The VarioRobot EISENMANN

多功能喷漆机器人
Exterior Car Body Painting EISENMANN

• The needs
• The existing solutions
• The EISENMANN concept
The needs for exterior car body application EISENMANN

• Paint quality (thickness, appearance)

 Reduction of the sources of defects (dirt, spits…)
 Control of the paint path
• flexibility
 Adaptability to production rate variation.
 Open to tomorrow’s car design.
(complex shapes, specific and brand dedicated shapes.)
• Investment cost reduction.
• Operating cost reduction.
• Commissioning and new vehicle introduction time reduction.
• Easy to maintain and operate.
Solutions in the past EISENMANN
Solutions in the past EISENMANN
The existing solutions EISENMANN
The existing solutions EISENMANN
The existing solutions EISENMANNEISENMANN
Grenoble

Machines Robots
Paint quality (thickness, appearance) + ++
Reduction of defects sources (dirt, spits…) ++ -
Control of the paint path
+ +++
flexibility
Adaptability to production rate variation - +++
Open to tomorrow’s car design + +++
(complex shapes, specific and brand -- +++
dedicated shapes.)
Investment cost reduction + -
Operating cost reduction - +
Commissioning and new vehicle introduction - +
time reduction
Easy to maintain and operate ++ +
Synthesis for a solution EISENMANN

• To adopt the ‘clean wall’ concept

• To get the flexibility and accessibility of the robots.
• To improve investment and operating costs.
• To include performing simulation and programming tools
common for the complete paint shop.
The Eisenmann VarioRobot concept EISENMANN

• 2,4 or 6 ‘clean wall’ robots

• Dedicated for the application of the
outside of the car body
• Improved accessibility to the
difficult parts to be applied

• Improved flexibility due to the increased working area of the

robots
• One kind of robot for the complete surface to be painted
• Easy to simulate, program and use.
• Robcad simulation included in the package
The VarioRobot EISENMANN

• 5 axes robot
 4 polar axes:
• 2 hollow wrist axes
• 2 shoulder axes
 1 vertical ‘Clean Wall’ axe
• On board colour changer
 Up to 45 colours
• Based on proven
components
• Bosh Rho 4 robot controller
included

Film
mechanical characteristics EISENMANN
Details of construction EISENMANN

Rotating turret

Rotating sealing
curtain

Shoulder axe
rotation

Cables and pipes

routing

Up/down sealing
curtain
Steering architecture EISENMANN
VarioCad
Off-line Programming Man-Machine Communication
脱机编程 人机界面
On-line VarioProcess Editor
联机式过程编辑

ETHERNET TCP/IP 以太网

Robot control device

机器人控制器
Administration of Contours INTERBUS S
Administration of paint processes
轮廓管理
油漆工艺管理

Robot panel
机器人控制柜
High voltage generator 高压发生器
Servo-drive (Axis + Pumps)
Electronic valve
伺服驱动 ( 轴和泵 ) ，电磁阀
Programming EISENMANN
VarioCAD 3D Off-line Programming System
VarioCAD 三维脱机编程系统
Contour, apply, ON/OFF Programming
Simulation and Down-load function
轮廓、喷涂、 开 / 关 的优化， 模拟和下载功能

VarioProcess On-line Editor 联机式过程编辑

Contour, apply, ON/OFF, colour changing, optimisation
轮廓、喷涂、 开 / 关、换色 和 优化
Example of application with 6 Bells EISENMANN

Simulation
Example of application with 4 Bells EISENMANN

Simulation
Example of application EISENMANN
Stations configuration EISENMANN

Base coat area clear coat area

solid colors or primer area
solid content medium size 0,25 large size 0,25 large size 0,45
thickness 20 20 40
body width 1,5 1,8 1,8
body length 4,2 4,9 4,9

conveyor speed number paint flow number paint flow number paint flow
m/min of bells of bells of bells
1 2 164 2 180 2 200
1,5 2 245 2 270 2 300 2 bells Station
2 2 327 2 360 2 400
2,5 2 409 4 225 4 250 4 bells Station
3 4 245 4 270 4 300
3,5 4 286 4 315 4 350
4 4 327 4 360 6 267
4,5 4 368 6 270 6 300 6 bells Station
5 6 273 6 300 6 333
5,5 6 300 6 330 6 366
6 6 327 6 360 10 240 6 bells Station
6,5 6 354 6 390 10 260 + 4 bells Station
7 10 229 10 252 10 280
7,5 10 245 10 270 10 300
8 10 262 10 288 10 320
8,5 10 278 10 306 10 340
9 10 294 10 324 10 360
9,5 10 311 10 342 10 380
 Booth comparison EISENMANN
VarioRobot Booth : Length 10 m,width 3,8 m Area 38 m²
多功能机器人：喷房 长 10 米，宽 3.8 米，面积 38m²

Station VarioRobots
Longueur 10 m
Largeur 3,8 m
Surface 38 m2

Robot Booth : Length 12 m, width 5,5 m, area 66 m² + 73% air supply

普通机器人：喷房 长 12 米，宽 5.5 米，面积 66 m² ，增加 73 ％的送风
量
 Booth comparison EISENMANN

ESTA Booth VarioRobot Booth

自动机喷房 多功能喷涂机器人喷房

10 000
10 000

3 800
4 600
Main advantages EISENMANN

Quality
• ‘clean wall’ systems, no beam above the vehicle
• Increased flexibility and accessibility of the paint trajectories. Application less depending on the
conveyor advance
• Possible Simulation and programmation possible before commissioning on site

Flexibility
• improved flexibility due to the increased working envelop and increased number of axes tofit with
the design and paint constraint of the new vehicle
• Improved control of the paint path on the critical parts of the vehicle such as A,B,C pillars or
specific design
• high number of colours mounted on-board ( 45 maxi ) compared to robots (~25) and to machines
(30)

Low operating cost

• Reduced booth width : 4.1 m pour 4.6 m in a standard 9 bells station and 5,5 m for a robot
configuration
• Booth length equivalent to a standard 9 bells station but lower than a robot configuration
• Less guns 6 instead of 9 for a normal configuration
- savings of one third of paint and solvent waste at colour change
- savings of one third of the compressed air consumption 
• Important saving of cleaning cost compared to machines and robots
 
Low maintenance cost
- percentage of saving nearly identical to the reduction of number of bells
The existing solutions EISENMANNEISENMANN
Grenoble
Mac. Rob. Flexi-Bell

Paint quality (thickness, appearance) ++ + ++

Reduction of defects sources (dirt, spits…) +++ -- +++
Control of the paint path + +++ ++

flexibility - +++ +++

Adaptability to production rate variation. + +++ +++
Open to tomorrow’s car design.
(complex shapes, specific and brand dedicated - - +++ ++
shapes.)
Investment cost reduction + + ++

Operating cost reduction - + +++

Commissioning and new vehicle introduction time - + +++
reduction

Easy to maintain and operate ++ + +

PowderBell EISENMANN

Quick
connector

Speed control by
disconnectable optic
fiber
Integrated
high voltage
multiplier

Possible
counter
electrode
HighSpeedBell EISENMANN

• HighSpeedBell (70 Krpm)

• Air bearing turbine.
• Incorporated high voltage
multiplier.
• Extra small external diameter
(100 mm) to avoid paint
pollution on the sprayer.
• Different versions
• External charge
• 2K system
• One or two circuits
HighSpeedBell EISENMANN

Anti-drop paint and

solvent connectors

Optic
Optic fiber
fiber
Removable
shaping air
ring

Quick
connector
XS valve to trigger all
paint and cleaning
functions

Air bearing
turbine
HighSpeedBell EISENMANN

Connecting nut

External
View of the connector cover

from the rear

HV
multiplier
XS Color Changer EISENMANN

• Miniaturised and modular

Color Changer
• The smallest of the market
• Easy exchange and
upgrade
• Suitable for a wide range of
product : waterborne, 2K,
solvent borne, 3k, etc..
• Flow and return or dead leg
version
XS Color Changer EISENMANN

45° paint
connector

Inter-connecting
screw

¼ turn
connector
fitting

XS valve
External Charge EISENMANN

• no high voltage cable to

the needles.
•Reduced capacity,
improved reaction speed
•Specially designed for
robotic application.
•6 independent high
voltage multipliers (one
per high voltage needle).
External Charge EISENMANN

•Each multiplier to be 80
KV, 80 µA. (total 480 µA).
•Control of the tension and
average current
•Better control of the each
needle no short circuit via
one needle.
Shock absorber
(max loss 80 µA).
resistor Low voltage transformer

High voltage
multiplier
Internal Charge EISENMANN

• Cartridge system to be
mounted on VarioRobot or
other multi-axes robots.
• Two cartridges system: one
in use, one in cleaning/filling
phase.
• Direct connection to each
colour (no colour change).
• Flow control media pushing
the piston and driven by
pump.
Internal Charge EISENMANN

• Cartridge exchange between

jobs : less than 10s Including.
• injector and inside bell
cleaning (during robot
positioning)
• Cartridge exchange.
• Outside bell cleaning.
• Paint losses during colour
changes: less than 15 cc.
• Water usage for colour change:
about 200 cc.
• All cleaning and filling device
located outside the booth.
• Possible manual introduction of
cartridges for special colours.
 The Ordered VarioRobots 多功能机器人定货情况 EISENMANN
VarioRobot Conveyor-
Throughput
Order Delivery SOP Product 油漆类型 Speed.
Amountl (Car/Hour)
定单 发货 投产 (Amountl 数量 ) (m/min)
机器人数量 车 / 小时 输送速度

MCC- SURTEMA Sept. July Aug. 6 12

(France 法国 ) 2001 2002 2002
Antichip+Silver Line Powder Paint (2) 1,8
2
Black Linie Powder Paint 1,25
2
Clear Coat Line Powder Paint 1,25
2

AVTOVAZ 32
Jan. End End
(Russia 俄国 ) 2002 2002 2002
Primer 63 6,5
1x6 Normal Paint (3)
2 x Paintline :
Base Coat 1st layer 2 x 37 3,82
2x4 Normal Paint (24)
Base Coat 2nd layer 2 x 37 3,82
2x3 Normal Paint (24)
Clear Coat 2 x 37 3,82
2x6 Normal Paint (2)

SEAT - VANEMA Jan. July Aug. 2

(Spain 西班牙 ) 2002 2002 2002
Base Coat 2 Normal Paint (16) 26

FAW Apr. Oct. Mar. 8

(China 中国 ) 2003 2004 2005 4
Primer / Base Coat 4 Normal Paint (6 / 12) 34
MCC Hambach Paint Shop Smart · New Powder Booth EISENMANN