discussion on automation of painting shop

7/31/2019 Discussion on automation of painting shop

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M. S. Ramaiah School of Advanced Studies 1

Discussion on automation of painting shop

M. Sc. (Engg.) in Advanced Manufacturing Technology

Members:

Module leader: Prof. Ramdas Chandrashekar

Sandeep N

Module title: Automation in manufacturing and systems simulation

Prashantkumar V K MR

Harish Simulator

Praveen Patelappa Integration consultant

Chennakeshava Automation expert


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Discussion

1. Requirements will be proposed by the MR

2. Simulation expert will propose the model

3. Integration expert will give the feedback on feasibility

4. Automation expert will give the details of equipments and

components needed

5. MR will give feedback considering economical feasibility

6. Step No 2, 3 & 4 will be repeated

7. Conclusion


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Problem description from MR


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Introduction to Problem

In a machine tool manufacturing industry all the enclosures are

made from sheet metals. In order to protect from the corrosive atmosphere

these are painted by spray painting method.

Painting shop contains mainly 3 areas Cleaning, Painting and

curing . All the components are handled manually during the process and

process is also done manually. There is a small oven which can hold300mmX300mmX300mm parts. Now the organization has decided to go

for the automation of the entire paint shop.

Cleaning Painting

Oven

Natural

curing

Present process in practice

Size of

component


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Reasons for opting automation

Cleaning of the components is done by manually dipping into the chemical tanks

and all components are handled manually using a crane.

Since the paints are hazardous to human health when it is inhaled or when it gets

in contact with the skin, these working areas are not safe for human beings.

Painting work is a repetitive but skilled work, it needs experienced and skilled

labour which adds up the component cost.

Man power calculation: average salary for one employee = 10000 X 14persons

140000/month

5 operators at cleaning, 4 painters, 2 persons at curing station, 3 persons fortransport

Till now a small oven was used for carrying out the curing of painted small

components. Now the organization is interested in buying the new oven which

can accommodate all the components.


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Component sizes varies from 30mmX30mmX2mm to several meters in

length.

There are only two types of paints used viz. blue and white.

There is no mix of these colours, components is painted either blue or

white.

There will be mix of components of both colours.

All the three areas has to be automated.

Power consumption and human involvement should be as minimal as

possible.

Parameters to be considered for Automation


7/23 M. S. Ramaiah School of Advanced Studies 7

Simulator



Simulation for Proposed model



Simulation block diagram

HMI /

control panel

Interfacing

circuit or signal

conditioners

SensorsAutomation

hardware



Integration consultant



Simulation for the above process will help in

controlling and monitoring the complete process,

thereby simulation is needed for above process in

order to simplify the automation.

Whether simulation needed



Controlling parameters1. Flow control for cleaning stations

2. Spray control for painting section

3. Temperature control for hot water and oven section

Monitoring parameters

1. Measuring size of the component

2. Temperature monitoring in hot water and oven

Controlling and monitoring parameters



Limiting parameters1. Segregation of the components should be done either

manually or components should be tagged with RFID or

other means

2. Two robotic arms will improve the quality of the sprayand shade of the paint



Interfacing stages

1. Sensor will sense the temperature of the hot water tank and

will send back the data to control panel, depending on data

heater for the tank will be actuated.

2. The conveyor will be fitted with sensors to track the

component location. Component will have caption ofnumbers in the control panel.

3. Paint level sensor will give data to the control panel which

is used for refilling the paint tank.

4. Sensors from the oven will be simulating the coilactuation/de-actuation process and also temperature of the

oven.



Automation expert



HOT WATER

CLEANING

TANK

FLUID LEVEL

SENSOR

INCOMING

SOLONOID VALVE

EXIT SOLONOID

VALVE

PUMP ACTUATION

CIRCUITS

TEMPERATURE

SENSORHEATER

Block diagram of automation hardware



ACID

CLEANING

TANK

FLUID LEVEL

SENSOR

INCOMING

SOLONOID VALVE

EXIT SOLONOID

VALVE

PUMP ACTUATION

CIRCUITS




HOT AIR

DRIER

COMPONENT

SENSOR

INCOMING

SOLONOID VALVEEXHAUST

PUMP ACTUATION

CIRCUITS

TEMPERATURE

SENSORHEATER




COMPONENT

CONVEYORS (1 OR 2)MOTOR DRIVEN

COMPONENT

HEIGHT SENSOR

(LASER CURTAIN)

ACTUATION OF

SPRAYER SOLONOID

(WHITE)

ROBOT ACTUATION FOR

PAINTING MANUPALTOR

ROBOT

ACTUATION OF

SPRAYER

SOLONOID (BLUE)

COMPONENT

COUNTER AND

REGISTERING




COMPONENTSENSOR

(INCOMING)

DETERMINATION OF SIZE

OF THE COMPONENT

DEPENDING ON LASER

CURTAIN DATA

OVEN COIL ACTUATOR /

DEACTUATOR

COMPONENT

SENSOR

(EXIT)

TEMPERATURE

CONTROLLER




Sl Device Qty Price/unit1 Solonoid 7 975.462 Pumps 3 35003 Thermocouple 2 563.54 Fluid level sensor 2 2159.545 Manipulated robot 1 18154506 Laser curtain 1 1500007 conveyor 2 210008 Sheetmetal tank 3 12000

Cost estimation


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Outcomes of the discussion

1. Much of the man power is reduced

2. Monitoring facility helped in controlling and troubleshootingthe system effectively.

3. Painting quality can improved compared to the earlier

process.


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M S R i h S h l f Ad d S di 23

Thank You

discussion on automation of painting shop

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