How Chain-on-Edge Conveyors Work

Arnold Machine Chain-on-Edge cleaning lines streamline the coating process by transporting parts through a series of stations designed for loading, pre-heating, spray application, drying, and cooling. We designed the system to utilize and apply two (2) coating materials throughout the process (solvent or water-based adhesive primer and top coat). The system can also be configured for a single-coat adhesive.

Here’s a detailed look at how they work:

1. Load Station: The operator manually loads the appropriate fixtures and parts onto the spindles presented in the load area. This area will have 6' of accessible fixtures for loading and an overhead light for easy visualization. The load station includes an operator work fan.
2. Pre-Heat Station: For the primer to adhere to the part, it must be preheated to a predetermined temperature. The pre-heat station in the oven consists of forty-eight (48) spindles to maximize cycle time and oven efficiency. Once the parts have reached temperature in the pre-heat station, they will be conveyed to the primer spray station.
3. Primer Spray Station: Parts will enter the spray booth, and the spindle will be engaged with a variable speed belt drive system for part rotation. Two (2) Krautzberger spray guns mounted to FANUC Paint Mate robots are utilized to apply the primer to the part.

The Spray Station controls airflow for maximum transfer efficiency and accommodates ease of cleanup and maintenance. 

A Keyence flow sensor will verify that a specific amount of primer has been sprayed from the spray gun between the primer spray station and the primer dry oven. If it does not detect the primer flow, it won’t apply a top coat to the part in the top coat station. The primer pressure pot will be located in the material storage cabinet and provided with all gun connections to the pot.

4. Primer Dry Station: After parts exit the primer spray station, they enter the oven for a series of cycles in the primer dry station. This area will allow the primer to dry further before applying the top coat. There will be eight (8) spindles in this station.

Specs & Features

Footprint – 17’W x 23’L x 11’8”H 

Utilities

• One (1) 1” airline at a minimum of 60psi (clean and dry)
• One (1) 16” exhaust run out of building
• One (1) 1” water line for fire suppression system
• One (1) 480v, 3PH, 125A electrical drop

Oven

• The maximum oven temperature is 130°F
• Electric convection heating system and forced air
• The oven is designed to maximize paint coverage and thickness, and the heating systems are designed not to damage the coating.

Spray Booth

• Spray guns can be fixed-mounted, servo-mounted, or mounted to FANUC Paint Mate 200iA/5L robots equipped with an auto-purge cycle.
• Pneumatic clamp cylinder and roller assemblies are provided in each spray station to engage the spindle base and ensure fixture centerline with the spray gun.
• The controlled spray booth air flow helps maximize the paint thickness along with the spray gun and booth cleanliness.
• Booth air flow will automatically adjust speed to maintain the required flow. A Magnehelic gauge will be used to measure atmospheric pressure change.
• Part rotation will be controlled and adjustable at the HMI with two rotations in front of each gun as a minimum target (there is also a non-rotate spindle option).
• One (1) light in the spray booth allows operators and maintenance to visualize the process easily. The light is protected from overspray and is approved for the environment.
• The Spray Booth is designed with adjustable airflow to minimize material build-up inside the booth.
• The booth filter system comprises a roll pad filter and a box filter.
• Part presence sensors allow the machine to spray when a part is present. If a part is not present and the machine is in automatic mode, the machine will not spray.
• The booth's exhaust design prevents the LFL (lower explosive flammable) from exceeding 25%.
• The Spray Booth design and airflow are such that the pressure difference from outside to inside the booth does not exceed three (3) inches in the water column.

Fluid Delivery

• Separate pressure pots for each material with all gun connections.
• Two (2) Devilbiss 15-gallon pressure tanks with agitator.
• Four (4) Krautzberger RA6 w/100 mm 45 Degree Extension spray guns with 0.8mm needle.
• For optimum part coverage, two (2) guns are used per station (two for the primer station and two for the top coat station, for a total of four Spray guns).
• Adjustable HMI on/off timer for pressure pot agitation 
• The paint pot agitation automatically maintains the HMI's speed (RPM). 
• Pressure pot fluid level is monitored and displayed on the HMI. When the level reaches 20%, the HMI will flash an alarm to the operator. At 10% fluid level, the machine will fault until the level is replenished to not less than 75% of the maximum.
• When a primer or top coat must be added to the pressure pots, the HMI will guide the user through safely removing the lid.
• Before allowing the COE to operate after adding the primer and top coat, the HMI will request that the operator input the approximate gallons of material added to the pot.
• Inline Graco fluid filters ensure no foreign objects enter the system. 
• Fluid pressure, fan air, atomization air, and trigger control can be accessed through the HMI and will be controlled separately for each gun. (FAN pressure is not available in the extension gun).
• Pressure pot, fan air, and atomization pressure are set up through a part recipe. 
• Pot pressure and mechanical flow control on individual guns regulate fluid pressure. All guns will have the same pressure.
• The fluid recirculation pump is provided when the spray process is not operating to prevent materials from settling.

Safety Features

The system conveyor utilizes cover guides to minimize the moving components near an operator. The operator area has multiple safety devices, including a mushroom button emergency stop and pull cord E-stop. The oven and coating booth utilize safety internal locked doors.

Trust Arnold Machine with Your Coating System Needs

Arnold Machine understands that choosing the right coating system is crucial for your business. We offer a range of solutions and expert guidance to ensure you find the perfect fit for your needs. Our team is dedicated to providing exceptional service and support, from initial consultation to installation and beyond. Contact us today to discuss your coating system requirements and discover how we can help you achieve efficient and high-quality results.

Chain-on-Edge Conveyor FAQ

• Can the system accommodate water-based material and/or solvent-based material?

  Yes, we can equip the system for either type of material.

• What types of surfaces can this system coat?

  It can coat the inside diameter, outside diameter, top face, and partially the bottom face. The system can accommodate multiple profiles. Parts don’t necessarily need to be cylindrical. 

• What should I expect for preventive maintenance?

  The ventilation system ensures that fumes from the mixing cabinet, spray booth, and cure oven are removed from the machine and filtered until they escape from the building. Ventilation is crucial for operator safety and machine cleanliness. The ventilation system comprises a blower, a pre-filter, and a secondary filter. 

  The pre-filter will see a lot of large particulates that will accumulate quickly and need to be replaced every week. The secondary filter will capture all of the smaller particulates that the pre-filter doesn’t catch and will also need to be replaced monthly. If filters are clogged, the system will sense there is no airflow and alarm out.

  The rotate belts are located beneath the spray booth. The rotate belts drive against the spindles on the chain, allowing the part to rotate while spraying for even coverage. If the rotate belts are not functioning properly the part will not rotate, allowing an uneven coat when spraying. The rotate belts (2) must be inspected weekly and replaced if worn. Look for fraying on the belt, tension of the belt, and/or damaged pulleys when checking the belt.

  Beneath the rotate belt is a gear reducer with an attached pulley that drives it. When inspecting the rotated belts weekly, also check the gear reducer to ensure there is a sufficient amount of oil and fill as required. If the machine user chooses to have fixed spindles, the rotate belts and springs must be removed. 

  Inside the spray booth are over-spray filters. These filters are connected to the ventilation system and pull the paint through the filter to collect and escape overspray. These over-spray filters need to be inspected daily and replaced as needed.

  Lid Lifts: The lid lift assemblies are inside the bulk mixing cabinet. The lids are connected to a sled attached to linear bearings and rails powered by a pneumatic cylinder. The linear bearings to which the sled is connected must be lubricated with light oil every 3 months. 

  Paint Filters: There are (2) Graco paint filters inside the mixing cabinet. These paint filters ensure no foreign material will be mixed into the pressure pots. These filters need to be checked and cleaned daily. When inspecting mixing booth components, check for fittings or line leaks.

  General Clean-Up: The user must keep the machine clean and free of build-up or debris to ensure all components function properly. General cleanup requires the user to:

  • Remove and clean all UHMW from the spray booth
  • Remove all dried material from pressure pot clamps
  • Sweep up material “cobwebbing” from inside of the spray booth
  • Sweep dried material from all spindles
  • Wipe spindles clean and lightly grease
  • Scrape off all build-up from around filters
  • Clean behind filter and stack area
  • Clean door windows inside and out on both the spray booth and material cabinet
  • Sweep dried material from drip trays