World’s leading mechanical and
plant engineering firm Dürr announced early this year the launch of EcoInCure
that offers best possible top-coat quality and maximum process reliability by
heating the bodies from the inside in combination with the innovative
transverse mode of operation.
Car major Skoda will use the
benefits of the new Dürr oven in the future in the Mladá Boleslav main plant in
the Czech Republic. Dürr is supplying all the system and application
technology, including the building, for the new paint shop.
EcoInCure features nozzles with long throw distances that blow hot air
into the inside of the body through the opening for the windshield. The flow
velocity around the outer skin of the body during this process is minimal. This
results in an undisrupted paint appearance with maximum quality. At the same
time, optimum transfer of heat inside the body enables extremely homogeneous
heating of both thin sheet and mass parts.
The result is up to 30% shorter heating times
with minimised thermal component stresses, which is especially important for
drying electric vehicles and multi-substrate bodies. The heating concept of
EcoInCure reduces the electrical energy requirement by 25% and regulates the
drying temperature with previously impossible precision and speed. The exhaust
air from the ovens is purified via the integrated Ecopure TAR afterburning
system with heat recovery and then used for the oven heating system. The entire
plant including data acquisition, data evaluation, and plant monitoring is
controlled by the Dürr software solution iTAC.MES.Suite.
The modular MES system
provides detailed information on the production workflows and the consumption
data at all times. For the first time, for example, Dürr is using the
electronic quality card for the drying process, which makes it possible to
track the drying quality of each body. This tried-and-tested technology from
Dürr is already used to coat well over 10 million bodies worldwide each year.
The latest Dürr robotic
generation is used in all process steps involved in painting. From the primer
to the base coat and the clear coat line, a total of 61 EcoRP third-generation
painting robots ensure efficient paint application. The exterior painting is done by the EcoRP E043i, the first painting
robot where the seventh axis is integrated into the robot’s kinematics. Two or
four robots are installed in each of the exterior painting cells. The
stop-and-go painting process means that they do not need a rail. This enables a
much better view of the booth, and eliminating the positioning axis
significantly reduces the maintenance effort in the robot cell.
The interior painting stations
are equipped with the six-axis robots of the type EcoRP L133i, which are
mounted on a rail. The identically constructed EcoRP L033i model without rail
is used for opening the hoods. The robots are assisted by Scara door openers.
The latest Dürr robot generation has a modular structure. The only difference
between the six- and seven-axis models is the additional axis of rotation in
the main arm. The otherwise identical components simplify spare parts
management, save storage costs, and make maintenance easier.
The robots are equipped with
the latest Dürr application technology. The EcoBell3 atomizer series together
with the associated EcoBell Cleaner D2 and the EcoLCC2 color changer delivers
low paint and solvent consumption as well as fast color changes within the
The third generation of Dürr
robots is controlled by the also newly developed EcoRCMP2 process and motion
controller. The control platform combines a multitude of sensors and actuators
in the painting robot and the higher-level maintenance or control systems. An
integrated interface makes the robot “cloud ready” and provides all relevant
data for current and future requirements in the Industry 4.0 landscape.
Even before the bodies get
their layer of paint, the welding and gluing seams are sealed fully
automatically. This ensures that no water can infiltrate into the vehicle
interior later. Dürr is installing a total of 19 EcoRS sealing robots with the
latest application technology at Skoda in Mladá Boleslav. These robots
undertake the task of sealing the seams from below, inside the body as well as
at the roof seams. The EcoDryScrubber, a dry separation system with limestone
powder as the binder, will take over the paint overspray separation in the
spray booth. This system requires no manual handling as it is fully automated,
robust, and easy to maintain, and requires no adaptation to different paint
systems. This makes it ideal for high-volume plants such as at ŠKODA. An
important point is the energy saving of up to 60% in the spray booth. By
completely eliminating water and chemicals, up to 90% recirculated air can be
used in production. This reduces the cost of conditioning fresh air and is the
deciding factor in the outstanding energy efficiency of the spray booth.
The performance of the
EcoDryScrubber is further improved through the use of the new V5.X system
software. It enables the system to be self-regulating. As a direct result,
optimum use is made of the limestone powder for binding the overspray, thereby
The dry separation system
results in highly concentrated and especially efficiently filtered exhaust air.
This enables a very compact air purification system, consisting of a highly
efficient VOC adsorptive concentration system (Ecopure KPR) with downstream
thermal exhaust air purification system (Ecopure TAR). The energy needed for
the Ecopure KPR system’s desorption air is recovered from the purified gas of
the thermal exhaust air purification system. This reduces the investment costs
for the exhaust air system by 60%. The energy requirement for exhaust air
purification is reduced by 80% in this combination.
The plant is designed for a
throughput of 30 vehicles per hour, and will be painting Skoda’s mid-range
models from June 2019.
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