Solutions for Paint Shops
A Chinese car manufacturer uses Turck’s BL compact stations, connectivity products and proximity switches in its new paint shop
Harsh ambient conditions in the paint line
The multi-stage painting process in the automotive industry, the high level of automation in the plant, and the different process steps coordinated in the extremely harsh conditions present the automation components used and the integrator with a particular challenge. The central task of the project was to automate the transport system of the paint line. It is based on an automated skid conveyor system. The autonomous and safe control of the skids on the rails requires the use of many position measuring points, sensor signals and motor control signals.
Open standard
The customer’s specifications included the alignment and control of the paint robot as well as the flexible integration of the conveyor belt systems – and all this while maintaining a constant level of production efficiency in full operation. The responsible engineers wanted an automation system that was based on an open protocol and which could be implemented with standard cabling.
It was decided to use DeviceNet. This fieldbus standard is an open protocol that provides the level flexibility to optimally meet the requirements of the paint shop. Due to the size of the plant Turck’s BL compact stations are installed, which route all inputs further via the bus cable to the next I/O station, and then on to the master. Turck’s BL compact DeviceNet modules with protection to IP67 are fitted on the steel support of the transport system along the entire length of the paint line – also directly next to the motor controller which coordinates the entire transport of the skids.
The customer uses BL compact stations with 16 digital inputs (BL CDN-8M12S-8DI-P) and the smaller version with eight digital inputs (BLCDN-4M12S-8DI-PD). They form the backbone of the entire bus system in the paint line.
Extremely robust
The compact stations are fully encapsulated in epoxy resin in order to achieve their tremendously robust design and IP69K protection. The thermal performance of the block modules is also impressive: They can withstand temperatures from -40 to +70 °C. Despite the high temperatures, the paint line does not effect the modules. The extensive diagnostic functions of the I/O stations enable the customer to increase availability and the required level of reliability. LEDs on the module provide workers with reliable status indication of the inputs locally in the field. The matching Y junction cables as well as the bus cable likewise come from the Turck portfolio.
Turck offers BL compact modules for analog signals, switch signals for connecting RFID read/write heads or other signal types. Individual BL compact stations were fitted with signal processors to meet the customer’s special application requirements in order to save costs on stations and cables. The system is perfectly matched to the application, is easy to maintain, and also includes proximity switches from the Turck portfolio as well as the fieldbus stations and connectivity products.
- Automobile
- Press Shop – Tool Identification
- Sheet Metal Thickness Measurement
- Body Shop – Welding Nut Detection
- Paint Shop – Skid Identification
- Area Guarding for Robotic Cells
- Final Assembly – Robot Assembly
- Inspection of Tips on a Welder
- Final Assembly – Diagnosis of Leaks
- Tier 1 – Bumper Identification
- Manual Feeding in Weld Cell
- Powertrain – Contactless Verification
- Body Detection in Automobile Production
- Detecting Black Parts on Black Door Panel
- Moonroof Clear Glass Detection
- Long-Range Inspection in Automotive Assembly
- Rubber Washer Detection on Engine Block
- Engine Block Part-In-Place Detection
- Electric Vehicle Detection in Charging Station
- Vehicle Detection in a Self-Serve Car Wash
- SUCCESS STORIES
- RFID Guides AGV in Suspension Production
- IO-Link Wired Silencer Production
- Workpiece Carrier Identification in Rear Vent Production
- Weld Nut Sensing
- RFID Traceability
- RFID in Engine Production
- Bumper Production with Identification
- Solutions for Paint Shops
- Welding and Assembly Sensors
- Angle Sensors for Assembly Systems
- Tool Identification
- RFID Identification of Injector Nozzles
- RFID in the Body Shop
- IO-Link Eases Differential Gear Production
- Pick-to-Light for Bumper Assembly
- RFID and I/O Modules for Safe Tool Changes
- Ply Orientation Inspection
- Chimie
- Detection of Pigs
- Remote Signal I/O
- Easy Connection of Field Devices
- Remote Tank Level Monitoring with DX70
- Signal Processing with System I/O in the Control Cabinet
- Signal Separation with Interface Technology in the Control Cabinet
- Identification of Hose Connections
- Efficient Monitoring of Cabinets in the Field
- Monitoring of Quarter Turn Actuators
- Planning and Assembly of System Solutions
- Success Stories
- I/O System Excom Creates Space in the I&C Rooms
- Zone 2 and 22 RFID
- Efficient Testing Control
- Intrinsically Safe Field Communication
- Process Control System Partnership
- Hazardous Area Remote I/O
- Dual Valve Position Feedback
- Flexibility with Fieldbus
- Asset Management with Remote I/O
- Correct Positioning with RFID in Carbide Production
- Energie
- Agro-alimentaire
- Dough Height Inspection for Accurate Measurement
- Dough Thickness Control in Rolling Machines
- Leading Edge Detection of Plastic Container
- Identification of Food Containers
- Date/Lot Code Verification
- Container Check
- Detection of Valve Position
- Barcode Reading on Depalletizer Station
- Reliable Cap Orientation Verification in Aseptic Areas
- Detection of Pipe Elbows
- Clear and Tipped Bottle Detection on Depalletizer
- Clear Plastic Bottle Detection
- Identification of Chocolate Moulds
- Frozen Food Packaging Label Inspection
- In-Line Bottle Accumulation on Single Filer
- Detecting Refrigerated Breakfast Rolls on a Multi-Lane Conveyor
- Success Stories
- Track and Trace in Meat Production with RFID
- Contact-free Encoder in Potato Production
- UHF RFID in Food Distribution Center
- RFID for Chocolate production
- Distributed I/O for Food Equipment
- Remote I/O for Distilleries
- RFID and Autoclaves
- IP67 Power Supplies for Conveyors
- Transparency in Chocolate Manufacturing
- Identification in Food Product Storage
- Equipement Mobile
- Distribution Lines for Field Sprayers
- Loading Dock Occupancy Monitoring
- Measuring the Ground Clearance on a Field Sprayer
- Monitoring Railcars Wheels Wirelessly
- Reach Stacker Status With Bright Lighting Indicators
- Angle Measurement on a Field Sprayer
- Determining the Boom Angle Position
- Material Flow Monitoring on a Combine Harvester
- Vehicle at Loading Dock
- Equipment Compartment Illumination on Fire Engines
- Wireless Forklift Signaling
- Two-Axis Tilt Measurement on a Combine Harvester
- Success Stories
- Position Measurement with RFID and Encoder
- Speed Control via Radar Sensor QT50
- RFID Guides AGV in Suspension Production
- Block I/O Modules on Super Yacht
- Wear-free Encoder on Hopper Dredger
- I/O for Dust Suppression
- Cabinet Cooling
- Quick Disconnect Connectivity
- Automation Solutions for Extreme Cold
- Remote I/O for Cranes
- Rugged Heavy Metal Lifting
- Rollercoaster Positioning
- Mobile Machinery Solutions
- Exact Height Positioning
- Critical Angle Sensing
- Angle Sensor Detects Platform Lift
- Predictive Maintenance of Machine Parts at Port-Based Coal Conveying Facility
- Pétrole et Gaz
- Emballage
- Identification of Printing Color Cartridges
- Reliable Operation of Machines
- Monitoring of Caps in Filling Lines
- Monitoring Changeover Processes
- Identification of Test Bottles
- Level Monitoring of Ground Coffee
- Box Insert Detection
- Carton Dimensioning
- Clear Container Detection
- Correct Label Verification
- Detecting Different Size Packages on a Conveyor
- High-Speed 2D Barcode Inspection
- Multicolored Reflective Package Detection
- Plastic Roll Diameter Measurement
- Tube Positioning Using a Registration Mark
- Vertical Form Fill Seal Machine Solutions
- Success Stories
- Pharma
- Monitoring of Quarter Turn Actuators
- Detection of Pipe Elbows
- High-Speed Tablet Counting With Fiber Amplifier
- Remote Signal I/O
- Planning and Construction of Super Skids
- I.V. Bag Liquid Detection
- Easy Connection of Field Devices
- Identification of Portable Tanks
- Identification of Cryovessels
- Identification of Mobile Containers
- Liquid Level Monitoring In A Large Tank
- Identification of Mobile Containers with Handheld Devices
- Identification of Hose Connections for Precursors
- Identification of Hose Connections in Sterile Areas
- Identification of Hose Connections in Ex Zone 1
- Identification of Big Bags and Bioreactors
- Identification of Single-Use Applications
- Semi-conducteur