Automotive Manufacturer Enhances Efficiency with Roll Coater
A key player in anti-vibration manufacturing within the automotive industry sought to improve their coating operations for rubber to metal bonded parts. Collaborating with Arnold Machine, they embarked on a project aimed at enhancing production efficiency.
The Challenges
- Integration of Two Systems: Merging separate systems into one required meticulous planning and execution.
- High Production Rate: Meeting a processing requirement of one part every 1.25 seconds demanded innovative solutions and precise engineering.
- Feeding Mechanism: Designing an automated mechanism to handle varied parts at double the previous speed proved challenging.
- Paint Flow and Viscosity: Maintaining consistent paint application in an open atmosphere while ensuring quality presented difficulties.
The Solution
The solution to this company’s challenges was a Roll Coater, an automated coating system that can be used for adhesive application. This system is meant for high-volume production and has upwards of 100% transfer efficiency, allowing minimal adhesive waste. The system design allows for one (1) operator to maintain it.
The Adhesive Roll Coating System operates by:
- Loading bulk parts into a powered tote dumper.
- Transferring parts to a bulk hopper and elevating them on a conveyor.
- Orienting parts onto spindle shafts using two separate loading mechanisms.
- Passing parts through an oven and primer/top coat applicator wheels.
- Verifying rotation with cameras.
- Conveying coated parts to achieve the desired temperature before unloading.
- Removing defective parts with a pneumatic diverter.
- Tracking coated parts with counting sensors for inventory management.
The Results
The Roll Coating System boosted transfer efficiency, reduced labor dependency, and increased capacity for our customer, leading to improved reliability and productivity. The system improved upon production goals and enhanced efficiency. Our customer plans to explore further collaborations with Arnold Machine and potential expansions based on successful continuous improvement efforts.
Improve Efficiency with a Roll Coating System
The successful implementation of the Adhesive Roll Coating System streamlined production, increased efficiency, and reduced waste, providing significant value to the customer’s coating operations. With improved throughput and minimized labor requirements, the system has set a new standard for reliability and performance. Click the button below to learn more about how our Roll Coaters can enhance your operations.