External pre-conditions for

two-tone painting with EcoPaintJet

October, 2020
Chennai Prashanth Alevoor, Head - Application Technology
Contents

1. Definition of two-tone paint process

2. Pre-conditions layout,
automation concept
3. Pre-conditions booth (process)
and object (car body)
4. Pre-conditions paint, paint supply

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Definition of decor paint process
Possible processes for two-tone application (decor painting)

a) Offline 2-tone process for BC with transfer-out & -in

Interm.
+ cycle time of Topcoat line remains
BC
Drying
Cooling Transfer- CC Drying independent of DC application
complete complete out / in complete complete
complete
+ Integration: Greenfield: simple Installation
Interm. Brownfield: high effort (space required)
DC Cooling
Drying
Roof Roof
Roof + 2-tone capacity: scalable up to 100%
depending on available space in the 2-tone area
+ for water based BC the process is market-ready
b) Offline single layer (monocoat) after standard Topcoat line
Interm. + Separate, robust paint process on cured CC.
BC Cooling CC Drying
Drying
complete
complete
complete complete complete no impact on cycle time of Topcoat line
+ Flexible positioning of DC application in the paint
Tran- DC Drying shop layout
sport Roof Roof
+ 2-tone capacity: scalable up to 100%
recommended solution = Box concept

Legend: BC = Base Coat; DC = Decor Coat (adapted for OFA applicator); CC = Clear Coat; sb = solvent based; wb = water based
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Pre-conditions layout & automation concept
Positioning and installation of the DC zone in the paintshop

Layout Automation concept

 Stop&Go robot station for DC application  Painting robot with all paint application functionality
 Robot zone do not require any scrubber (dosing, color change, applicator cleaner, etc.)
Installation can be placed on "normal" floor, e.g. concrete  High-precision 3D-measurement of car body position and
 Additional space needed geometry (tolerance compensation)
− for process a) (BC application)  Robot installed on rail (7th axis)
− intermediate drying (oven) of contrast surface  Auxiliary equipment for regular (automated)
− cooling of contrast surface − Applicator cleaning
− for process b) (Monocoat on cured CC) − Jet inspection
− final drying (oven) of contrast surface  Automatic generation of painting paths
 No additional space needed for masking/de-masking  3D-model of car body required
 In case 1 robot is sufficient to paint the contrast surface,  Other required information:
the booth can be more narrow (e.g. 4,5 m instead 5,5 m) − ratio of two-tone bodies from complete production or
 Robot (rail installation) must be de-coupled from the cycle time for the new process
building (avoid vibrations) − cycle time in TC-line
 Substructure must be strong enough for high precision  Sequence of usual and 2-tone bodies in the TC-line must
application be defined for optimum production output

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Pre-conditions booth (process) and car body
Marginal conditions to be considered

Process Air Contrast surface (of car body)

 process air in similar quality (humidity, temperature,  horizontal surfaces, inclination max. 20-30°
purity) as for other paint zones  Flat surface or slightly bended (like car body roof)
 downdraft can be reduced to approx. 0,15 m/s  Start/End of paint path are outside of the contrast surface
usually > 0,25 - 0,50 m/s, depending on atomizer − means for example that the window flange is painted
 air recirculation is possible (energy saving) completely or partially and needs to be covered later

Oven capacity
 must be sufficient for the contrast surfaces, not for the
complete body

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Pre-conditions paint and paint supply
Marginal conditions to be considered

Paint for Decor coating Paint supply

 Starting from the usual BC paint, the decorative paint DC  the same kind of paint distribution can be used as for
must be adjusted usual paint, considering the chosen process:
 the adjustment will be done in cooperation with paint  the DC paint needs its own paint system
manufacturers.
 the feasibility of the DC paint needs to be confirmed by
paint test.

 For every customer, it is important to have the test trial to be done at Durr test centre in Germany, with
the car and the paint adapted to the applicator requirement.
 Test duration anticipated to be 2 weeks.
 Customer to supply Paint and trial vehicles in good condition for the tests.
 Based on the results, proposal can be made for the application solution.

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October, 2020
Chennai
www.durr.com

Prashanth Alevoor, Head - Application Technology

External pre-conditions for

two-tone painting with EcoPaintJet
“Subject to change. The information in this presentation contains only general descriptions or performance characteristics,
which may vary in different cases. The requested performance characteristics are only binding it they are expressly agreed
in the contract.”

Dürr Systems AG
34, Carl-Benz-Str.
Bietigheim-Bissingen
Germany, 74321

+49 7142 78 2437

meinhard.lutsch@durr.com