iGIOTTO

配备高性能喷涂机器人的吊挂式涂装线

实现稳定的涂装质量,以及最高的生产效率和最少的停机时间,是涂装复杂3D物体以及门窗的公司面临的主要问题。

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鉴于手工涂装工艺不能客观量化涂装产品的消耗量和生产能力,也不能保证稳定的成品质量,所以催生了门、窗、展架或复杂的三维物体的涂装生产自动化,以应对以下客户需求:

  1. 节省时间
  2. 提升复杂工件涂装质量
  3. 减少油漆消耗
  4. 提高生产率

机器不能完全代替人力。使用机器人涂装窗户、门和三维物体(如散装的椅子或乐器)时,还需要一名操作人员来控制和监督整个工艺流程,将最繁重的任务留给机器人来执行。这种作业方式将最大程度地降低在作业时间、油漆消耗、涂装质量稳定性和生产效率方面的人为误差。

采用高性能拟人机器人对展架和三维物体进行涂装,工艺可重复性高,品质稳定,油漆消耗量低,并且机器人极高的运行速度也将大大提高生产率。

那么,如何在不用手动编程的情况下获得最有效的作业路线,并最大限度地提高每个工件的的涂装质量呢?

目前,可以根据待加工的复杂工件几何形状,通过手动编程的方式设置机器人喷臂的运行路线。但是这种方式使机器人在接收运行命令并反复执行的同时,也会反复重现手动编程存在的误差。另一种方式是通过特殊软件进行点对点路线编程,但是,当您要求生产重复性高、油漆消耗少且涂装时间短时,最好的解决方案则是高性能的拟人机器人,例如带cVision工具的iGiotto机器人,其配备的3D扫描仪能够自动生成复杂形状的作业路线。

iGiotto

拟人喷涂机器人与cVision三维工件读取系统:稳赢组合

 

iGiotto是一个完整的水性涂料和溶剂性涂料喷涂系统,配套拟人机器人,专为涂装大型工件如门、窗框或形状复杂的物体而设计。工件通过吊挂式系统进行传输,喷涂过后分批进入集中式干燥隧道。

喷枪作业速度和喷枪至工件表面距离稳定,有助于降低油漆消耗并确保漆膜均匀。与此同时,从环境友好方面来看,能耗的降低和废料的减少也将帮助用户提升生产的可持续性。

cVision软件可自动读取待加工工件的三维图像,并计算出加工该工件的最佳喷涂路线。最新一代的自动三维读取系统(激光+摄像机)能够以前所未有的精度获取运输中工件的位置、尺寸和形状。

让您的涂装工艺成为您在各个业务层面的最强竞争优势

iGiotto喷涂机器人结合赛福徕特有的cVision 3D自动扫描工具,实现涂装流程的全自动化,全面提升涂装质量和稳定性,从而进一步降低油漆成本。

面对挑战,企业可以通过投资这样一套高级自动化软件来增加利润,并快速提升竞争力。以下是我们能够解决的主要问题:

  • 编程    
    目前,您可以通过手动编程的方式设置机器人喷臂的运行路线,用于加工复杂几何形状的工件。机器人会自动学习和记忆动作,并对后续同样的工件重复作业。您也可以选择使用线下软件进行点对点路线编程,但是需要您针对不同批次工件,手动输入相关数据以获取相对应的涂装加工参数。
  • 涂装
    人工喷涂窗框时,除了有经验的技术工人成本比较高,还存在产量波动和涂装质量不稳定的问题。同时,人工作业时油漆消耗量通常超过最佳值的15%至30%,从而导致过滤器更换和处理成本过高。
  • 产出
    喷涂小批量产品或定制产品时,工人需要暂停生产线,以便更换油漆颜色或编程新的运行路线。以上这些问题都会导致生产效率的低下,并且过多停产也会造成生产成本的大幅上升。
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那么,现在来看看我们如何通过iGiotto和cVision解决这些问题:

cVision的自动扫描功能避免了对机器人手动编程的麻烦,这意味着用户根本无需花费时间进行参数设置,所有程序均自动完成。您可以节省至少50%的作业时间,并且从始至终保持最优加工参数和涂装质量。

激光扫描和超清摄像头联合作业,使Igiotto能够通过数据库检索到已有的工作菜单,自动生成精确的运行路线。

当iGiotto开始工作时,它会自动优化并提升预先设定的运行路线的准确性。在喷涂门时,一般使用3枪支架,在适量节省油漆的同时还能最大程度的保证涂装质量和稳定性。即使切换产品类型,也可以在设备不停机的情况下换色,避免停产损失。当新的工件种类进入吊挂线时,设备软件可确保iGiotto在不中断生产的情况下从一种工件切换到下一种工件,从一种颜色切换到下一种颜色。

新型三枪支架

最近推出的三枪支架,特别适合喷门板。相对于传统的双枪,三枪能够大幅提升生产效率。在门板喷涂作业中,只需一遍喷涂即可,无需往返重复,大约可节约40%作业时间。

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Useful Finishing articles. Read more:

Frequently Asked Questions

What materials can I use overhead coating solutions on?

Practically any material can be coated.

吊挂式门窗涂装线的优点是什么?

考虑到门窗的尺寸较大,吊挂作业是必须的。此外,将门窗悬空吊挂也方便进行正反双面涂装。

如何评估涂装质量?

涂装质量的判定主观性比较强,但使用自动涂装系统可最大程度的确保各个生产批次漆膜质量的一致性/涂装精度。

如何使门窗涂装流程更高效?

人工涂装存在涂装效率和质量不稳定的现象,进而影响整个涂装工艺的能效,而自动涂装系统则在控制油漆消耗量和涂装质量一致性方面优势突出。

 

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.

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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Products and Solutions

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