Absolutely most efficient powder painting line in Finland with 1.44m/min and c/c 100mm support distancy. Productivity with main products increased 33%. Pretreatment line leaks fixed and process developed to next level. Twin track transfer conveyor fully renoviert. Powder painting equipment (Trasmetal) support. Factory ventilation as well powder filter system development to fix basic design errors.
High volume aluminium factory profile painting line tecnical support, system teaching, service planning and service work leadership. Development of updated paint shop user manual for chrome free powder painting.
Powder painting transfer conveyor grounding point cleaning system to ensure propper grounding. Before system assemply both chains had to be cleaned several days because of old powder burned to support surfices. This problem is very typical.
For aluminium profile pre-treatment before profile powder painting. Main bridge recycled technology. Three applications with PLC programs, computer HMI and process control according customers requests. All in active use.
Five automatical powder painting line turn-key designs from scratch. Conveyor components were all recycled. Electric heating curing ovens.
New floor coated with chemical resistant coating. Crane track design. Crane was recycled to these new tracks. Pre-treatment tanks are also recycled but also two new tanks 8x1x2m^3 will be made.
Mechnaical design and dimensioning.
Parts were bought from a local bakery. From those componets and some extra parts we designed a new line. Every part were measured and documented.
Sand floor shall be soon have a new floor. Open wall will be shut by sandwitch panels waiting only floor foundation.
Recycled and remodified old conveyor supported from floor level which reduce flexibility. Pilar positions must be carefully designed. To the roof is was not allowed to fix any supporting elements.
World's largest cruiser ships hoisting application evaluation and solution research. Picture center above passenger lift 'Central park' service crane assembled according to our proposal drawings.
Mechanical details desing, middle heaven, layout, controls system design, conveyor electric cabin design, plc program design and programming, computer HMI programs, automatical quality data collection and intelligent interface for easy checking. Exhaust and fresh air input ventilation as well as powder exhaust main designs using existing machinery.
Automated power and free (P&F) conveyor simple HMI panel. Electric diagrams, mechanical costruction, connection to PLC and computer HMI. Two chains forward/backward, stop 1-5 open/close, mode selector Auto/Manu. Siliminium panel body for hard use.
Old eccentrical driving system changed to standard centric crane I-beam trolleys.
Old factory where was established a new painting shop. Based on to our mechanical design a local company made a project and installed new tracks. Roof support was not allowed.
All mechanical and electric controller desings by us. A 'turn-key' project.
Recycled crane under way to rinse aluminium profiles. Rigid steel construction support previous known problems with vertical guides. Construction support a gage from swinging in a case of line emegency stop.
Existing 2.nd floor was removed to a a point seeing stair joint. Stairs designs to ensure safe entry to office.
CSF Schwaben track support fixed to adjustable I-beam support which makes track assy easy and accurate.
Our design and integration to crane technology. Ready gages and trolleys waiting production to start up.
Empty gage trolley waiting a gage from pre-treatment process. Oven construction by a subcontractor.
Crane capacity was increase 10-20 times from previous use. Design contructions were made to improve mechanical reliability and automation. From old crane was taken only technology which was evaluated probber working.
Pre-treatment tanks in position. Crane lifted to its tracks.
A simple guide to position product for automatic lift up. Inductive switch is reguired for loading activation and ensure start up.
Oven output and unloading area covered with a exhaust cap to reduce hot air and curing smoke disadvantages.
Technical inspections and local personel support to provide propper service for hoisting and conveyor applications.
Automatical diesel engine 5 color painting station conveyor and color change control panel. PLC control. Required color code received from control HMI computer which read escort memory tags before product enter to the painting station.
Rotary encoder (yellow) measures linear position where as double inductive limit switvh maesures vertical position in both crane vertical guides. Recycled and new construction support each others.
Crane and material handling machine power and control system cabeling designs and project management including component selection, ordering and installation management.
Diesel motor individual robotised painting program and wet painting color selection were controlled with escort memory chips. Escort memory also provide accurate product flow times for motor final insallation. Line was started with a production of 13.000 motors and updated up to 24.000 motor manufactured annually. Design, installation, development and upgrades.
Recycled crane with improved stability to ensure automation. Old crane had problems to stuck in position because of false construction.
Steel construction designs for Line (yellow/red) and middle heaven (light grey). Line design changes taking in count pull nose distancies. Old and new conveyor parts used to enable conveyor re-cycling. Orginal line built 1988. Detectors changed to inductive type. Some old conveyor parts kept because customer request - link chain power unit. Line still in production use. Conveyor by Caljan DK.
All mechanical and electric designs. Two power supplies to enable production plant one high voltage transformer service/out of order. Orginal transformers were old CCCP ones. Still in production.
Control pilar mechanical design. Electric wirings and system start-up.
Heavy wood industry machine wheel load study to improve product quality. New solutions for motor control, gearboxies and control systems.
Old existing hoist recycled. Added vertical positioning toothband tracking with double input indcuctive encoder to count up/down position with old japanise IDEK plc which had only one counter input. Counter was used for crane positioning. Crane is still in used as designed.
To ensure rigid construction and reduce dust to drop down, conveyor lines are supported under rigid 'middle heaven'. Construction enables accurate track support construction.
Gage and crane design by us. Dry oven right by a sub constructor. Bath designs by the customer.
Customer's firsts 3-axis portal robots for cam shaft palletizing to their storage boxies. New empty storage box piled over full layer of cam shafts. Awarded by 'Finnish key work of the month' on Finnish TV company MTV3.
Pallets on their own pile. Different pallet sizes to improve transportation efficiency. Intermediate cardboards in two adjustable pile positions filled automaticly according user pile layout. Cardboads hold palletized product piles better in shape while transportation. No fixed pallet places, computer HMI enables easy teaching. Communication consult for PLC<->PC. Project start-up.
Problems to be solved: 1) 15 seconds/one box, a'20kg 2) low headroom Solution: Fixed pilar at both sides of belt conveyor. Lift one layer and fill belt conveyor according transfer speed. Customers control system.
1. palletizing robot were was solved increasing product weights and numbers. Sugtion system developement, pilar hoist with internal built pneumatic hoisting zylinder and tooth band drive system. Computer HMI with fluent pallet positions - Notice: No fixed storage points, positions centers were teached by driving crane above storage center.
Automated crane computer control TEKES project started 1985. Scissors guide was developed for this project and computer controlled crane was presented at Hannover Fair 1987. Tooth band driven crane for long distancies was patented FI86291 17.2.1989. Picture project Sime made computer SQL based HMI product storage system and consulted control cabin manufacturer how make PLC program for Siemens S5 PLC.
Low headroom make possible to increase above locating show theater height. Spare piston crank shaft located on a turn table in the midle of 4 diesel engines. Empty place was for broken piston-crank shaft. Customers problem (pilar) was turned to winning solution how reduce piston sideway lifting. Shipyards first electric driven lifting system was built according Loyds register. English language documentation.