Dürr’s 12th open-house, focused on intelligent flexibility, is running online this week.
For the first time, Dürr is holding its open-house virtually. This week the company is presenting its new products to increase efficiency and profitability in manufacturing while reducing resources for large volume manufacturers and small electric car start-ups.
The 12th open-house includes presentations, interviews and technical demonstrations focused on solutions that will replace the previous line concept with a future-oriented configuration based around flexible, intelligently connected process modules which can be scaled to meet customers’ requirements.
“What manufacturers need most these days from the painting process is flexibility, cost efficiency, and sustainability. We answer this need with our concept of the paint shop of the future, which overcomes the limitations of the inflexible production line. Instead, the 120 or so individual operations are executed in scalable modules or small sections, in parallel and timed precisely to the needs of the individual body,” stated the CEO of Dürr, Jochen Weyrauch. “This makes it easy to extend capacities and channel different vehicle types through the painting process. Ideally, even individual items can be handled while production is underway.”
Intelligent flexibility and artificial intelligence
Single stations can be custom equipped using the automated guided vehicle EcoProFleet, the first AGV specifically developed for paint shops. In combination with a high-bay storage, it lays the foundation for intelligent material flow control along the whole process. The DXQcontrol software controls each AGV, so all modules are always efficiently used directly from the pretreatment phase.
The new modular system design of EcoProWet PT, on the other hand, is based on standardized chambers instead of immersion tanks arranged one after another, in order to allow more flexibility and save space. Dürr has further automated the seam sealing phase with the new EcoSealJet Pro automatic applicator and the DXQ software powered by artificial intelligence.
The box configuration for the painting process in the EcoProBooth combines the application of the primer and base coat layers in one single spray booth, eliminating two of the three usual conveying operations. Moreover, it is also suitable as a standard spray booth with the same robot equipment for both base coat and clear coat.
The overspray-free EcoPaintJet Pro painting system is now able to automatically apply two-component paints (2C), besides two-tone lines for car roofs, colour changes, vertical surfaces and decorative paint applications. In addition to this, the atomizer generation EcoBell4 can deliver shorter color change times and automated atomizer cleaning, therefore allowing to paint more units at the same time. Low paint and solvent consumption help to make production more sustainable by reducing VOC emissions.
The software belonging to Dürr’s DXQ series ensure that the processes interact smoothly in the modular concept, transforming the box-based painting system into a smart factory. DXQplant.analytics uses AI algorithms and machine learning modules to collect and analyse sensor data, messages, and information, helping to identify correlations and avoid errors. A feedback feature constantly provides the algorithm with additional information, so predictions about the need for maintenance can become more and more precise.
“The many participants from all over the world, well in excess of 1,000, and all of the enthusiastic feedback are indicators of the great interest generated by the first virtual open house. Our concept for the paint shop of the future is a complete success. It delivers exactly what manufacturers need,” concluded Weyrauch.