Project №197

Project №197 for the client:

• Automated powder coating line
• E-COAT PRO AUTO/Set of sprayers
• E-CONTROL PRO/Control cabinet
• Electro Motion ZX02® (1500 mm)/Robot manipulators
• 150 LT. POWDER COATING TANK/Tank for paint
• E-COAT PRO V2 HOPPER/Manual installation for applying powder paint/with a tank
• Spray chamber KN-2 complete with column filters (P-6)

General information about the line

Automated conveyor line for applying powder polymer coating with a zone for preliminary surface preparation of products.
Products are hung on the overhead conveyor manually. To increase the productivity of the line, use the densest and uniform hanging. The products are placed on hanging hooks (not included in the delivery), which can withstand the appropriate weight and are able to ensure high-quality grounding of the products.
In the degreasing zone of the sink, the metal surface is cleaned of oil and dirt. Washing zones are designed for cleaning products from chemical solutions.
The product is heated in a drying oven to evaporate water from the structure.
The spraying chamber is used to apply the polymer coating manually.
Sintering of the paint takes place in the polymerization furnace at a given temperature of up to 230 ºC.

Recommended conveyor speed: from 0.8 to 1 m/minute.
Maximum weight of products: up to 50 kg.
Maximum dimensions of parts: 2000 mm x 1000 mm x 50 mm.
90% of parts with dimensions up to 1000 mm x 500 mm x 200 mm.
The details are metal panels made of low-carbon steel and galvanized steel of various shapes.

Up to 320 kW is required for the line to go into operation (about 1 hour).
Further, the line operates in the range of up to 300 kW. Available up to 300 kW/(320 kW).

Nominal heating capacity of the line at start-up and exit to working mode:
Surface preparation: ~ 54.75 kW
Drying oven ~ 68 kW
Polymerization furnace ~ 194 kW
Sputtering chamber ~ 15 kW
Drive 1 kW

Necessary leads to the line:
Electricity 380V / 50Hz.
*Air: Mach 1500 l/min. pressure 6 Bar (cleaned of moisture and oil).
* Water: Max 10 l/min.

Washing machine – aerosol type surface preparation line (3 sections)

Type of heating: electric. Shades – 6 pieces of 6.3 kW each = 37.80 kW.
Water heating: 40-60 degrees.
The size of the tanks – chemistry: 1650x2200x850,
wash #1: 1650x1000x850,
wash #2: 1650x1000x850.
SPERONI monobloc pump: 3 pcs. Pumps 12 kW.
Air curtains: 2×2.2 kW. Exhaust fan: 0.55 kW.
The material of the tunnel body is stainless steel AISI 304, thickness 1.2/1.5 mm.
Metal structures – steel 3 with powder coating.
The material of the baths is AISI 304 stainless steel. The material of the nozzles is AISI 304 steel.

Desiccator

Type of heating: electric with forced convection of hot air.
Power of the TEHiB cassette: 60 kW.
Convection fan: 4 kW.
Air curtains: 2×2.2 kW.
Exhaust fan: 0.55 kW.

Spraying chamber under the manipulator, with a cyclone and a block of filters

Materials:

• The camera cabin is AISI 304 stainless steel with a thickness of 1.2 mm.
• Cyclone, filter block, recovery system – St3 with powder coating.
• Cyclone – 1 set.
• Block for 9 filters (Ø 320×600 mm), electromagnetic valve – 9 pcs.
• Exhaust fan: 15 kW. Lighting: (15W) – 6 pcs.
• The box is stainless steel.

The first level of the camera is automatic painting of 6 guns, three on each side. Next – post repainting (OTK) on both sides. The door in the body of the spraying chamber (place of the painter). The painter is standing on the floor, outside the case – the spraying chamber.

Polymerization oven

Type of heating: electric with forced convection of hot air.
Power of the TENs cassette: 2×90 kW.
Convection fan: 2×4 kW.
Air curtains: 2×2.2 kW.
Exhaust fan: 0.55 kW.

Cardan type conveyor

Conveyor length: up to 150 m/p.
Recommended conveyor speed: from 0.8 to 1 m/minute.
Drive mechanism with a reducer: 1 kW.
Interval between suspensions: 400 mm.
Suspension load capacity: 25 kg x 2 points = 80 kg/suspension.
Automatic lubrication station in 4 points.

Power cabinet with control panel

The line is equipped with one control panel, from which the start-up and control of all processes of the system are carried out.
Additional conveyor emergency stop buttons at the painter’s workplace and in the product hanging area.

E-COAT PRO AUTO

E-COAT PRO AUTO / Set of sprayers – 6 pcs.
Automatic powder coating gun.
Weight: 900 gr.
Length: 350 mm.
Input voltage: 13 V.
Output voltage (max.): 100 kV.

Electro Motion ZX02® (1500 mm)/Robot manipulators

The stroke of the gun is 1500 mm. The height of the robot is 3100 mm. Platform width – 650 mm. Length – 900 mm. Weight – 348 kg. Max. load capacity – up to 50 kg, 200-240V AC 50/60 Hz 1.5 kV.

Spray chamber KN-2 complete with column filters (P-6)

Body parts are made of stainless steel AISI 430 1.2 mm.

Technical characteristics:

• Electric power of the camera, kW: no more than 8.8
• Mains voltage, V: 380
• Working pressure of compressed air, bar: 6.0
• Current frequency, Hz: 50