Tour an Active Construction Site

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Kevin Howe, IntelliFinishing Project Manager

IFconstruction

Kevin just finished the setup on IntelliFinishing’s latest project installation. During the construction process he took us on a brief tour. It was an active construction site so the system wasn’t running yet. View the tour video >>

The IntelliFinishing system starts with a lift, which is basically an elevator-style, drop section. The orange pieces of the conveyor will come down to a lower height making it more ergonomic for connecting the parts to the carrier. Then it will rise back up after the part information is loaded and send the carrier into the system.

The control stations will have a touch screen monitor that will display different part information.

The uninstalled load bars are the mechanical pieces that support picture frame style hangers that will in turn support the customer parts. The metal trolleys are the load trolleys that support the weight of the entire piece. The rubber wheels on the top contact our spinning tube and provide the propulsion for the conveyer system. It is a friction setup with a spring tension pressing against the tube. The IntelliFinishing system is unique as it goes forward and reverse directions. This typical configuration is capable of supporting 3,000 pounds, including the weight of the load bar.

From the elevator-style lift section we proceed downstream towards a manual wash booth area. In this instance, we’re interfacing to a customer provided wash booth. We are going to control the doors that will slide open and closed pneumatically. Internally the wash booth will be similar to a manual car wash bay. The operator will select a cleaner rinse, a phosphate rinse and a sealer to keep the parts from flash rusting.

From the wash bay we head to the small drip zone. Currently this is a manual pull through section, which the customer requested for Phase 1. In Phase 2 we will add an automated wash parallel to this section. At that time most of the parts will go through the automated wash so in the future, less volume will run on the pull through section.

Parts will then be pulled to the first motorized section after the wash booth to air blow off. The air blow off is also similar to a car wash system with nozzles and large, electrically powered air blowers. The nozzles will be directed at the parts to dry off any of the residual water.

After the blow off area is a dry off oven. This oven is a little smaller, holding one carrier at a time. The oven is used to help boil off any leftover residual water that was not taken care of in the air blow off stage. It also helps to preheat the part, getting it ready prior to powder coating.

We head out of the dry off oven and around the corner to the powder coat booth. This is a manually applied powder station at this time. They will have several operators, one on each side, applying the powder coat to the parts. Monitors will also let the operators know what color they are supposed to be painting and what is coming up next.

The last station is the cure oven. This is a 450° powder oven. It has 3 motor stations and will be able to hold 3-4 carriers worth of parts at a time. When the units are finished curing, they come out to a several storage areas to give them time to cool.

Since our system is an oval it then brings us back to the beginning. This is the backside of the lift elevator section we saw at the start.

View the construction tour video >>

Using Big Data To Track Your Parts

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When it comes to capturing big data to track and market your future business, Konnection software allows you to use a variety of collected data from your plant floor to make decisions for your business. Imagine being able to use PLC, equipment, process and ERP/MRP data to see past trends and analyze root cause and energy use over your entire process.

Production data is key to making sure your system is efficient and profitable. Konnection software turns your data into easy to read graphs detailing the information you have in a reviewable database created by your real-time production. This allows you to monitor production like never before. Recognize trends, view your total number of jobs and carriers, maximize shift productivity and track unproductive aspects of your floor.

Process tracking allows your company to ensure quality of your work and provides your operators detailed work instructions, the ability to compare shift reports and closely monitor energy and resource usage. Ensure that your parts went through the finishing system in the same amount of time every time. Use our software to check coating times, or when carriers entered and exited the system. With this information you can answer questions about what’s happening at every point in your process. With Konnection software, you’ll know everything about the process — even down to if your operator held or released the carrier within the allotted time.

systemreport
Production data is key to making sure your system is efficient and profitable. Konnection software turns your data into easy to read graphs detailing the information you have in a reviewable database created by your real-time production.

Tracking your parts is essential to making sure you are getting the most out of your process, and ultimately your business. With this level of system reporting, you can easily locate parts in the finishing system, and have their data accessible at a later date via serial numbers. An overview screen gives a visual representation of your stations and are color coded for quick detection for status review. You can see what is loaded on each carrier, where that carrier is in your system and then quickly export the selected data via spreadsheets or .csv files. Data can also be filtered by any field, allowing you to look at the production of a single part over a month or at all parts produced in a day.

Our Konnection software connects to your factory floor to your upper level software like SAP and your ERP seamlessly with the format of the data translated to read E-Net, DeviceNet, ProfiBus, ModBus, Serial and many more. The core of our software is SQL server that utilizes redundant servers, and is capable of using your existing hardware. This web-based software is visible from mobile devices and can even send text messages and alarms fault to the screens.

For more information on how you can maximize your plant floor, contact IntelliFinishing with your request for Konnection software.

A Plan for Every Part

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A Plan for Every Part©

Ever wish you had a different finishing line for every type of part you have to paint or powder coat? Large heavy parts take more time to process than small thin ones. Some parts require additional masking and others don’t. Different chemistry is required for different types of metals… the list seems to be endless.

IntelliFinishing has presented to a variety of audiences recently and manufacturers are impressed with the “Plan for Every Part©” technology. Each item you process gets the best finish available, just like the system was built specifically for that part.

Unlike traditional finishing systems where the system is built for your longest or heaviest part, which results in over-baking of other parts; the IntelliFinishing finishing system provides capabilities that are unmatched in the finishing industry.

With conveyors that move load bars of parts at varying speeds which are based on the parts’ unique size and material, an IntelliFinishing system offers capabilities in ONE LINE that would take MULTIPLE LINES for traditional systems. Customers have been amazed at what can be accomplished with layouts that are not limited by a one-way, one-speed conveyor.

The IntelliFinishing system is not for everyone.

  • Do you finish a variety of sizes of parts?
  • Do you finish parts that are made from different materials?
  • Do your processes for finishing ever change?

If you answered YES to any of the above questions, then you may want to see how an IntelliFinishing system is rocking the world of finishing. Contact us at info@intellifinishing.com.

Part II: Changing the “Game”! – Improving Paint System Design

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The capabilities of the IntelliFinishing turnkey system are numerous, as are the features this system has.  Having the ability to move parts in individual areas forward and backward, as well as moving at different speeds, without affecting the rest of your line has been a key element in understanding the savings benefit of the IntelliFinishing System.  Not only does this save in floor space usage, it also saves in energy costs, and chemical and water usage.

Imagine if you could only drive your vehicle in the forward direction, at one speed which is based on the vehicle driving in front of you…this scenario limits your abilities to get where you want to go. So why have a finishing system with that same limitation? Give us a call at 888-886-6363 or email us at info@intellifinishing.com. We’ll take the time to talk to you about your needs, answer any questions you have about the IntelliFinishing System and design a system that meets and exceeds your expectations.

Part I: Changing the “Game”! – Improving Paint System Design

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Part I: Changing the “Game”! – Improving Paint System Design

IntelliFinishing has had a great start in the introduction of our new industrial paint system. We’ve had a fantastic response from numerous companies that do industrial coating. I think our favorite comment so far has been, “Wow! Seriously,…I can do that?” It was a great “ah-ha” moment.

IntelliFinishing is really changing how people think about finishing systems. We know it is hard to pull your mind from the way a finishing system has always been; stationary, single speed, single direction, take it or leave it type systems. Once you understand the IntelliFinishing system, it will shatter your preconceived notions and known limitations of what a paint finishing system has been. 

Here are some highlights from the Paint System Designs we’ve created:

  1. Opened up three bays of floor space, that’s 1200 sq. ft., utilizing our advanced conveyor and system technology, while also adding additional process equipment.
  2. Fit an entire Powder Coating system; load/unload area, 3-stage washer, dry-off oven, cooling areas, powder booth, cure oven and bias banking into a 2,540 sq. ft. area to process a 19’ long part.
  3.  Designed a complete liquid and powder system as one singular system; giving the customer ultimate flexibility to run their ever changing parts. When their customer demand needs more liquid painted, it wasn’t a problem; and if that afternoon they needed to run parts through powder for another customer, it could all be done on the same system.

We have had a fantastic time developing these paint system designs and implementing them for our customers.  It has allowed us to share our knowledge and excitement about the IntelliFinishing system, as well as expand our technology to meet the ever changing needs industrial finishing companies face, and trust us; there have been some interesting challenges!  The solutions we have developed due to the flexibility of our system have brought about a number of “ah-ha” moments from our customers as their conventional understanding of conveyors and finishing systems is quite suddenly thrown out the window.

Give us a call at 888-886-6363 or email us at info@intellifinishing.com and let us know about your challenge!

Rachel Snyder

Engineering & Sales Coordinator

IntelliFinishing