Challenge
For many visible components, coating the back previously required a second coating pass. This meant manually turning the components, long throughput times, extensive set-up work and rising costs. At the same time, OEMs increased their requirements for texture values, appearance and repeatability – requirements that standard racks could no longer meet.
- A second coating pass for the back is essential
- Manually turning the components between passes
- Long throughput times and extensive set-up work
- Increasing requirements for texture specifications and repeatability
- Standard racks have reached the limits of cost-effectiveness
Solution
KSK developed specially adapted rotating, tilting, swivelling and combination racks that can be moved by robots. This enables the front and back to be coated in a single pass. The racks allow close component arrangement, optimal robot access and horizontal positioning in the dryer. A key success factor is the early involvement of the coating specialist in component development: hooks, eyelets or other process-relevant details can be incorporated during the design phase and removed again after coating. Rack technology thus becomes an integral part of component and process development – Design for Coating.
- Specially developed rotating, tilting, swivelling and combination racks
- Robot-controlled movement for simultaneous front/back coating
- Closely spaced components and optimal robot access
- Horizontal positioning in the dryer
- Design for Coating: early involvement in component development
Results
- Elimination of an entire coating pass
- Significantly reduced cycle and throughput times
- Uniform coat thicknesses on the front and back
- Stable, production-ready and highly reproducible process
- Significantly lower costs per component