Discussion on automation of painting shop

M. Sc. (Engg.) in Advanced Manufacturing Technology

Members:
Prashantkumar V K Harish Praveen Patelappa Chennakeshava MR Simulator Integration consultant Automation expert

Module leader: Prof. Ramdas Chandrashekar Sandeep N Module title: Automation in manufacturing and systems simulation
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Discussion

1. Requirements will be proposed by the MR

2. Simulation expert will propose the model

3. Integration expert will give the feedback on feasibility

4. Automation expert will give the details of equipments and

components needed 5. MR will give feedback considering economical feasibility 6. Step No 2, 3 & 4 will be repeated 7. Conclusion
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Problem description from MR

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Introduction to Problem
In a machine tool manufacturing industry all the enclosures are made from sheet metals. In order to protect from the corrosive atmosphere these are painted by spray painting method. Painting shop contains mainly 3 areas Cleaning, Painting and curing . All the components are handled manually during the process and process is also done manually. There is a small oven which can hold 300mmX300mmX300mm parts. Now the organization has decided to go for the automation of the entire paint shop.

Oven

Cleaning

Painting Natural curing

Size of component

Present process in practice

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Reasons for opting automation

Cleaning of the components is done by manually dipping into the chemical tanks and all components are handled manually using a crane. Since the paints are hazardous to human health when it is inhaled or when it gets in contact with the skin, these working areas are not safe for human beings. Painting work is a repetitive but skilled work, it needs experienced and skilled labour which adds up the component cost. Man power calculation: average salary for one employee = 10000 X 14persons 140000/month 5 operators at cleaning, 4 painters, 2 persons at curing station, 3 persons for transport Till now a small oven was used for carrying out the curing of painted small components. Now the organization is interested in buying the new oven which can accommodate all the components.
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Parameters to be considered for Automation

Component sizes varies from 30mmX30mmX2mm to several meters in length.
There are only two types of paints used viz. blue and white. There is no mix of these colours, components is painted either blue or white. There will be mix of components of both colours. All the three areas has to be automated.

Power consumption and human involvement should be as minimal as possible.

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Simulator

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Simulation for Proposed model

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Simulation block diagram

Automation hardware

Sensors

HMI / control panel

Interfacing circuit or signal conditioners

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Integration consultant

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Whether simulation needed

Simulation for the above process will help in controlling and monitoring the complete process, thereby simulation is needed for above process in order to simplify the automation.

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Controlling and monitoring parameters

Controlling parameters 1. Flow control for cleaning stations 2. Spray control for painting section 3. Temperature control for hot water and oven section

Monitoring parameters 1. Measuring size of the component 2. Temperature monitoring in hot water and oven

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Limiting parameters 1. Segregation of the components should be done either manually or components should be tagged with RFID or other means 2. Two robotic arms will improve the quality of the spray and shade of the paint

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Interfacing stages 1. Sensor will sense the temperature of the hot water tank and will send back the data to control panel, depending on data heater for the tank will be actuated. 2. The conveyor will be fitted with sensors to track the component location. Component will have caption of numbers in the control panel. 3. Paint level sensor will give data to the control panel which is used for refilling the paint tank. 4. Sensors from the oven will be simulating the coil actuation/de-actuation process and also temperature of the oven.

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Automation expert

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Block diagram of automation hardware

FLUID LEVEL SENSOR PUMP ACTUATION CIRCUITS

TEMPERATURE SENSOR

HEATER

INCOMING SOLONOID VALVE

HOT WATER CLEANING TANK

EXIT SOLONOID VALVE

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Block diagram of automation hardware

FLUID LEVEL SENSOR PUMP ACTUATION CIRCUITS

INCOMING SOLONOID VALVE

ACID CLEANING TANK

EXIT SOLONOID VALVE

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Block diagram of automation hardware

COMPONENT SENSOR PUMP ACTUATION CIRCUITS

TEMPERATURE SENSOR

HEATER

INCOMING SOLONOID VALVE

HOT AIR DRIER

EXHAUST

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Block diagram of automation hardware

COMPONENT CONVEYORS (1 OR 2) MOTOR DRIVEN ACTUATION OF SPRAYER SOLONOID (WHITE) ACTUATION OF SPRAYER SOLONOID (BLUE) COMPONENT COUNTER AND REGISTERING

COMPONENT HEIGHT SENSOR (LASER CURTAIN)

ROBOT ACTUATION FOR PAINTING MANUPALTOR ROBOT

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Block diagram of automation hardware

COMPONENT SENSOR (INCOMING)

DETERMINATION OF SIZE OF THE COMPONENT DEPENDING ON LASER CURTAIN DATA

COMPONENT SENSOR (EXIT)

OVEN COIL ACTUATOR / DEACTUATOR

TEMPERATURE CONTROLLER

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Cost estimation

Sl 1 Solonoid 2 Pumps

Device

Qty 7 3 2 2 1 1

Price/unit 975.46 3500 563.5 2159.54 1815450 150000

3 Thermocouple 4 Fluid level sensor 5 Manipulated robot 6 Laser curtain

7 conveyor
8 Sheetmetal tank

2
3

21000
12000

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Outcomes of the discussion 1. Much of the man power is reduced 2. Monitoring facility helped in controlling and troubleshooting the system effectively. 3. Painting quality can improved compared to the earlier process.

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Thank You

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