Electro-coating of a different kind
November 2013 – In conventional EC baths, electricity is supplied in sections to the whole dip tank. With EcoDC MACS Dürr has developed a new concept for the targeted supply of electricity and voltage to dip tanks, which has a positive effect on energy consumption as well as the coating quality of the car bodies.
EcoDC MACS represents an innovative concept for supplying electricity to dip tanks used in electro-coating. Its special feature lies in its modular anode control, which creates a voltage profile that moves with the car body. The basis of this is the flexible control of individual anodes or groups of anodes located opposite one another with the help of a modular rectifier system.
This means, more specifically, that conventional rectifiers based on thyristor technology are being replaced by modular IGBT-based rectifier systems, thereby opening up new possibilities. Thanks to the modular control of individual anodes, the software for the system control can be programmed to generate an individual voltage or current profile for each type of car body.
EcoDC MACS offers many benefits. Only through IGBT technology an efficiency of more than 96 % across the full voltage range can be achieved. As well as the targeted, partial supply of electricity this provides energy savings. In addition, the modular design of the system helps to control the coating process. This in turn leads to quality improvement.
And the modular design offers another feature: in the event of a failure of one of the modules or anodes, the neighboring anodes can take over their task. This ensures that there is no loss of production if individual anodes fail. An additional standby rectifier is thus not required.
Thanks to its integrated galvanic isolation, the system can be connected to the normal power supply network of the factory. Isolating transformers used for conventional systems are not required for this technology. Further advantages of the system are its small footprint and scope for expansion. Well-known customers such as Audi, Volkswagen, Porsche, Ford, SGM, or Fiat are already successfully using EcoDC MACS.