The fresh- and exhaust-air flows are controlled in response to the current energy demand, depending on the oven’s capacity utilization. That greatly reduces energy consumption. Photo: Dürr

Energy on demand for the oven

Dürr’s EcoSmart VEC intelligent air-management system controls fresh and exhaust air fully automatically

Rastatt, December 2015 – Dürr has incorporated a new software solution for managing fresh- and exhaust-air flows at Daimler. When drying freshly painted bodies, EcoSmart VEC substantially reduces the gas and electricity consumption at the Rastatt site in Germany. The intelligent air-management system adapts the oven’s energy consumption to its current demand.

As the oven is fed continuously with hot air, any breaks in production, or idle cycles in particular, mean that far more heat is supplied than is necessary. Even if car manufacturers already rely on energy-optimized, exhaust-air purification systems, a great deal of heat is still lost to the environment. From experience, the figure is around 50 percent. To counter this problem, Dürr has developed the EcoSmart VEC air-management system.

In conventional oven systems heated by pure gas, fresh-air intake and exhaust-air removal are operated at a constant volumetric flow. Previous attempts to resolve this problem by adapting the energy budget to the oven utilization level were unsatisfactory in terms of effectiveness and speed of response.

Individual supply of air to each oven zone

EcoSmart VEC works predictively. The air-management system, which is protected by several patent applications, controls the volumetric flow of fresh and exhaust air according to the number and position of the vehicles that are located in the oven at that moment. A body counter is located directly at the air-seal entrance. Based on the conveyor speed, the air-management system calculates in which oven zones bodies are currently located, and how this capacity utilization will develop in the course of production. On the basis of this and other information – for example, the weight and surface area of the car body – EcoSmart VEC can control the fresh- and exhaust-air fans fully automatically. In this way, the system ensures an optimum and individual supply of air to each oven zone at all times.

“With this new approach, we have succeeded in combining the two aspects of energy efficiency and consistently high paint-finish quality,” says Oliver Iglauer, R&D project leader at Dürr responsible for developing EcoSmart VEC. “Due to the potential of EcoSmart VEC to make significant reductions in the flow of fresh and exhaust air, this system is of interest not only for production, but also for the earlier commissioning and ramp-up phases of drying systems. In these cases, the gas and electricity savings can be as much as 50 percent, meaning that the system will pay for itself within this very short time.”

The supply of heat to the drying ovens depends also on the interaction with the exhaust air purification system that is part of the oven installation. The burner in Dürr’s Ecopure TAR system heats the solvents released by the body-drying process, thereby rendering them harmless. The residual heat from the pure gas produced in this way is used to heat the oven zones.

EcoSmart VEC ensures optimum interaction between process exhaust air purification and process heating. Fewer bodies mean less solvent. This, in turn, means that there is less exhaust air. As a result, the gas burner requires less fuel, since the energy content of the pure gas diminishes. The fans also have to move less air, and so electrical energy can also be saved,” explains Oliver Iglauer.

The integration of EcoSmart VEC in the existing ED oven in the Rastatt plant was a pilot project. Daimler’s TeBIS energy-logging system quickly showed considerable savings in gas and electricity consumption. The paintwork on the dried bodies showed a consistently high quality. Daimler would therefore like to incorporate the system in other oven systems.

Holistic overall concept

The ED oven in the Rastatt plant has a raised design. It already has an effective air-seal system with its A-type seals. However, Dürr still had to overcome one more hurdle before it was able to incorporate EcoSmart VEC in the commonly used straight-through ovens. If the fresh-air supply is reduced here, this generally has a negative impact on the sealing effect of the air seals – with the formation of condensate in this area being a possible consequence. To counteract this effect, Dürr has developed a new, optimized fresh-air seal especially for use in straight-through ovens. A patent has also been applied for this product which requires up to 50 percent less fresh air compared to a standard air seal, but offers an equally reliable sealing effect. 

The total volume of fresh air is divided into a variable and a constant flow. The variable flow – which depends on the number of bodies in the oven – is fed to the process via recirculating units. The air seals, on the other hand, are supplied with the constant fresh-air flow. This creates the best conditions for reliable sealing.

“The newly developed air seal means that we have the exclusive capability to offer an integrated concept. EcoSmart VEC can therefore also be used in straight-through ovens,” declares Oliver Iglauer.

Your contact: Oliver Iglauer

“One united team for our customers”
EcoInCure: A revolution in car body drying
Equipped for the Industry 4.0 environment
Smart, flexible and easy to use
iTAC.MES.Suite – Synergies for the production of the future
Trained employees ensure quality
High-quality modifications
Modular and automated
Energized and ever ready
Tried and tested for many decades
Smart, safe and precise
All about painting, gluing and sealing
The 1,000th EcoBell Cleaner D2 will be Mexican
Keeping high-speed trains looking their best
Big quality for small parts
Cutting operating costs and saving resources
"We combine digitization know-how with industry expertise"
Innovative body drying from the inside
Autonomous driving brings major changes to end-of-line technology
Increased system operation efficiency with digital documentation
Painting processes optimized before the start of production
Reducing cycle times and investment with the right nozzle
Perfectly integrated, process optimized
Optimized emission values and reduced consumption of resources
Dürr wins visionary new product award
Dürr is „Global Champion“
Shop floor meets IT
At the cutting edge of autonomous driving
A unique combination that is ready-to-use
Go and See – Practical relevance is the lifeblood of successful project management
Increasing system availability with smart services
Laser scanning for optimized processes in brownfield projects
Combining skills at one location
Dürr receives Ford Motor Company´s World Excellence Award again
Smart control technology makes new Dürr robots even more powerful and well-prepared for Industry 4.0
Maximum production efficiency in the age of Industry 4.0
Robot supports workers precisely and reliably
First time installation of Dürr’s EcoDry X technology
Integrated balancing solution using laser measuring technology
A paint shop that can fit through a door
Dürr acquires KBA-CleanAir
New generation of robots from Dürr: More versatile painting through additional movement options
Digital maintenance assistant from Dürr increases plant availability
“Digitization has gained great momentum”
New addition to the EcoBell3 family
A focused and accurate detection of flaws with EcoReflect
Tailor-made solutions for dry separation
Intermediate oven with CO2 heat pump: cost-efficient and environment-friendly
Dürr Supplier Award presented for second time
Smart products and networked factories
Smart product: Green: all ok, yellow: maintenance required, red: replace pump immediately
EcoScreen 3D-OnSite: increased performance and speed
Digital fingerprint enables targeted troubleshooting
Optimizing production worldwide
Dürr sells 2,000th sealing robot
Accurate testing for reproducible quality
Dürr opens new US campus
The best customized modification
Thank you for your positive feedback and your ideas!
Reliable tracking in a complex production process
Machine duo impresses in the workshop
Finding the most economical solution together
Faster service for Korean automotive industry
Dürr modernizes paint shop in China in record time
Experiencing and understanding technology
The 10,000th Dürr robot is heading to Spain
x-DASalign ensures safety
Meeting stricter emission standards in China with Dürr's exhaust-air purification systems
EcoShot Meter: a piston dosing system for many types of application
High-speed balancing now also available as a service
Volvo Group Trucks presents Dürr with supplier award
Higher energy efficiency thanks to turbine with optimized compressed-air consumption
Energy on demand for the oven
Human and robot operate directly as colleagues for tank fitting
Dürr test stands increasingly growing in importance – even for “autonomous driving”
Precision work on the ground floor
EcoGun2 3D is more compact and lighter with minimum pressure loss
EcoEMOS SCADA increases the efficiency of the entire production process
Speeding up spare parts delivery
Dürr is on the right track in Russia
Testing the burners of exhaust-air purification systems under live conditions
Three metropolises and huge emotions
Automated water-based paint application: high efficiency in interior painting
Dürr service hotline: competent support 24/7
EcoEMOS Andon supervisory control system optimizes the assembly line in automotive production
CARDANO: ease of operation, fast processes, high process reliability
Dürr creates state-of-the-art paint shop on the Indian market
World’s largest ventilation air methane/coal mine methane oxidation project goes live
Innovation in atomizer cleaning
Producing wheels ready for installation – with high process reliability and maximum flexibility
Dürr EcoEMOS software for all production areas
CO2 refrigerant provides sustainability and security of investment
Dürr presents its "Industrial Products"
Energy and heat from wood-based residues
Dürr selected as strategic partner
State-of-the-art test stand for pumps from Dürr
"Greenfield projects are the 'compulsory' program, while brownfield projects are 'freestyle'"
Always a big step ahead with adapters from Dürr Somac
EcoSupply P: Minimum paint loss through piggable paint supply systems
Dürr offers promising combination
Dürr opens sixth training center for paint systems
Tailor-made: balancing system for roller manufacturing
Dürr creates further testing and training opportunities
One supervisory control system – many functions
First accredited testing laboratory for balancing equipment worldwide
Dürr web shop for "Industrial Products" online
First concentrate, then purify
Thanks to ORC equipment: geothermal power station becomes more efficient
Dürr robots qualify for the Korean market
Dürr sets up new "Industrial Products" area
Perfect alignment prior to final vehicle assembly
Higher efficiency with minimum cleaning
G3 Blue is faster, lighter and more ergonomic
“Dürr´s focus is on increasing our customers’ production efficiency”
Providing sustainability and security of investment: compressed air drying with CO2
Fully redesigned – presenting the new CABflex3
Precise conveyor technology for complex oil spray system
New building enhances flexibility in production
Operating costs reduced and disposal costs eliminated
Lights out, video on!
Innovations in application technology
Ferrari records a higher production output
Balancing crankshafts efficiently and conveniently with BARIO
EcoC-IC oven – for targeted use of heat
Software for paint shops revised
Award for innovative wheel alignment stand x-wheel truck d
For fast, precise interior painting
EcoReBooth saves space while reducing material consumption and costs
New test center for handling doors and hoods
Dürr provides a good basis
x-DASalign – precision and safety
Technologies with excellent energy efficiency
Paint separation – one step ahead
Dürr opens technology center in Tokyo
Dürr rewards its best suppliers
thermea heat pumps for five-star hotel
Dürr receives Daimler Supplier Award
Scania continues to rely on powder paint and Dürr as a partner
Space-saving design and low energy consumption
Precisely balanced for smooth running
Dürr provides network for commercial vehicle community
Faster and more accurate glue application
Environmental protection goes global
New location in Shanghai: service and local product development expanded
One-stop solution designed and built in-house
CIC ovens: the world's first use in truck manufacturing
Cleanliness is a key quality factor for more competitive edge
New chassis geometry measurement system
New expertise for Russian carmakers
Faster commissioning
High demand for innovative paint booth concept
Environmentally friendly refrigerant requires investment
Special design for Amorak as a highlight
From micro gas turbines to heat exchangers
Economical and quick to use
Faster results in cleanliness testing
New machines for the Chinese market
From zero to 100 percent production within just four days
For excellent performance at the VW factory in Puebla
Efficiency results in sustainability
Rethink the idea of a paint booth
A perfectly cleaned and dried surface
Quality, flexibility and profitability guaranteed
Alternative oven heating
Savings in energy consumption of around 80%
Quick and economical application
The EcoCBase W3 covers a wide range of cleaning tasks
A new perspective for sustainable painting
Distec makes small series economically feasible
Optimizing the process chain
Coated in premium quality at reduced unit costs
Simple and efficient cleansing of process bath fluids
Fast fault analysis and speedy troubleshooting
Teaching filling technology know-how all over the world
Efficiency and quality in the painting process
A topic of high priority
EcoCAgile: A new flexible cleaning system for the Chinese market
Further development for FASmotion
Existing energy used more efficiently
New test center for parts cleaning in the USA
Automated gluing and coating of rotor blades
Electricity from waste heat
German engineering – high-quality built in India
Tailored closer to customers' needs
New generation Ecopaint RoDip E
x-wheel truck d goes to America
Innovative, award-winning products by Dürr
High flexibility and short start-up period
Valuable advantages for customers
Dürr in Turkey: Not only painting cars
New robotized cleaning system
Complex logistics and exact planning required
Cost savings in paint usage and maintenance requirements
Fast, reliable and customized
The new generation of solvent-based cleaning systems
Pioneering and outstanding technology
Dürr Somac filling systems for commercial vehicles, too
Dürr acquires environmental technology specialist LTB
Space for robot assembly significantly extended
Automatic interior painting in just nine days
More robots and training rooms
CPM received “Supplier of the Year” award
New test center for cleaning systems
TIIS certification for Dürr robots in Japan
Electro-coating of a different kind
A leap in high-pressure technology
In just four weeks
Flexible, fast, and energy-efficient
Lowering energy costs and emissions
Exploring Dürr innovations

To top