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Metal painting

In the metal painting segment, Eisenmann focuses on customers dealing with trailers and agricultural and construction machinery, as well as the wheel industry.

The over 100 complete plants we’ve constructed for painting agricultural and construction machinery, trailers and rail vehicles speak for themselves: Eisenmann boasts countless prestigious references. Roughly one in three agricultural machines and one in two trailers worldwide are treated and coated on our plants. With over 130 wheel painting plants completed, Eisenmann is a world leader in this area. One out of every four car wheels is treated on Eisenmann plants.

The foundation for an immaculate paint job, especially for metal or plastic parts, is thorough pretreatment and primer application.

CO2 cleaning
CO2 snow cleaning has established itself as an energy-efficient alternative to wet chemical pretreatment. This technique eliminates the need for the energy-intensive steps of drying and cooling the parts before they can be treated. The only waste produced is the dirt blasted off the parts. The air flow in the booth and in the inlet and outlet seals is critical for the cleaning results.

Spray Pretreatment
For metal and plastic parts that cannot be immersed, Eisenmann also builds plants for chamber pretreatment and continuous pretreatment. A special focus is placed on the optimization of water consumption. The result is a significant cost savings on both fresh water and waste water purification.

EC plants
Flawless primer application forms the foundation for a consistent paint structure. When it comes to metal parts in particular, cathodic electrophoretic coating (EC) is a highly efficient economical option. Large batches of mass-produced goods, heavy welded structures for construction machinery or entire bus chassis – depending on the throughput and weight or size of the parts, dip coating can be done continuously or in discontinuous cycles.
For each of our concepts, Eisenmann offers an optimal combination of process and conveyor system, always integrated with the perfect logistics concept. All the process engineering peripheral equipment is available from our one-stop shop and likewise individually tailored to our customers’ needs. The result is plants that save both energy and resources.

Whether you’re using wet paint or powder paint, Eisenmann will develop the best plant design for your needs. We put quality, cost-effectiveness and environmental friendliness first.

Application Engineering
As a capable partner to our customers, Eisenmann also develops and delivers process-reliable and efficient systems for all types of application processes. Our selection spans the full range of complete solutions for sub-suppliers and manufacturers of products made of metal. The plants feature the latest application engineering technology, intuitive controls and intelligent and material-conserving supply systems. The result is a maximum of efficiency and a minimum of resource consumption in production.

Dry separation
Eisenmann’s E-Cube is a widely successful and popular separator system. Thanks to its sophisticated filter technology, the E-Cube uses no chemicals, water or other additives (e.g. binding agents) whatsoever. This saves resources and simplifies waste disposal. The energy-efficient and resource-conserving E-Cube can be used in every phase of wet painting (i.e. for wheel, plastic and general metal painting). The system comprises 60 to 80 percent recycled materials, is easy to handle and can be operated by anyone.

Wet separation
Eisenmann offers two separation processes for wet erosion: compact cross-current Venturi scrubbers and double cross-current Venturi scrubbers. They can be used to treat different paint systems in a variety of volumes and adapted coagulations. In plants for automatic coating, most of the air which is suctioned out and scrubbed of paint mist is then fed back into the booth (recirculated-air operation). In oder to ensure that the permitted solvent concentration in the spray booth is not exceeded, a partial flow of the circulating air rate is released as exhaust air.

The paint drying process transforms a liquid or powder coating into a mechanically solid state. Eisenmann has built countless dryer systems, perfecting this process over the course of more than 60 years.

Convection dryers
Convection or air circulation drying is primarily used for paint curing. However, it’s also suitable for drying adhesives, gels and water. In addition, these dryers are also used to preheat parts prior to coating. Eisenmann dryers use targeted air flows to achieve optimum efficiency. The can also be split up into multiple heat-up and holding zones.
Rapid heat-up and even temperature distribution can be individually adjusted to suit the workpiece geometry. The focus is on achieving fast processing times and high throughput rates while maintaining consistent quality.

Infrared dryers
In infrared radiation drying, the workpiece is heated up. The intensity of the radiation depends on the wavelength spectrum and thus on the radiation temperature. Temperatures of 3,000 degrees Celsius can be reached. Eisenmann’s infrared radiation dryers feature a compact design and extreme adaptability, allowing radiation to be used for a variety of different paints. Highly efficient, as well as direct and material-conserving applications result in energy-conserving and efficient processes.

Smart Oven
In the Smart Oven, clean gas is piped out of the dryer exhaust air cleaning system, indirectly heating the fresh air in the dryer. The combustion air for the burner is taken directly from the dryer, and the combustion gases are fed to the RTO exhaust purification system along with the dryer exhaust.
This reduces gas consumption, especially since heat loss is kept low due to the low number of roof openings. The Smart Oven requires fewer attachments than similar concepts. The heating units integrated in the tunnel eliminate the need for costly steel structures. This dryer is more compact and lighter. The integrated heating system also reduces the overall surface. This results in less transmission heat and pressure loss.

Effective logistics concepts for the coating of metal and plastic parts are crucial to achieving optimum material flow and effectiveness in the overall plant. Complex, dynamic systems require detailed analyses. Our simulations can provide transparency and planning reliability and greatly assist with commissioning.

Skid conveyors
Lighter loads such as plastic parts undergo various processes on the skid conveyor. The precise guiding quality ensures optimum positioning accuracy and repeatability. This makes the skid conveyor particularly well-suited for use with robotic painting systems.

Power & Free
Thanks to their high flexibility with regard to speed and media, Power & Free systems can be used to combine a variety of production facilities and processes. This minimizes the number of workpiece transfers and system changeovers. This applies both to the Overhead Power & Free system and the Inverted Power & Free conveyor, capable of targeted workpiece infeed and pick-up, buffering, sorting and dosing. These systems can also be used for continuous workpiece conveyance. As a result, they allow for extremely energy-efficient, economical and flexible direct connection to upstream and downstream zones, as well as completely internal material flow.

Heavy-duty Power + Free 668
The Power & Free 668 heavy-duty conveyor system is designed for the flexible transport of heavy parts weighing up to 8,000 kg. With highly resilient trolleys that have proven themselves over and over in production, as well as sturdy components, this system guarantees a high degree of process safety and reliable high-temperature applications. With stacking and buffer functions, as well as chain-linking and transfer capabilities, this low-maintenance and low-noise conveyor is guaranteed to provide the flexibility you need.

Moveable Hoist System
The Moveable Hoist System is the most compact option around for a resilient conveyor system for heavy and large loads of up to approx. 10,000 kg and 20 meters long. The system conveys the vehicles with workpieces along the narrowest space, widthwise and lengthwise, fully automatically or semi-automatically, throughout the entire plant. Moveable Hoist combines all the manufacturing and handling steps in the painting plant individually and highly flexibly.

Masking robots, pick & place technology, wheel grippes, pallet grippers, specially developed grippers, systems for handling of thin-walled and fragile workpieces or vacuum gripper systems: Eisenmann offers a wide range of products for automation, i.e. for the connection between robot and workpiece. Our modular Execution Manufacturing System, or E-MES, ensures intelligent and flexible production.

Masking station
Automotive manufacturers around the world need aluminum wheels with paint-free functional surfaces. This requires the surfaces to be masked. Eisenmann has developed an automatic masking unit with an image recognition system capable of reliably handling large part quantities and sustainably increase production. The hoppers of the Eisenmann masking station can hold up to 10,000 elements which are automatically infed one at a time in the correct position by a robot. The robot uses a vacuum suction device to grasp the masking parts and inserts the balls and stoppers into the screw holes of the individual wheel types.

Wheel gripper
The wheel gripper developed by Eisenmann facilitates the transfer of wheels between the different process steps and contributes to automation in wheel processing. It weighs significantly less and reduces gripping time by up to 30 percent. It also helps lower energy costs. The wheel gripper boasts flexibility and optimal availability. Proportional technology ensures maximum precision and short cycle times.

Pendulum compensation robot
One absolutely crucial factor for high-quality painting with robots is to ensure that parts are positioned accurately. The pendulum compensation robot developed by Eisenmann stops suspended parts from moving on the conveyor before they reach the paint booth. Special hydraulic dampers are used to cushion the pendulum forces. They allow for the consistently optimum transfer of the parts to the booth, where they can then be painted reliably in the defined position.

Wheel identification and tracking
In addition to the wheel concepts for E-mobility wheels, the biggest trends in aluminum wheel development are currently big-data-related topics like wheel recognition and individual wheel tracking. This makes processes trackable, transparent and easier to optimize in the long run.

E-MES production management system
The award-winning Eisenmann Manufacturing Execution System, or E-MES for short, networks the factory, both horizontally, i.e. across the entire manufacturing process, and vertically, across all process levels - from the ERP to the PLC. With integrated data logging, analysis and display, it ensures thoroughly transparent production and logistics processes. E-MES can be variably implemented as anything from a simple operating and monitoring system to a complete MES solution. With its integrated data logging, analysis and display, it ensures thoroughly transparent production and logistics processes, forming the basis for every Industry 4.0 solution.

Virtual commissioning
And Eisenmann offers digital services throughout the entire value-added process. Automated software creation with E-PASS allows for virtual commissioning and intensive testing of the entire plant software in advance. This shortens the project execution time up to the start of production by up to 30 percent.

Digital services
All machines, functions and documents are managed through our service cloud. In conjunction with the service app, customers can request remote support and connect to an Eisenmann service technician. Communication occurs by scanning QR codes on the components or via smart glasses.

Contact

Name

Katharina  Baumann

Firm

Eisenmann Anlagenbau GmbH & Co. KG

Telephone

work T
+49 7031 78-1593

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