5 tips if you're considering automating your paint line

There are many strong reasons to invest in robotic painting equipment . Given the benefits of automating a paint line, here are five steps to consider before implementation. 

By automating your industrial paint lines, you can improve operational efficiency, reduce costs and stay profitable in the demanding market of today. The benefits of automation  outweigh the investment costs by far. To get the most out of your automatic painting, you should consider the following spray painting tips.
 

1. Analyse all costs and savings

Robotic painting technology is often considered to be too expensive. The initial investment can be large, but automating a finishing process will increase output while reducing costs and providing benefits for years to come. Moreover, the cost of automation is decreasing every year. However, when considering moving into robotic painting, it is vital to develop a long-term plan so that the bottom-line savings that can be expected are precisely calculated and well understood. Operating with the most energy-efficient equipment available may provide the largest savings, but no opportunity is too small, because it all adds up.
 

2. Choose a spray gun with a high transfer efficiency 

By choosing the right spray gun, you can increase the transfer efficiency of your paint system. A rotary atomiser generates a fine droplet size that is more consistent compared to other atomisation methods, resulting in a higher transfer efficiency and finish quality.

The fluid is delivered with a low pressure supply and distributed by means of a bell cup spinning at up to 60,000 rpm. This high rotation speed subjects the paint to a high centrifugal force, which pushes the paint along the surface of the bell cup. When the paint reaches the edge of the bell cup, the centrifugal force breaks the paint into a fine cloud of fluid particles. When the cloud of paint droplets is directed or shaped by two shaping airs, the pattern of the paint droplets can be shaped and propelled towards the part.

3. Add an electrostatic effect

By adding an electrostatic effect to the rotary atomiser, you can achieve maximum transfer efficiency. The charge is generated by an electrostatic power supply within the rotary atomiser. The bell cup itself is charged, transferring the charge to the paint as it flows through the bell cup. The charged paint droplets are attracted by the grounded target. An electrostatic effect provides excellent wraparound to the back of the part. Thanks to this electrostatic effect, a rotary atomiser produces a superior finish with very high transfer efficiency. 
 

4. Opt for modularity and scalability 

Some rotary atomisers have a modular, scalable design, which gives users the flexibility to start small with one controller and work their way up to more or to install a complete system all at once. This modularity allows users to meet their production needs and budget.

Several separate controllers are possible:

• electrostatic controller
• speed controller
• electronic air controller
• system logic controller 

5. Ask for advice

Paint lines have never been easier or less expensive to automate. Automation of paint lines should be approached as a long-term strategic decision and a great opportunity to redesign your process and explore your entire value stream. For more details on robotic painting in general or the ProBell rotary spray gun in particular, don’t hesitate to ask the Graco specialists for advice .

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Spotlight on: ProBell rotary spray gun

• Modularity allows customers to design a system to meet their production needs and budget
• Easy system integration with existing PLC or new installation
• Controller interface allows for easy management of spray parameters 
• Improved safety and reliability with a low voltage cable and adjustable arc detection settings
• Configurations for a hollow wrist robot, solid wrist robot, fixed mount or reciprocator mount
• Bell cups are optimised for superior spraying with a variety of pattern sizes and flow rates
• Delivers high-quality finish thanks to fine, consistent droplet size
• Compact, lightweight design allows for lower payload robots or reciprocators to be used – saving money