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 firstname.lastname@example.org.
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:
- 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.
- 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.
- 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 email@example.com and let us know about your challenge!
Engineering & Sales Coordinator
A “Chainless” Power & Free Conveyor?
The IntelliFinishing conveyor is a bolted together floor supported system with friction driven trolleys on a rotating tube instead of a chain to drive the system. Due to the bolt together construction, this conveyor can be easily modified and moved and can be installed in half the time of conventional conveyor systems. We offer a variety of conveyor models with the ability to handle different weight categories which enables us to further customize a system to fit your specific process needs
With our Chainless Power & Free there is no maintenance or mess of keeping the conveyor constantly lubed, additionally there is no mess or contamination of lubes, oils, or grit falling onto the parts processed. All of the moving components in the conveyor system are lubricated for life.
Each conveyor section has a separate motor which allows individual sections of the conveyor to speed up a part in a process area or slow a part down based on the part recipe. The separate motors also turn off and on the individual conveyor sections when there is a part present making this system more energy efficient because the full system isn’t always running, only the process areas being used at the given time. Additionally, the Chainless Power & Free conveyor has a much quieter operation due to no metal on metal noise.
Capabilities of the Conveyor (partial list):
- Change processes or destinations of products with immediate system response
- Set up in-line speed changes
- Run trolleys both forward and backwards
- Stop a carrier for processing without stopping the entire line or holding up production
- Easily incorporate vertical lifts and shuttles to move parts to another line without unloading
- Negotiate inclines and declines
- Accumulate loads in line
- Have both driven and non-driven lines on the same system
- Dip the conveyor into tanks
- Run the conveyor through Dry-off and Cure Ovens up to 450 degrees
- Highly configurable and modular
Recipe Based Finishing System
With a Recipe-based system, carriers with dissimilar parts can run back to back and each can be treated differently based on the process data entered into the system as a “recipe”. There is no longer a need for batching your whole line with like parts to get quality. When you enter commands or process instructions for each part family or group of characteristically like parts each time that “recipe” is selected at the loading point all of those like parts will receive the same process. If you have a different carrier of parts, all the operator needs to do is select that recipe at the load area HMI screen. When that carrier gets to a process area, the system will automatically run the selected process for that part family.
In the Wash:
The recipe entered allows for different types of metals or parts with different pretreatment requirements to each have their own unique wash Recipe. For example it is possible to remain longer in a section, skip a section, or bypass the whole wash. If you have changes in your wash process due to extra dirty parts or changes in chemicals requiring your system timing to be different all you need to do is update the recipe.
In the coating application:
In the coating application area, displays show the process for each part coming through, where to apply the coating, which color, and any special instructions unique to those parts. For applications with masking options, the work instructions show pictures of where to apply masking, caulking, or any other special procedures.
In the cure:
Thick parts and thin parts do not need to be run separately in a batch mode. With a recipe based system, parts that have 20 minute cure time and parts that have a 40 minute cure time can be run on the line at the same time. You will no longer over-bake your thin parts just to make sure that your thicker, longer curing parts get cured as desired. Ovens can adjust temperature, air turns, and cure time depending on the parts loaded on the system.