Automating Documentation of Finishing Quality
To achieve consistent coating quality and to increase the rate of production, Sprimag is increasingly using real-time monitoring of relevant process parameters. Amount of coating used, paint distribution over the surface, and appearance.
One reason for the increasing demand for integrated process controls in coating systems is the rise in documentation requirements within the automotive industry. However, coating system owners themselves are keen to monitor, analyze and document coating processes, to ensure consistent production quality, and as such, to reduce rejected parts.
So that consistent coating quality and production reliability can be achieved, the complex interactions between system technology, coating material and environmental conditions must be controlled. For this reason, in addition to the already standard process controls, systems to monitor coating thickness, viscosity and flow rate as well as the temperature of parts or coatings are increasingly being used in modern coating systems.
An example of these systems in an automated system. A color sensor checks the first coat immediately after application. Following the application of the second coat, the entire coating thickness is measured using a system for contactless coating measurement. Data collected from process controls and the system program are stored in the control system.
Another piece of technology for integrated real-time process monitoring in an anti-friction lacquer coating system is a camera system that checks the quality of the coating. As part of this process, a fluorescent assembly anti-friction lacquer is applied initially, and the coated area is photographed multiple times under UV light. After the pictures are assessed, the operator receives the signal as to whether the part has been coated correctly or not.
Process monitoring to maintain a consistent quality of coating is vital, particularly for components from the engine compartment, to continue to ensure that the engine will function correctly. The metal parts are pre-warmed before coating to ensure consistent coating quality. Therefore, the temperature of parts is measured and checked directly before the coating process, with any deviations being reported directly to the control system.
Today, the possibilities for monitoring, analyzing and documenting processes are very varied. Choosing the right systems from the available plant technology is dependent, among other things, on the function that the coating must perform, quality requirements and economic aspects. In addition to the integration of process monitoring into a new coating system, existing systems can also be upgraded.
The ability of documentation and proof of application are becoming more of a requirement. Companies who participate in the automotive components market can use their ability to provide proof of methodology as a marketing and selling point. Many upgrades are to the pre-treatment sector which secures the knowledge with the the newest mechanical contrivance in the digital monitoring of surface cleanliness in-line.