Automatic interior painting in just nine days
September 2013 – With vehicle interior painting too, the trend is more and more towards automation. This brings benefits in terms of productivity and quality. Automation is not just a worthwhile investment in greenfield plants. Existing systems can also be upgraded very quickly. This is illustrated by an upgrade project at Hyundai in Ulsan (South Korea) where Dürr installed and commissioned four robot stations for interior painting in just nine days.
The upgrade work in Ulsan was carried out during the plant’s summer shutdown. As a result, it was not necessary to interrupt production specifically. When Hyundai restarted the paint shop after the shutdown, all four robot stations merged seamlessly into the production process.
Dürr installed two stations for the automatic interior base coat application in each of two top coat lines in Ulsan. Each station is equipped with two painting robots and two door-opener robots. Type EcoBell2 atomizers ensure precise paint application.
During the nine-day upgrade phase there were 20 Dürr experts from Germany and Korea on site, together with other staff from a local installation company. Dürr Germany was responsible for the installation of the mechanical and electrical systems and had overall charge of the project during the installation of the new systems. Dürr Korea handled the commissioning and the robot teaching and acted as the interface with the local suppliers.
The Hyundai operation was meticulously prepared in order to meet the tight schedule. Ahead of the project, all the brush parameters (e.g. rotation speed, shaping air, paint volume) were determined in the Dürr Technology Center in Bietigheim-Bissingen to ensure that the stringent quality standards were met as quickly as possible. During the pre-commissioning process, the robot paths were programmed for all requested body types and extensively tested. Further software tests were performed to guarantee that commissioning would run smoothly in the customer’s plant. After that, the four stations were dismantled and began their container journey to Korea.
The use of Sercos 3 represents a technological highlight in Ulsan. Dürr has already successfully used the drive and process bus system in a number of projects. In Ulsan, too, it has been contributing to trouble-free data exchange between the hardware components of the four automatic interior painting stations since the beginning of August 2013.