Pretreatment as a Prerequisite for First-Grade Coating
Plastics tend to acquire an electrostatic charge fast and thus attract dust. Even minor contaminations cause rejects. Cleaning and pretreatment of the components is a fundamental prerequisite for good wetting and paint adhesion and thus decisive for the successful coating of plastic components.
Well-established is cleaning by using wet chemical methods. Parts with a normal degree of soiling are cleaned by means of alkaline spray degreasing and then rinsed with DI water. More heavily soiled parts are degreased in two stages at higher temperatures and using higher spray pressures.
Examples of other pretreatment procedures used in Eisenmann plants:
- CO2 cleaning
- Low-pressure plasma process
- Fluorine treatment
- Flame treatment
- Sanding and activating with the VarioSurfer
Customized Paint Shops for Plastic Parts
Separator systems E-Cube
Having delivered more than 300 paint shops for plastic parts, Eisenmann is the leading global industrial solutions provider of the industry. We offer innovative solutions for painting plastic parts of all kinds such as automotive components as well as rotor blades for the windpower industry.
Since the paint is applied fully automatically on plastic parts for quality reasons, Eisenmann designs air-conditioned spray booths according to the requirements.
Apart from high air circulation rates, the circulating air flow in the spray booth provides for considerable energy saving due to a low fresh air/exhaust air ratio.
Range of Applications of the Ovens
On the one hand, Eisenmann ovens are used for the evaporation of water following the pretreatment (Powerwash), on the other hand, for drying the paint and for curing following the painting process.
Dry-Off Ovens / Cure Ovens
The air flow in cure ovens and dry-off ovens is generally implemented via air injection ceilings with filters and an additional prefilter stage in the heating unit. Usage at circulating air temperatures of from approx. 80 C° to
100 C°. Heating is optionally performed using gas, hot water, thermal oil or steam.
In the dehydration ovens, the workpieces are dried by blowing with dehumidified air.
For plastics paint systems, ovens equipped with infrared and UV radiators are used for paint curing of diffusion disks, reflectors and windpower blades, for example. The following infrared radiator models are available:
- Carbon radiators
- Ceramic radiators
- Gas radiators
Material Flow through the Paint Line for Plastic Surfaces
When choosing a conveyor system, for most of the plastics you should always pay attention to how prone the plastic is to attract dust and dirt. Eisenmann generally recommends a bottom-mounted conveyor system, e.g. based on an upside-down circular conveyor or a Power & Free conveyor. This ensures that the workpiece surfaces are not soiled by wear debris of an overhead conveyor.
- Skid Conveyor System
The skid conveyor systems are of great significance in the field of paint shops for plastic parts. Mostly they are made up of carrying chain conveyors, turning stations and lifting tables, lifting mechanisms and transfer units and generally feature hard-coded skids.
- Circulating Conveyor
This bottom-mounted conveyor, often an upside-down circular conveyor, is equipped with customized workpiece holders. Carriers, booms and head spindles range among the design variants.
- Power&Free Floor Conveyor
The Power&Free (P&F) floor conveyor is based on a dual-rail system just like the traditional P&F overhead conveyors. The conveying chain runs in the upper rail; it conveys the trolleys with the workpieces by pusher dogs in the lower rail.
Process Data Acquisition and Control
As a systems supplier, Eisenmann integrates the complete plant control technology from one source. The problem of having to deal with a variety of interfaces does not arise. Our competent specialists have years of experience in the following fields:
- Project planning/ creating functional requirements
- Circuit diagram design and the manufacture of control cabinets
- Creating software for PLCs and visualization systems
- Material flow control, process control systems and the connection to customer ERP systems (E-MES)
- Commissioning, on-site production support and training
Due to extensive planning and counseling, concepts can be taken into account as early as in the project planning and tender preparation stages that result in a plant that is easy to maintain, energy efficient and economic.
To reduce downtimes, Eisenmann offers a remote maintenance option for all important control components.
Eisenmann Manufacturing Execution System E-MES
Example for the visualization of an oven temperature profile in E-MES
The Eisenmann Manufacturing Execution System (E-MES) is a browser-based production control system connecting the entire production facility – both horizontally, i.e. across the manufacturing process, and vertically, i.e. throughout all levels, from ERP down to shop floor IT. Due to integrated data capture, analysis and visualization E-MES ensures complete transparency, and can be used variably from simple operator control and monitoring system to a modular MES solution.
All data is accessible to users anywhere, at any time – no clients need to be installed. As a result, both the production and the maintenance staff on site, as well as colleagues and managers from anywhere in the world can monitor plant and equipment from a laptop, tablet, smartphone or smart-watch.
By means of user-defined key performance indicators, E-MES provides crucial information and insights – allowing users to critically review past manufacturing processes and make better decisions going forward.
E-MES is designed around a platform-independent, modular structure: further functionality modules can be added later in line with specific requirements. The E-MES portfolio offers made-to-measure solutions for every customer, from user-friendly operation and monitoring to high-level planning and control functionality. The production control system is configured in accordance with the specific requirements of the customer’s production facilities.
For more information, please visit: www.enisco.de