iGIOTTO

Overhead coating lines with high
performance ANTHROPOMORPHIC ROBOT

Achieving coating quality and consistency, together with the highest production efficiency and minimal downtime is the major issue facing companies who are coating complex 3D objects, as well as windows and doors.

If, on the one hand, a manual coating process does not allow to objectively quantify the consumption of coating products and the production capacity, in addition to not guaranteeing consistent finish quality, on the other hand, automating the coating process of doors, windows and fixtures or complex three-dimensional objects allows to promptly respond to the 4 main needs of our customers:

Save time
Improve coating quality where trajectories are complex
Reduce paint consumption
Increase productivity

The Robot will not completely replace manpower. For applications including coating windows, doors and three-dimensional objects such as disassembled chairs or musical instruments, the anthropomorphic spraying robot needs a person to control it and monitor process stages, while leaving the heaviest tasks for the robot to carry out. This allows users to minimise all the manual operations that are likely to create problems in terms of time requirements, paint consumption, and inconsistent quality and productivity.
Repeatability in the coating process of fixtures and three-dimensional objects with high-performance anthropomorphic robots guarantees consistent quality and lower product consumption. Finally, the robot's extremely high operating speed considerably increases productivity.

So how is it possible to obtain the most efficient trajectories while maximising coating quality on every single piece and completely avoiding manual programming?

At present it is possible to program the robot manually by physically guiding its spraying arms around complex geometric shapes. This means that the robot learns how to move and replicate not only movements but also the related inaccuracies due to manual programming, piece after piece. Other solutions include point-to-point trajectory programming via special software However, when you need high repeatability, low paint consumption and shorter application times, the best solution is a high-performance anthropomorphic robot, such as iGiotto with cVision, the 3D scanner able to automatically generate trajectories of complex shapes.

iGiotto

ANTHROPOMORPHIC SPRAYING ROBOT AND cVision 3D READING system:
THE WINNING DUO

iGiotto is a complete spray coating system for water-based and solvent-based products using an anthropomorphic robot designed to paint large-sized objects such as doors, window frames or objects with a complex shape, and materials other than wood. Products transit on overhead lines and exit the spraying area into a drying tunnel before being collected in batches. Constant speed and constant distance between the spray guns and the product optimise lacquer consumption and ensure coating consistency. In environmental terms, lower consumption and less waste improves sustainability.

cVision acquires the 3D image of the piece to be coated and uses its special software to determine the best trajectories. The latest-generation, automatic 3D reading system (laser + camera) acquires position, size and shape of pieces in transit with unprecedented precision.

Turning your coating process into competitive edge for your business, at all levels.
iGiotto when used in conjunction with our exclusive cVision 3D Reading Barrier ensures time savings through coating process automation, improves the quality and consistency, thus leading to reduced lacquer consumption and lower costs.

Faced with the following key issues, companies can become instantly more competitive by investing in a system where special software and automation provide immediate benefits. These are the main challenges we have addressed:

PROGRAMMING Today’s options allow you to manually program a robot by physically guiding its spraying arms around the complex geometrical shape. The robot learns how to move and replicates the movement piece after piece. You can also program point-to-point trajectories using a software off-line, but each batch will require your manual intervention to enter data into the software to obtain the coating parameters.
COATING Apart from the cost of a skilled operator, manual spraying of window frames often leads to fluctuating yields and coating inconsistency. Lacquer consumption frequently exceeds the optimal amount by 15 to 30%, leading to high filter replacement and disposal costs.
OUTPUT Production batches can often be small or customised. Operators will need to stop the line for colour changeover or to re-program the trajectories. All this is an obstacle to production efficiency and incurs costly downtime.

So let’s see how we have solved these issues thanks to iGiotto and cVision:

cVision avoids the need to manually program an anthropomorphic robot. This means no time at all spent defining trajectories. It’s all done automatically. You save time (at least 50%), can be sure of obtaining optimal parameters and consistent coating quality from the first piece to the last. The combined action of the laser and ultra-high resolution cameras allow iGiotto to automatically generate precise work trajectories based on the “recipes” of objects present in its database.

When iGiotto comes into play, the robot capitalises on the accuracy and optimisation of the pre-defined trajectories. In the case of doors, spraying with the new 3-gun wrist now saves considerably on lacquer consumption and ensures the best possible quality and consistency. Colour changes can be performed without even stopping the equipment, even for different products, so downtime is eliminated. And as new pieces enter the overhead line, the software makes sure iGiotto can switch from one piece to the next and one colour to the next without interrupting production.

New 3-gun wrist

The recently introduced 3-gun wrist, especially for coating doors, enables companies to enhance their production efficiency compared to the conventional 2-gun wrist. While spraying the front of the door, just one pass is necessary reducing spraying time by approx. 40% and there is no need to have crossover trajectories.

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Frequently Asked Questions

What materials can I use overhead coating solutions on?

Practically any material can be coated.

What are the advantages of vertical door and window coating?

Given their considerable size, being able to hang doors and windows is essential. Moreover, overhead lines allow both sides to coated.

How can I measure workpiece coating quality?

While quality is entirely subjective, using an automatic system guarantees coating application consistency/precision on the produced lots.

How can I make my window coating process more efficient?

While an automatic coating system ensures steady product consumption and ensures application consistency throughout the day, a manual system may cause significant variations in terms of both productivity and quality. This variation is the main source of low coating process efficiency.
What's more, our software enhances efficiency, making the operator's work easier.

How easy is it to programme a coating robot?

It couldn't be simpler. Our 2D or 3D scanner captures images of the piece to be coated as it passes. The software then automatically generates the trajectories needed for optimal piece coating.

How long does it take to clean a machine?

That depends on the machine in use. As a rough guide, from 10 minutes for the simplest up to half an hour for the most complex. In the case of a window coating line, there will be several machines performing different applications.

Can coating consumption be controlled?

Yes, with the aid of additional systems.

Can workpiece dimensions be checked?

Yes, by using a specific 2D and 3D scanner.

Can I coat my windows assembled or disassembled?

Coating can be done either way without any shape or size restrictions. It's this aspect, in fact, that makes overhead lines so advantageous.

What do I need to know to start coating?

Little previous experience is needed to start coating. However, close consultation with specialists is essential to find the process that's right for you, based on, for example, productivity goals and the material to be coated. What's more, our solutions require little worker supervision.

How long will a coating system last?

We have plants that have been in regular operation for over 25 years.

Can I limit colour changeover downtimes?

Yes. Colour changes are done almost exclusively while the machine is running.

Can I manage programming of my workpieces easily?

Trajectories are programmed automatically by our machine control software. The only information that needs to be added concerns the speed/distance/angle of the spray guns.

Are the edges coated too?

Yes.

Can I coat disassembled musical instruments?

Depending on the type of instrument, they can be coated either assembled or disassembled.

What do I need apart from the coating machine?

Both the coating and the spraying equipment are usually supplied. A sanding solution will also be needed to complete the process.

How can I boost productivity?

Automatic spraying solutions (e.g. iGiotto or reciprocators) are ideal for this. Manually coating pieces that can be as large as 5000 x H3000 mm is problematic and results in low productivity. Manual coating also means poor application consistency and excessive or uncontrollable product consumption. This affects the final quality of the coating and the piece.

How flexible is the line?

A line must be flexible. It must be designed according to customers' needs and their available space.
When it comes to shape, size and thickness, overhead coating poses no particular limits. In fact, the same station can even be used to coat 2 pieces in different ways.

How many people are needed to run the line?

From a minimum of 2 people for a simple line, up to a maximum of 4 for more complex ones.

Products and Solutions

The search function is now available for complete production lines. All you need to do is select the material involved, the market sector or the finished product. Whichever search criteria is used, a corresponding solution for your spray coating line is obtained in just 3 steps. Search results will indicate the most suitable solution, based on the level of flexibility required, the productivity range and the overall footprint. Solutions are classified as small (S), medium (M) or large (L).

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