Special design for Amorak as a highlight
September 2012 – The schedule was ambitious, but the employees from Dürr Bietigheim and Dürr Wolfsburg demonstrated strong teamwork when joining forces to modify a paint shop for VW in Hannover. Since then, the plant has been equipped with a fully automatic robotic system for painting the Porsche Panamera, the T5 Transporter and the new VW pick-up Amarok.
The focus of the contract in Hannover was the switch from gantry systems to flexible robots. Ten EcoRP L033 type robots were installed for the exterior application of the base coat. Six of them are located at the base coat 1 station, which uses EcoBell2 atomizers with external charging. The four other robots are responsible for base coat 2 application using air atomized spray guns.
Two further painting robots (type EcoRPL 133) were delivered for automatic interior painting. They are supported by two handling robots (type EcoRP E033 Opener), which open the car doors. Both are located in an elevated position, at a height of about two meters. This provides better reach and ensures that the robots are not exposed to the atomized paint spray. In addition two robots were added to the clear coat zone, where Dürr had already installed six robots in 2009/2010.
One of the technological highlights in Hannover – apart from the highly flexible EcoLCC color changer, which reduces material usage and cost – is a spray gun customized specifically for the VW Amarok. It is used between the cab and the cargo box of the pick-up, where standard atomizers cannot reach due to the small gap. As products made by other manufacturers were out of the question, Dürr quickly developed a customized product with which VW is highly satisfied.
Dürr only needed three weeks to complete the modification project, according to APT Project Manager Marco Steinbach: “Within a short space of time, we worked on four painting stations, converted one booth, replaced the conveyer system and put everything into operation.” Dürr delivered everything to VW from one source and worked without a ‘safety net’. There was no back-up line available in Hannover, so any delays would have caused a loss of production. But Dürr met the agreed deadline and earned a lot of praise from the customer. Thanks to the good cooperation with the VW project team it was possible to keep the deadline and fulfill all the goals together.