Movement Technology: Accurate and Economical Coating
The automatic electric reciprocators are subjected to constant loading, so the reliability and robustness of the reciprocator mechanism is particularly important. The electronic controller offers the latest movement technology for high quality application requirements and an optimal surface finish.
A very wide variety of work pieces have to be coated. Intelligent movement technology leads to better coating quality and a massive reduction in the powder consumption. The automatic reciprocators are controlled using the following control concepts:
Central control module CCM Prima and reciprocator module RCM Prima
Central control module CCM-D1 with reciprocator controller LSR-D1
The stroke speed can either be held steady, or two different stroke speeds can be set. For example a specific coating zone can be traversed more slowly or more quickly, and thus more or less powder applied.
This is used in a combined reciprocator and gap/height controller for horizontal gun arrangements. It offers considerable benefits when coating work pieces with different dimensions as part of one coating order. The reversing points for the guns are variable so the part can hang at any height required. In addition to this, the automatic powder reduction will ensure that with shorter stroke movements the powder output will be reduced to suit.
For uniformly distributed film thickness on flat parts the automatic sine curve is used. This guarantees that the whole surface of the work piece will be covered evenly. For this the gap/height controller module measures the actual speed of the conveyor. The controller for the reciprocator calculates the optimal lifting and lowering speed from the stroke height and the conveyor speed and regulates these to suit.
Suitable for more complex automatic coating processes with a maximum of up to 12 powder guns. The reciprocator slide is fitted with 16 rollers ensuring smooth stroke movements without any natural vibrations.
Due to its motor rating of 0.75 kW, it is best suited for simple serial coating processes.
For the vertical arrangement of spray guns. This allows an optimal integration of compact, fast color-change booths into the units.
With this control module the short stroke unit can be controlled with a DigiTech system:
A special feature is the Delta matching. When using short stroke units the work pieces are coated more thickly at the top and bottom, because the guns have to travel a longer distance at the reversing points and therefore apply more powder. The SSR-D1 can increase the stroke speeds at the reversing points and thus distribute the powder evenly on the work piece.
The automatic depth controller is recommended for production runs with work pieces of different depths. The depth of the components is recorded immediately as they enter the booth, using horizontal light strips, and is passed on to the MRS-D1 control module.
The pre-defined position of the spray units is entered as a parameter for the work piece. When the parameter is called up, the guns are automatically moved into the desired position.
When changing the color, doing maintenance or cleaning the powder booth, the guns have to be moved out of the booth. The parking position can be pre-defined and stored as a parameter and if required be called up and automatically moved to.
With changing depths of work pieces, it is necessary to position the spray system correctly for spraying. The positioning trolley is also useful in the cleaning process, for color changes or to facilitate maintenance.
The “ZW” can be operated through a manual forward and reverse switch or by an external WAGNER Controller from the PrimaTech or DigiTech control systems.
Since the position of the work pieces is known precisely due to the recording of the component, the point of action of the guns can be specied exactly, so it is possible to dene a pre- or post spraying distance. The same applies if it is intended to spray over or under the work piece.
Work piece recognition by light sensors and tracking them when passing through the powder booth is a core function of all control variants. In comparison to simple time controls, the synchronization with the conveyor speed, using a pulse encoder flanged to the conveyor drive will avoid a collision between work pieces and guns. Conveyor speed can be changed at any time while control parameters are adjusted automatically.
The height controller is used with vertically aligned guns for coating components of varying heights. Here the stroke remains constant. The sequence and the gap between the parts of different heights can be freely selected. Powder guns that would spray past the work piece are not switched on.
Ensures that spraying only occurs when there is a work piece in front of the gun. The powder feed is switched off in the gaps.
The coating of complicated parts such as e.g. the internal coating of cabinets requires the individual movement of independent guns. The Z axis with rotary drive makes this possible without the purchase of an expensive robot.