Energy saving and consumption reduction in automobile painting production
Painting is the most energy intensive production process throughout the car production process. According to statistics, the energy consumption of a large painting plant is equivalent to the energy consumption of a city with a population of 50,000 and its commercial area. Because of this, Dürr has been researching energy-efficient plants for many years with the goal of reducing the actual cost per unit of product. The company put forward the slogan of “green painting workshop†and organized a large number of experts to develop a paint shop mode with optimized energy and consumption. This can bring benefits to customers in two aspects: it can greatly reduce unit cost and has good environmental benefits. In the automotive painting production, if the green coating workshop of Dürr is used, it can not only reduce energy consumption by 60% and fresh water consumption by 44%, but also reduce the amount of fresh water by 33%. % of carbon dioxide emissions. This workshop integrates more than 20 advanced technologies for energy saving and consumption reduction, which greatly improves the energy saving and ecological balance of automobile coating production. New pre-treatment process: rotary dip coating and heavy metal-free processing The green coating workshop uses energy-saving technology from the pretreatment process, applying RoDip rotary dip coating and cationic electrophoretic coating process. During the dip coating process, the entire body can be rotated in the dip tank to avoid overflow and dripping of the paint. The use of RoDip technology can reduce expenses in construction investment, materials, personnel, equipment maintenance and energy consumption, thereby significantly reducing the unit cost – CPU (costs per unit). We use a European factory that produces 300,000 car bodies a year as an example. The green paint shop reduced the unit cost of the plant by 16%. The first reason is that space is saved. Since the car body can be rotated 360° in the dip tank, the slope of the inlet and outlet is not required, which greatly shortens the length of the dip tank. The second reason is that the amount of paint is reduced by reducing the volume of the dip tank. Not only can the cost be reduced, but the coating can be better circulated in the pool, which improves the efficiency of coating heating. This not only saves more than 35%, but also reduces wastewater discharge and treatment. The third reason is that this technology can reduce the pollution of the workpiece and prevent the surface from sag and potholes, which not only improves the product quality, but also reduces the workload of trimming, refinishing and polishing the workpiece, reducing the manpower. cost. Another advanced pre-treatment process is the AquenceTM chemical “self-stroke†process developed by Dürr in collaboration with Henkel. This process can achieve good corrosion protection with only a few process steps, forming an organic water-based protective film on any iron-containing surface of the workpiece, and does not use any heavy metal-containing materials. The cost advantage of this process is that the entire production process is a chemical process that does not consume any electricity. In addition, management costs can be further reduced due to fewer process steps and ease of integration. The newly developed non-stick spray dry separation process uses the EcoDryScrubber non-stick spray dry separation process to bring the coating production closer to the “green†target. Compared with the traditional wet separation process, this process can save 30% energy if it is calculated according to the whole process of automobile painting. If it is only calculated by the production process of the coating station, the energy saving effect can reach 60%. The main feature of the EcoDryScrubber process is that the air in the coating station is circulated and can carry away dry, non-stick spray particles. Since air can be recycled, the amount of air treatment is greatly reduced compared to conventional painting stations. Compared to conventional wet separation processes, clean water is no longer used when dry separation does not adhere to the spray. In addition, because this process greatly reduces the emission of carbon dioxide and spray particles, it also has good environmental characteristics. Another feature related to environmental protection is the use of limestone powder as a binder in the dry separation process. When the limestone powder is saturated, it can be directly applied to other production processes without any treatment, such as for cement manufacturing or flue gas desulfurization. . The paint sludge produced by wet separation is an environmentally harmful waste that must be managed before it can be discharged. According to statistics, if a standard coating plant adopts energy-saving measures in the reuse of thermal energy, the coating cost per car can be reduced by 7.2 euros. According to different geographical locations and different production complexity, the unit cost is even reduced. Up to 14 euros. Reasonable air recycling in this area is an important part of reducing costs, which is universally applicable throughout the world. This aspect of the benefits will be affected by the local ambient temperature and humidity, and of course subject to the quality requirements of the product coating, which is very important. Improve coating utilization In addition, Dürr produces an EcoBell2 high-speed rotary atomizer. The atomizer is equipped with a 6-color high-speed paint conversion device. The loss of paint is only about 4 ml per color change, and the paint loss of the atomizer is as high as 40-50 ml. Moreover, the color change time of this atomizer is only 6 seconds, and the time saved by some workshops is equivalent to an increase of 5% of the production capacity. In the spraying process inside the car body, the high-speed rotary atomizer is more effective than the ordinary pneumatic atomizer. Dürr's new EcoBell2 HD nebulizer features a bell-shaped cup nozzle and a shaped airflow ring technology that greatly enhances the precision of the spray focus. This technique can generally improve efficiency by 25% when applied to internal spraying and 50% in special cases. Of course, the ingenious design and configuration of the painting equipment can also save costs. For example, when the vehicle body is painted, the robot is placed on the elevated moving rail, which not only makes the atomizer more convenient to enter the working surface, but also improves the coating. Utilization, and can reduce the space of the painting station, further reducing production costs. The robot plays an important role in the painting station, and the robot's moving rails can be arranged in layers. The operating robot that opens the hood can be arranged on the upper rail, and the painting robot is arranged on the lower rail, and the two robots work on each other. With this arrangement, the length of the painting station can be reduced by at least 1-2 meters, which reduces construction investment and reduces production costs. Car body sealing treatment is an important part of coating production, such as seam sealing, coating of car chassis protective layer and cavity rust-proof wax filling. Using robots to increase the automation of these processes can effectively reduce labor and material costs. Advanced automation technology can ensure high precision and high repeatability of machining positioning, improve the accuracy of feeding and synchronization of work, which can save material cost. Glance at everything and control everything to help users improve energy efficiency and reduce consumption. Dürr has also developed EcoEMOS monitoring and management software for global promotion and added EcoEMOS energy management module that users are very interested in. This software can help users evaluate the data they consume, compare and reduce the consumption of possible compressions against reference curves based on their own characteristics. In addition, EcoEMOS software combined with a work schedule module can also analyze and compress non-production time consumption. Based on long-term accumulated experience, Dürr has developed this new software, providing a very practical tool for energy-saving industries to save energy and reduce consumption. Experts provide an optimized assessment for the coating plant. If the existing coating plant is analyzed and evaluated, there will be a huge room for optimization. In this regard, Dürr has successfully provided expert assessment services to customers in Europe, Asia and the United States. As a leading international company specializing in coating plant equipment, Dürr holds a wealth of technology and experience in coating production. It turns out that this assessment really plays a key role in optimizing the production process for customers and saving costs. Conducting assessments will conduct a variety of investigations, and then focus on how to improve the utilization of energy and materials, how to adjust the production layout or formulate systems and regulations to optimize production according to customer requirements and priorities. Of course, through evaluation, we can also develop more reasonable production standards for enterprises. a new form of cooperation About Dürr Dürr GmbH is an internationally renowned group of companies providing machinery and plant equipment. 85% of the company's sales are distributed in all areas of the automotive industry, as well as advanced technologies and products in the aerospace industry, machine tool manufacturing, chemical and pharmaceutical industries. Dürr Group's operations are mainly divided into two parts: the Coating and Assembly Systems Division provides coating and assembly equipment for automotive car body and chassis production; the equipment and systems produced by the Measurement and Processing Systems Division are used in engines and The manufacture of transmission systems and automotive assembly are also used in other industrial fields. Dürr has established 44 operating outlets in 20 countries around the world. With sales of 1.6 billion euros in 2008, it has 6,100 employees. The elevator is mainly composed of mechanical system and electrical system. At present, the most commonly used elevator at home and abroad is the traction elevator, which is mainly composed of mechanical system and electrical system. The mechanical system mainly consists of five parts: traction drive system, car and door machine system, weight balance system, guidance system and mechanical safety protection system; The electrical system mainly consists of three parts: electric drive system, electrical control system and electrical safety protection system. Elevator Spare Parts,Elevator Spares,Elevator Replacement Parts,Elevator Cabin Parts Suzhou Stable Trade Co., Ltd , https://www.stable-elevator.com
Figure 1: RoDip rotary dip coating improves both quality and cost.
Figure 2: The use of a non-stick spray dry separation process in a painting station can save up to 60%.
The use of advanced application technology is also an important way to reduce unit costs. In addition to labor costs, material costs are the most important factor. Materials include paints, other coatings and sealing materials. The potential for savings is great. For this reason, Dürr has developed the EcoPurge LCC color change system, which reduces the loss of paint when changing the color of the paint during the painting process, and shortens the time for color change. In this system, each paint is delivered directly to its respective control valve, so different paints do not have a common paint line. This color changer can be set up to 36 paints. The time of paint color change will be affected by the model and process requirements, but it is generally less than 10 seconds, and the paint loss per color change is less than 10 ml.
Figure 3: Using the EcoBell2 ICC high-speed rotary atomizer to reduce paint color change time and increase productivity.
At present, Ford Motor Company is implementing the ABF program (Aligned Business Framework) to inspect and select its key suppliers, and then establish long-term partnerships to improve mutual profitability. Dürr was named Ford's ABF Global Partner, which means that Dürr is the preferred supplier for Ford's contract for coating equipment and will continue to develop new technologies and processes. As a result, Ford will also be one of the few automakers in the world that can produce better products with lower cost, more highly standardized parts and systems.