Automobile Industry (4) | Intelligent Manufacturing Application Sharing in Automobile Painting Workshop, Helping Intelligent Manufacturing Upgrade of Automobile Industry

Based on the combing and analysis of the current research status and trends in the automotive field, the characteristics and internal laws of automotive interior and exterior coating materials and processes, this article elaborates on the future development direction to meet the requirements of automotive interior and exterior coating design and application, combined with CASUN Intelligent for 14 years The smart logistics implementation project experience in the car park explored how to solve the pain points of the car body painting, formulate the direction of the intelligent coating planning and the application of AGV in the paint shop.

Introduction to Automotive Painting Workshop

The task of the paint shop is to coat the body-in-white completed in the welding shop with layers of paint. In addition to strengthening the body’s anti-rust, the main purpose is to make the body look more beautiful. The painting workshop mainly applies various processes to coat the paint on the surface (surface of the base) and dry it to form a film or spread the paint on the surface of the paint. The function of painting is mainly to protect and decorate. The painting process generally requires cleaning, electrophoresis, color paint, varnish, and other steps. In this process, automation and intelligence are more demanding.

As one of the five main processes of automobile OEMs, body painting realizes the three basic functions of body anti-corrosion, sealing, and decoration. Due to the high cleanliness requirements in the workshop, the variety of equipment, and the high degree of automation, it leads to a large investment in a process. Once it is stable When it is put into production, the investment in the later new models is often the lowest among the other major processes, but the production of car body coating is a large energy consumer, a large consumer of consumables, and a large consumer of harmful solid waste and VOC emissions. On the basis of advanced technology, the intelligent planning of car body painting is also an effective way to solve these pain points.

The development direction of intelligent automobile coating

The salient feature of the paint shop is that the process layout generally adopts a multi-layer, three-dimensional, regional, and clean layout. The body coating and painting use robots. There are many elevators in the workshop, the total power of the drive motor is large, and the body transportation is fully automated. The conveying distance is long, and in order to guarantee the production of multiple varieties of body coating, a large amount of energy needs to be consumed. In order to reduce energy waste, the plant is designed in accordance with sealing, heat insulation, shock absorption, noise reduction, and full air-conditioning air supply. From the analysis of these characteristics, through the deployment of various sensors and big data analysis, the car body painting is upgraded from the automation stage to the intelligent stage, and the realization of intelligent painting can effectively reduce the energy consumption of a single-vehicle. The following aspects can be explored.

The key directions of intelligent car body coating:

1) Building an intelligent transportation system;
2) Intelligent control of car body marshaling station;
3) Intelligent air conditioning management system;
4) Intelligent temperature control system;

Intelligent transportation upgrade for body painting

The coating process generally requires cleaning, electrophoresis, paint, varnish, and other steps. The coating workshop has a long conveying distance. The total conveying distance of the 60JPH workshop is as long as 6–7 kilometers. , Material storage, material preparation, distribution, coating production line side transfer, etc. can all use intelligent conveying equipment in large quantities. Of course, AGV plays an important role, such as the automatic transfer of the white body after painting through the AGV.

Intelligent transportation upgrade for body painting

The coating process generally requires cleaning, electrophoresis, paint, varnish, and other steps. The coating workshop has a long conveying distance. The total conveying distance of the 60JPH workshop is as long as 6–7 kilometers., Material storage, material preparation, distribution, coating production line side transfer, etc. can all use intelligent conveying equipment in large quantities. Of course, AGV plays an important role, such as the automatic transfer of the white body after painting through the AGV.

Application of AGV in coating process

The paint itself is very harmful to the human body, and the entire coating production line is almost an unmanned production line. Manual work is mainly in material scheduling, paint mixing links, production line monitoring and equipment support services. In terms of the degree of automation of a single production line, 100% automation is basically achieved, and AGV is more widely used, mainly used in the transportation of car bodies.

AGV application benefits

Reduce cost and increase efficiency

AGV/AMR can realize 24-hour high-speed repeated operation, and the work cycle is much higher than that of labor, so it can greatly improve the work efficiency of the paint shop, and also reduce labor costs and management costs.

Safe and reliable

Avoid repetitive, boring procedures and heavy manual labor’s impact on workers’ status, avoid the resulting quality degradation and accidents, and effectively improve production safety and product quality.

Green

AGV/AMR can operate in a dark field environment and can reduce the working space, thus effectively reducing the energy consumption rate and the material consumption rate.

Flexible production

AGV/AMR can be flexibly increased and decreased to promote the flexible process of manufacturing, and to achieve the rapid delivery of orders by sales and production.

Precautions for AGV application scenarios

Accurate docking of AGV and spraying production line

The spraying line in the painting workshop is relatively fixed, and the workload for each additional model or location modification is very large, and even needs to be dismantled and reconstructed. In order not to affect the production of the models in production, the transformation time is usually very short and the transformation is difficult.
Because the position of the AGV trolley is not fixed, the production site can be changed arbitrarily, breaking the fixed demand mode of space for the line body.
The paint shop has a high degree of automation. With the support of the intelligent management system, the application of AGV needs to focus on the docking with the original spraying system and the optimized management of the handling route, so as to give full play to the flexible production advantages of AGV in the coating process.

Precautions for AGV application scenarios
Accurate docking of AGV and spraying production line

The spraying line in the painting workshop is relatively fixed, and the workload for each additional model or location modification is very large, and even needs to be dismantled and reconstructed. In order not to affect the production of the models in production, the transformation time is usually very short and the transformation is difficult.
Because the position of the AGV trolley is not fixed, the production site can be changed arbitrarily, breaking the fixed demand mode of space for the line body.
The paint shop has a high degree of automation. With the support of the intelligent management system, the application of AGV needs to focus on the docking with the original spraying system and the optimized management of the handling route, so as to give full play to the flexible production advantages of AGV in the coating process.

AGV anti-paint performance

The spraying workshop is highly painted, and the AGV is inevitably exposed to the paint when entering and exiting the spraying workshop during transit. Therefore, the AGV needs to have a certain degree of paint resistance and solvent resistance, which is easy to clean and keep clean;

AGV is highly adaptable to workstations

After the white body is sprayed, the weight of the body increases, which is generally about 1000KG. The AGV used for handling needs to have a certain degree of rigidity to meet the precise docking with the workstation under different load conditions.

Increasing living standards have changed people’s demand for automobiles, and more and more personalized needs are driving changes in automobile manufacturing methods, and advanced production lines with high flexibility and high intelligence have emerged as the times require. AGV replaces the traditional fixed conveyor line to make production more flexible, breaks the limitation of traditional production line platformization, and can realize mixed-flow production on different platforms and more models; at the same time, it breaks the boundaries of the production process and can formulate corresponding production processes according to different processes. , Production path, so as to make more reasonable use of production resources, and promote the realization of the development of “Industry 4.0” in the automotive industry.

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