A system for reducing layers and increasing efficiency of automobile four-coat paint spraying

Abstract

This utility model discloses a layer-reduction and efficiency-enhancing system for four-coat automotive paint spraying, including a spraying production line and a control system. The spraying production line is sequentially equipped with a primer spraying station, a color paint spraying station, a pearlescent paint spraying station, and a clear coat spraying station. The primer spraying station is equipped with one primer spraying robot, the pearlescent paint spraying station is equipped with one pearlescent paint spraying robot, and the clear coat spraying station is equipped with two clear coat spraying robots. The color paint spraying station is equipped with only one color paint spraying robot, and the primer used by the primer spraying robot is a colored primer that matches the color of the paint to be sprayed. In this way, only one color paint spraying robot is needed to spray one coat of color paint to achieve the target color depth and effect, saving the configuration requirement of a color paint robot; saving color paint materials; simplifying the spraying process, shortening the spraying time per vehicle, and improving work efficiency; and eliminating the methods of "offline priming" and "manual touch-up painting", saving labor costs.

Description

Technical Field

[0001] This utility model relates to the field of automobile manufacturing technology, and in particular to a layer reduction and efficiency improvement system for four-coat paint spraying of automobiles. Background Technology

[0002] In high-end automotive painting, a typical four-coat system is used: one layer each of primer, color coat, pearlescent finish, and clear coat. Traditional four-coat spraying requires each coat to reach the thickness recommended by the paint manufacturer to ensure consistent color (acceptable ΔE value) and sufficient hiding power. Achieving this requires a minimum configuration of painting robots: typically one primer robot, two color coat robots (for two coats to ensure film thickness and hiding power), one pearlescent finish robot, and two clear coat robots. However, many painting plants are limited by initial investment or production line layout, resulting in an insufficient number of robots, particularly lacking dedicated pearlescent finish robots or a second color coat robot.

[0003] To resolve this contradiction, existing technologies typically employ three alternative solutions: (1) Offline base coating: The car body is moved outside the production line and partially coated using manual spraying or other methods before returning to the production line. This method is characterized by high labor costs, low efficiency, and a tendency to cause quality fluctuations. (2) Manual touch-up: After online spraying, unqualified areas are manually repaired. This method also suffers from unstable quality and high costs. (3) Online spraying twice: The car body is allowed to circulate twice on the line to complete all coatings. This method significantly increases energy consumption, prolongs the production cycle, and reduces production efficiency.

[0004] Therefore, there is an urgent need for a layer-reducing and efficiency-enhancing system that can efficiently complete four-coat effect spraying without increasing the number of spraying robots or reducing coating quality. Utility Model Content

[0005] To address the technical problems existing in the background art, this utility model proposes a layer reduction and efficiency improvement system for four-coat paint spraying of automobiles.

[0006] This utility model proposes a layer-reduction and efficiency-enhancing system for four-coat automotive paint spraying, comprising: a spraying production line and a control system communicatively connected to the spraying production line; the spraying production line is sequentially equipped with a primer spraying station, a color paint spraying station, a pearlescent paint spraying station, and a clear coat spraying station; the primer spraying station is equipped with one primer spraying robot, the pearlescent paint spraying station is equipped with one pearlescent paint spraying robot, and the clear coat spraying station is equipped with two clear coat spraying robots; the color paint spraying station is equipped with only one color paint spraying robot for completing a single coat of color paint, and the primer used by the primer spraying robot is a colored primer that matches the color of the paint to be sprayed.

[0007] Preferably, the color of the colored primer is the same as or similar to the color of the subsequent painted paint, and the color difference value ΔE is less than or equal to 1.5.

[0008] Preferably, the control system has a built-in spraying parameter control module that matches the colored primer and the reduced-layer spraying, used to control the flow rate, spray width, forming air pressure and turbine speed of each spraying robot, so that the single-pass spraying film thickness reaches the preset standard.

[0009] Preferably, the film thickness standards preset by the spraying parameter control module are: 15-25μm for colored primer, 10-20μm for colored paint, 5-15μm for pearlescent paint, and 30-50μm for clear varnish.

[0010] Preferably, the primer spraying robot, the color paint spraying robot, the pearlescent paint spraying robot, and the clear coat spraying robot are all configured as six-axis or seven-axis linkage high-speed electrostatic rotary cup spraying robots.

[0011] Preferably, it also includes a paint supply and mixing device located next to the spraying production line, wherein an independent paint supply circuit is established between the paint supply and mixing device and the primer spraying robot.

[0012] In summary, this utility model has the following beneficial effects: By using a primer spraying robot with a colored primer that matches the color of the paint to be sprayed, since the colored primer already provides a good color base and hiding power, there is no need for a second paint spraying robot to spray a second coat of paint. Only one paint spraying robot is needed. This paint spraying robot only needs to spray one coat of paint to achieve the target color depth and effect, saving the configuration requirement of a paint spraying robot, reducing the rigid requirements on the number of robots for the spraying manufacturer, reducing the initial investment in equipment and the space occupied on the production line; at the same time, reducing one coat of paint spraying saves paint material; avoids the "two-round online spraying" scheme, simplifies the spraying process, shortens the spraying time per vehicle, reduces baking energy consumption and production line operating energy consumption, and improves the overall production cycle and capacity; it eliminates the methods of "offline base coating" and "manual touch-up painting", saving labor costs and avoiding the quality risks and management costs caused by manual operation; the colored primer provides excellent base color hiding power, ensuring color consistency from the process source. By combining the high-precision parameter control of the control system, the uniformity of film thickness of single-layer spraying is ensured, thereby guaranteeing that the color difference (ΔE) and appearance effect (orange peel, gloss) of the final paint surface consistently meet high standards.

[0013] Additional aspects and advantages of this invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of a layer reduction and efficiency improvement system for four-coat paint spraying of automobiles, according to an embodiment of the present invention.

[0015] In the picture:

[0016] 1. Spray coating production line; 2. Control system; 3. Primer spraying station; 4. Color paint spraying station; 5. Pearl paint spraying station; 6. Clear varnish spraying station; 7. Primer spraying robot; 8. Color paint spraying robot; 9. Pearl paint spraying robot; 10. Clear varnish spraying robot; 11. Paint conveying and mixing device; 12. Independent paint supply circuit. Detailed Implementation

[0017] The embodiments of this utility model are described in detail below. Examples of these embodiments are illustrated in the accompanying drawings, wherein the same or similar symbols denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this utility model, and should not be construed as limiting this utility model.

[0018] like Figure 1 As shown in the figure, this embodiment proposes a layer reduction and efficiency improvement system for four-coat automotive paint spraying, including: a spraying production line 1 and a control system 2 communicatively connected to the spraying production line 1; the spraying production line 1 is sequentially provided with a primer spraying station 3, a color paint spraying station 4, a pearlescent paint spraying station 5, and a clear coat spraying station 6; the primer spraying station 3 is equipped with one primer spraying robot 7, the pearlescent paint spraying station 5 is equipped with one pearlescent paint spraying robot 9, and the clear coat spraying station 6 is equipped with two clear coat spraying robots 10; the color paint spraying station 4 is equipped with only one color paint spraying robot 8, which is used to complete a single coat of color paint, and the primer used by the primer spraying robot 7 is a colored primer that matches the color of the paint to be sprayed.

[0019] Specifically, the color of the primer is the same as or similar to the color of the subsequent paint coat, with a color difference value ΔE less than or equal to 1.5. This ensures sufficient color coverage and allows it to replace one coat of paint.

[0020] Thus, by employing a primer spraying robot 7 that uses a colored primer that matches the color of the paint to be sprayed, and because the colored primer already provides a good color base and hiding power, there is no need for a second paint spraying robot 8 to spray a second coat of paint. Only one paint spraying robot 8 is needed. This paint spraying robot 8 only needs to spray one coat of paint to achieve the target color depth and effect, saving the configuration requirement of a paint spraying robot, reducing the rigid requirements on the number of robots for the spraying manufacturer, reducing the initial investment in equipment and the space occupied on the production line; at the same time, reducing one coat of paint spraying saves paint material; avoids the "two-round online spraying" solution, simplifies the spraying process, shortens the spraying time per vehicle, reduces baking energy consumption and production line operating energy consumption, and improves the overall production cycle and capacity; it eliminates the methods of "offline base coating" and "manual touch-up painting", saving labor costs and avoiding the quality risks and management costs caused by manual operation; the colored primer provides excellent base color hiding power, ensuring color consistency from the source of the process. By combining the high-precision parameter control of the control system 2, the uniformity of the film thickness of the single-layer spraying is ensured, thereby guaranteeing that the color difference (ΔE) and appearance effect (orange peel, gloss) of the final paint surface consistently meet high standards.

[0021] Furthermore, the control system 2 has a built-in spraying parameter control module that matches the colored primer and the reduced-layer spraying, used to control the flow rate, spray width, forming air pressure and turbine speed of each spraying robot, so that the single-pass spraying film thickness reaches the preset standard.

[0022] Furthermore, the preset film thickness standards of the spraying parameter control module are: 15-25μm for colored primer, 10-20μm for colored paint, 5-15μm for pearlescent paint, and 30-50μm for clear coat.

[0023] In this embodiment, the primer spraying robot 7, the color paint spraying robot 8, the pearl paint spraying robot 9, and the clear varnish spraying robot 10 are all set as six-axis or seven-axis linkage high-speed electrostatic rotary cup spraying robots. The specific structure is the same as the existing structure, and will not be repeated in this article.

[0024] Furthermore, it also includes a paint supply and mixing device 11 located next to the spraying production line 1, with an independent paint supply circuit 12 established between the paint supply and mixing device 11 and the primer spraying robot 7, in order to avoid cross-contamination with traditional color primers.

[0025] It should be noted that the specific structure of the paint conveying and mixing device 11 can refer to the existing structure, and will not be repeated in this article.

[0026] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A layer-reducing synergistic system for automotive four-coat paint spraying, comprising: A spraying production line and a control system communicatively connected to the spraying production line; the spraying production line is sequentially equipped with a primer spraying station, a color paint spraying station, a pearlescent paint spraying station, and a clear coat spraying station; the primer spraying station is equipped with one primer spraying robot, the pearlescent paint spraying station is equipped with one pearlescent paint spraying robot, and the clear coat spraying station is equipped with two clear coat spraying robots; characterized in that the color paint spraying station is equipped with only one color paint spraying robot for completing a single coat of color paint, and the primer used by the primer spraying robot is a colored primer that matches the color of the paint to be sprayed.

2. The system for automotive four-coat paint spraying according to claim 1, wherein The color of the primer is the same as or similar to the color of the subsequent paint, and the color difference value ΔE is less than or equal to 1.

5.

3. The system for automotive four-coat paint spraying according to claim 1, wherein The control system has a built-in spraying parameter control module that matches the colored primer and the reduced-layer spraying. It is used to control the flow rate, spray width, forming air pressure and turbine speed of each spraying robot so that the single-pass spraying film thickness reaches the preset standard.

4. The system for automotive four-coat paint spraying according to claim 3, wherein The preset film thickness standards of the spraying parameter control module are: 15-25μm for colored primer, 10-20μm for colored paint, 5-15μm for pearlescent paint, and 30-50μm for clear coat.

5. The system for automotive four-coat paint spraying according to claim 1, wherein The primer spraying robot, the color paint spraying robot, the pearlescent paint spraying robot, and the clear varnish spraying robot are all configured as six-axis or seven-axis linkage high-speed electrostatic rotary cup spraying robots.

6. The system for automotive four-coat paint spraying according to claim 1, wherein It also includes a paint supply and mixing device located next to the spraying production line, and an independent paint supply circuit is established between the paint supply and mixing device and the primer spraying robot.

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