Polyurethane Manufacturer Increases Production with Robotically Applied Single Coat Adhesive
The Client
A global leader in polyurethane product manufacturing reached out to Arnold Machine to create a process that maximizes coating material usage and control the efficiency of the process. They provide process engineering services and produce components for OEM and Tier 1 & 2 manufacturers. With a reputable background in manufacturing and molding within the industry, the client is dedicated to developing and delivering polyurethane products that solve demanding challenges.
The Previous Process the Client Used
The previous process that the client was working with was a purely manual process. This led to material waste and a low efficiency production rate. Each step below was done manually by an operator:
- Surface Preparation: Clean metal substrate thoroughly to remove contaminants.
- Prepare the Adhesive: Follow manufacturer's instructions for preparation.
- Apply the Adhesive: Use a brush/applicator to apply an even adhesive layer. In some cases, handheld spray guns were used.
- Curing: Allow the adhesive to cure per manufacturer's recommendations in a separate curing oven.
- Post-bonding Inspection: Inspect the bond for defects and ensure it meets specifications.
- Cleanup: Clean excess adhesive from work area and tools.
The Project Scope
The client aimed to utilize a smaller mini-Chain on Edge Coating Machine to maximize coating material utilization and control the process efficiently. This machine–an automated spray coating system–features an automatic indexing design, an operator or robotic load area, twelve preheating stations, one spray coating station, and twelve post-heating stations. The system allows for consistent operations, with 48 fixture spindles and a 25-30 second cycle time per part, and can be used for adhesive application.
The Company Challenges
The client faced several challenges:
- New staff learning the equipment and process requirements.
- Customer Tooling: Accommodating customer-designed tooling that required many dimensions and masking.
- Robot Mounting: The robot mount needed repositioning, requiring modifications to the frame.
The Solution
The client needed a solution that could handle a high product mix with various shapes and sizes. Arnold Machine showcased options focusing on flexibility, expandability, and dependability. The system allowed for future automation and quick-change tooling, accommodating a wide range of shapes and sizes for adhesive application.
Operation Steps
- Operator prepares the system by adding adhesive to a pressurized pot and setting the pressure.
- Operator places the part fixtures onto the chain on edge system.
- Operator uses a test part to set spray gun controls.
Production Steps
- Operator loads and unloads parts on the conveyor chain.
- Parts are pre-heated in a tunnel oven, indexed through twelve stations.
- A FANUC Robot applies adhesive using a programmed path.
- Parts continue through a drying oven, indexed through twelve stations, then unloaded.
How the End Product Helped the Company
Implementing this system brought significant improvements for the client:
- Consistent coating thickness and quality across all part models.
- Reduced rejection rates and increased uptime.
- A 20% increase in production throughput due to automation, reducing manual intervention and enabling continuous operation.
Improve Your Adhesive Coating with a Chain-on-Edge Conveyor
By integrating the mini-Chain on Edge Coating Machine, the client achieved greater efficiency, reduced material waste, and improved production consistency. The automated system increased throughput, minimized rejection rates, and ensured uniform coating quality across all part models. Click the link below to learn more about how Arnold Machine’s Chain-on-Edge Conveyors can optimize your coating operations.