Robotic Spray System
The Arnold Robotic Spray System is an automated alternative to applying material by manual sprayers. Hand spraying might be deemed necessary when a part contains difficult to reach regions or critically masked areas. However, such manual spraying is rife with inconsistencies. Variations in spray pressure and atomization, direction, thickness, among other things, bring noticeable coating differences from part to part in any production line. Arnold Machine has taken advantage of the recent advancements in automated motion and control to spray coat parts that were recently deemed too difficult to automate for mass production. State-of-the-art robotic spray systems are coming on-line, replacing inconsistent hand spraying processes with ones that provide high reliability and consistency that is unattainable with other methods.
The Arnold Machine Robotic Spray System is designed as a four or five-step process. Each process is completely isolated from the others to prevent any cross contamination of solvents or spray media. The parts to be sprayed are mounted in Ultra-High-Molecular-Weight polyethylene (UHMW) pallets. These high strength, corrosive resistant, and low friction pallets have the hydrophobic properties required to hold targets safely without absorbing any of the spray or adhesives themselves, making them easy to clean and reuse. The fixtured parts are then processed through the following stations with loading and unloading being executed at the same station.
- Pre-Heat booth
- Primer Application booth
- Primer Presence Verification (available in both index and robotic equipment)
- Top Coat Application booth
- Cure Heat booth
The robotic spray system is fully automated and controlled at the same location as loading and unloading. The operator can control such parameters as heat, spray time, rotation speed, gun positions, as well as fan and atomization pressures. These are programmed through an advanced Human Machine Interface (HMI) with data collected and stored for each part that the system processes. The system can be programmed to run various parts and programs in batch runs. Individual parts within each batch can be selectively sprayed and indexed with unique parameters and control recipes from part to part. The robotic sprayers have excellent control and feedback monitoring, with motion tolerances of ± 0.0005″ (±0.0127mm). The environment is also consistently monitored during applications. Filter conditions are recorded and fan speeds are automatically adjusted and the operators are alerted if adjustments are required. During process, the operator, and the system can continually monitor the application of primer and top coats through a centralized vision system. If a part is not suitably coated with primer, then it is recorded, and that part will not be sprayed with the top-coat. If this happens three or more successive times, the system will halt, and the operator will be notified. Once the parts are coated they are returned to the operator at the same load/unload station. Cycle times run between 8-15 seconds per every two parts, depending on coverage and complexity.
These machines can be further customized with various levels of automation and fixturing to meet the customer’s needs. They are designed to be used with either water or solvent based materials when working with adhesives and adhesive primers. Point of fact, the 9913 Robotic Paint/Spray Machine, designed originally for the automotive industry. However, since its original conception it has been adapted to spray adhesives for production within the energy industry. These systems have an inherent flexibility that makes them customizable to fit various unrelated industries. Arnold Machines is a full-service provider, they deliver entire packages from concept to installation and beyond.