial Software Company) this becomes reality: It captures, analyses and visualises large amounts of data and brings maximum transparency and foresighted intelligence into the production processes around the painting plant.

Smart Service Solutions

The factory of the future is rounded off by smart engineering and service solutions along the entyre value-added process. The automated software creation with E-PASS allows virtual commissioning on the Digital Twin and thus intensive testing of the complete system software in advance. This shortens the time to the start of production, processing risks are identified at an early stage and can be corrected in good time. This reduces project runtimes by up to 30 percent.

New possibilities also in After Sales: All machines, functions, customer-specific information and documents are managed via a central administration and service platform, the Eisenmann Service Cloud. This tool has state-of-the-art IT security standards for maximum data security and can also be integrated into existing cloud solutions. The service app for mobile devices serves as an interface to the cloud. It is equipped with various standard and individual functions with which documents and services can be accessed quickly and directly. If necessary, remote support is simply requested and a connection to the service technician is established. Communication takes place by scanning QR codes on the components or via smart glasses on which the customer receives relevant information and instructions. The app enables users to view their systems from anywhere in the world at any time.

Innovative hardware

However, the basis for outstanding product quality remains state-of-the-art hardware. These include efficient atomizers, innovative paint supply solutions and modular high-pressure pumps for material supply. Clever technologies such as the infrared thermal imaging camera in the powder coating oven also contribute to optimum surface quality. In addition to the established VarioBell v.2 high rotation atomizer, which is used for all component requirements due to its compact design and variable spray jet – from complex cavities and undercuts to wide surface coatings – the newly developed VarioBell v.3 opens up further options: Combined with the VarioCharger metering and potential separation system, it allows the application of 2-component water-based paint under high voltage.

Compact and flexible: VarioBell v.2 atomizer. © Eisenmann

World premiere at Lamborghini

In Sant’Agata Bolognese, Italy, the luxury SUV Urus from Lamborghini will be painted in a Smart Paintshop from Eisenmann, in keeping with the spirit of Industry 4.0. This system revolutionizes classic automotive painting: away from the rigid line principle to highly flexible workshop production with line elements. This means that currently available production resources such as dryers or certain painting booths can be used efficiently, even if different paint variants or components made of different materials are produced simultaneously on the line.

In a world first, each Lamborghini Urus car body is individually painted according to customer-specific instructions. Usually a very difficult and costly undertaking in serial automotive painting. The design and layout of this plant, which will be completed at the end of 2018, form the basis for the paint shop’s high degree of flexibility.

Series production with batch size 1

Here, too, the E-MES production control system forms the head. The intelligent control system with online planning, material flow control and integrated digital operator guidance takes automotive painting to a new level. “With E-MES, we have succeeded in clearing the way for painting a wide variety of bodies, materials and end-customer-specific surfaces in a single system,” explained Enisco managing director Werner Gruber. “For a long time, production systems have been engineered to support standardized high throughput processes. We are now able to implement highly flexible series production with batch size 1,” he continued. In addition to the production control system, Eisenmann is supplying a sealing system complete with material supply, equipment, top coat spay booths fitted with E-Cube for overspray removal, dryers, a high-bay warehouse, conveyors, and workstations. Thanks to direct charging, VarioBell for top coat applications can be used for interior and exterior painting as well as for painting plastic and metal components. In accordance with the principle of highly flexible workshop production, the various painting processes are thus covered with just one bell.

“The optimal combination of flexible hardware, intelligent software and digital services was achieved at Lamborghini by exploiting all the synergies of Eisenmann,” explained Gruber. This is how intelligent, networked and individual production becomes reality at the Italian forge for super sports cars.

Urus Production. © Lamborghini 

Product quality prediction

Industrial change through digitization, however, goes even further. Enisco is working intensively on integrating all software components to implement the production system of the future: in addition to dynamic production planning, the core is an intelligent production control system that enables the tracking of individual parts and the complete documentation of the process, even beyond coating. This “birth certificate” of the workpiece serves as a basis for predicting product qualities within a Big Data Analytics platform.

As a founding member of the MindSphere World user organization at the Siemens MindSphere booth in Hanover, Eisenmann demonstrated new possibilities: “With the help of IoT platforms and our applications, our customers can network their own production systems worldwide and thus obtain unprecedented comparability of their production, quality and maintenance data,” explains Daniel Hartmann of Enisco. Thanks to this transparency and big data analytics, users can gain comprehensive insights and sustainable increases in the efficiency of their production systems.

Paint Shop builder shop builder Eisenmann has developed into an experienced system supplier offering comprehensive solutions and services in all areas of surface treatment: from flexible conveyor technology such as the Moveable Hoist System and the efficient E-Cube paint separation system to comprehensive services and operator models. Eisenmann builds the paint shop of the future.

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