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Continuous spraying systems are typically used in wet chemical processes for medium and high throughputs. During the wet chemical pretreatment, metal surfaces are cleaned under the influence of chemicals and heat. Water serves as a carrier material. Pretreatment and cleaning are carried out regularly in several synchronized process steps. Between these process steps are rinsing processes.
The process structure itself depends on the workpiece shape and size, part throughput and the material to be processed. As part of the plant project planning, AFOTEK develops in cooperation with the chemical supplier a pretreatment concept for parts cleaning which is tailored to the needs of the end customer 
Parts can be transported by conventional conveyor systems as well as the AFOTEK Shuttle Conveyor System (ASF).
Continuous spraying systems are environmentally friendly, energy-efficient and investment-friendly.
 


 

Chamber spraying systems are mostly used within the metal industry. Adjustable nozzles spray a liquid cleaning medium onto the workpieces, which are supposed to be cleaned. Contaminations are thus dissolved and flushed from the workpiece by the energy of the spray nozzles.

In chamber spraying systems, several treatment steps are carried out in one chamber. The workpieces move into one or more chambers, depending on the required throughput and the required treatment steps.
 
As part of the project planning, AFOTEK equips the spraying system to ensure that the workpieces are optimally flooded from all sides. This includes an offset nozzle system. The workpieces pass through the chamber spraying system hanging on a conveyor, occasionally also laying loosely on a conveyor belt.
 
Compared to immersion pretreatment systems, significantly shorter treatment times at lower bath temperatures can be achieved due to the additional mechanical effect of the spraying process. In addition, the space requirement is smaller compared to immersion pretreatment plants and the process control is simpler.
 


 

Workpieces, which have surfaces that are difficult to access, are advantageously treated in immersion cleaning systems. They ensure that not only the external surfaces are treated but also all cavities. This type of pretreatment is particularly recommended for complex geometries where a spray system cannot reach the entire surface.

AFOTEK plans and projects the entire system based on customer-specific products and requirements and develops the optimum concept in cooperation with chemical suppliers concerning the number and length of the process steps.
 
The various immersion basins are usually arranged in rows or in a horseshoe-shape. The size of the immersion pretreatment depends both on the size of the workpieces and on the required treatment steps. An integrated conveyor system completes the automated process of the AFOTEK immersion pretreatment.
 
Compared to conventional spray pretreatment systems, immersion pretreatment is characterized by lower energy consumption as well as high-quality corrosion protection of steel and aluminum components.
 


Many plastics used today attract particles floating in the air due to electrostatic surface charges. These particles affect the painting quality, o.k. rate, rework rate and reject and should therefore be professionally removed before coating.
Since the removal of these particles can hardly be achieved with conventional methods, AFOTEK uses ionization devices for cleaning - if it is reasonable and necessary. The ionizing units neutralize the surface and thus improve the quality of the coated end product. In this process, the workpieces are usually wetted from above and/or from the side. 
AFOTEK has developed a circulating air process for the ionization zone that does not require expensive compressed air, so that enormous savings potentials can be achieved concerning process costs.

 


 

Flame treatment belongs to the physical surface treatment procedures,particularly of plastics. During flame treatment, the surface is briefly heated with a gas-flame with excess oxygen without beginning to melt the plastic.

 

Activating the surface

Specifically in the plastic coating field, but also in that of adhesive application, prior treatment of the surface with a flame is often required. We choose the optimal solution for you depending on the materials to be treated and the existing surface tension.

beflaemmung

During CO2 cleaning, carbon dioxide and compressed air are used as blasting media. It is a dry, healthy and environmentally friendly cleaning process that is operated without the use of chemicals and/or solvents. The advantage is that the workpieces must not be dried after the CO2 cleaning, which means that the production process can be shortened and the cycle time optimized.

CO2 cleaning is mainly used for the pretreatment of finely structured and sensitive workpieces.

AFOTEK designs CO2 cleaning to meet the specific needs of our customers. It can be used both in continuous and cyclic operation.
 
CO2 Behandlung 01

Systematic flexibility
The flexibility of the ASF is based on a completely modular rail system with which a wide variety of system layouts can be implemented.
The transport rails consisting of anodized aluminum profiles with internal rollers are the heart of the ASF. Additionally, transport shuttles are used as product carriers, which do not need much greasing, are low-maintenance and run in the transport rails. Depending on the size of the parts, the transport shuttles are custom-made in different lengths from 1 to 8 meters.
Depending on individual requirements, transport rails can be arranged in parallel in parts of the system, for example in the cross transfer magazines, buffers or ovens. That way, a large number of product carriers can be moved simultaneously in the smallest spaces. Cross transport is also possible in this constellation and ensures a closed transport cycle within the system.
Due to the highly flexible, modular design, layouts in almost any size can be realized. The conveyor technology from AFOTEK adapts perfectly to the spatial conditions and customer production processes. This allows compact solutions to be implemented over several floors in confined spaces.
In addition, the ASF can be extended and adapted cost-effectively at any time, since the desired modules, such as buffers or cross transfer magazines, can be easily integrated into the existing system. Overtaking sections can also be retrofitted without any problems.
 
The advantages of the ASF drive concept:
  • Space-saving design
  • System can be implemented on several levels
  • Expandable conveyor system
  • Fast and uncomplicated installation of the system
Learn more about the ASF in our product flyer - take a look now!
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 Don't let them put you on the chain

With conventional conveyor technology solutions, the entire transport of goods uses one conveyor chain, so that all components travel through the system at the identical, defined conveyor speed. As a result, all workpieces pass through the pretreatment, painting and drying processes with identical cycle times.

In comparison, with the ASF each transport unit has its own drive unit with an individual control unit. Each product carrier can thus be individually controlled as required. This enables variable process speeds within the system on the one hand and reverse travel within the process on the other.

That way, it is possible to drive through the coating cabins systematically at a lower speed and to drive through the plant at high speed on free transport routes. Consequently, processing cycle times of the ASF can be configured independently, resulting in significantly higher efficiency, lower process costs and faster throughput times.

The shuttles can bridge up to 250 mm without transport rails, which means that the conveyor rail can be interrupted, e.g. at fire doors or other fire sections, without restricting transport.

 

 The advantages of the ASF drive concept: 

  • Speeds, directions of motion and stops are variable and reversible.
  • Buffers allow any retrieval options (e.g. sorting function or use as "bag station")
  • Product carriers can be individually controlled and regulated
  • Different process speeds within the plant possible

Learn more about the ASF in our product flyer - take a look now!

Querschnitt1The AFOTEK Shuttle Conveyor System is an innovative transport system with maximum flexibility. The conveyor system is characterized by its modular design and can therefore be extended and/or adapted as required. A further advantage compared to conventional solutions can be found in the drive concept. The ASF goods carrier transport does not depend on one chain; each goods carrier can be controlled separately and individually - a new dimension in goods carrier logistics.
 
Learn more about the ASF in our product flyer - take a look now!

AFOTEK, as a partner for turnkey painting systems, offers holistic solutions for complete electrical plant equipment.

The basis for the execution of the AFOTEK control technology are mainly automation solutions by Siemens. The individual control concept tailored to the needs of our customers usually consists of automation and visualization systems from the SIMATIC series. The complete functional operation and monitoring of the plant is realized via the visualization system.

The programming itself is carried out by our own qualified automation technicians and engineers to guarantee optimum support for our customers, even after plant commissioning. As standard, control programming is executed in the modern SIMATIC TIA portal in ladder diagram (LD) or in function diagram (FBD), if necessary also in structured text (SCL), instruction list (IL) or step chain programming (GRAPH, SFC).

KTL Ofen
AFOTEK-
plant visualization of a cathodic dip-paint coating oven. 

Parameter
AFOTEK-
System visualization parameter overview.

A uniform and clear program and data structure with explicit descriptions enables the plant operator to easily diagnose and assign plant components. By using self-developed, standardized function blocks of the AFOTEK software library, we ensure the high quality of our control programming.

Visualisierung Pulveranlage Vorbehandlung
AFOTEK-System visualization of a pre-treatment system.

After the control programming is completed, we internally carry out a virtual commissioning. As part of the virtual commissioning, we test all functions and optimize weak points before commissioning. The result is a significantly shorter commissioning on our customers` site.

Remote access to the systems is provided via VPN routers at request of our customers. Release is executed via a key switch in the control cabinet. An included authorization system logs access and restricts the access to an authorized group of people. Remote access enables us to support our customers quickly and cost-effectively in fault analysis and troubleshooting.

Visualisierung Fördertechnik Pulveranlage
AFOTEK-
Visualization of conveyor technology in a powder coating plant

Depending on the automation aspirations of our customers requirements, it is possible to record and provide energy, process and quality data and/or to connect higher-level systems (PLS, MES, ERP). For this purpose, we analyze the necessary processes together with our customers at an early stage in the project and document the necessary interfaces as a basis for the implementation of the interface.

Our services in the field of electrical and automation engineering:

  • Project management of electrical and automation engineering
  • Hardware planning and CAE design
  • Production of switchgears
  • Software project planning and visualization
  • Electrical assembly and installation
  • Commissioning and training
  • Service and support
  • Electrical maintenance

Your advantages of AFOTEK electrical and automation engineering:

  • Qualified team of in-house automation technicians and engineers
  • Intuitive, clear plant visualization
  • System support via remote maintenance
  • Shorter commissioning due to virtual commissioning
  • Possible connection of the AFOTEK control to higher-level systems
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Example of automation technology above the plant on a separate walkway.
Virtual process optimization of painting systems via AFOTEK Paint

3D real time simulations identify flaws early on and optimize the system throughput.

AFOTEK Paint shows the material flow of the painting system virtually in 3D via real time simulation to monitor and optimize various system and process scenarios. Moreover, all up- and downstream processes of the system can be integrated into the simulation, such as upstream assembly lines. This enables the system operator to define and optimize the material flow as well as the output of the painting system or the total plant prior to production start. 

Engl. 1 High QualiAFOTEK Paint within the company process.

AFOTEK Paint is a tool, which is adapted to the needs of the system operator and which allows the simulation of the material flow in different forms (modules).

Eng Module lowModule overview AFOTEK Paint.

The module AFOTEK real time simulation enables the virtual simulation and optimization of the system to virtually simulate, test and optimize various scenarios prior to system realization. Bottlenecks and system throughput can already be identified and optimized during planning phase. Moreover, the module AFOTEK plant planning allows the integration of the total plant into the simulation, including all up- and downstream processes, like upstream assembly lines or high bay warehouses. That way “What if” scenarios and best practice solutions can be identified to optimize not only the processes of the painting system itself but also the total plant. Both modules can be expanded by the module AFOTEK Energy. Within the simulation, this module can detect energy and gas expenses of the painting system to consider in detail heat losses, energy consumptions and thus the operation costs of the system in the context of different scenarios and to optimize them during system design.
AFOTEK real time simulation enables showing individual logistic processes via a digital plant twin.

Optimally, AFOTEK real time simulation already takes place during planning or sales phase and includes the virtual test of different system variations concerning material flow of the painting system. Different planning alternatives get tangible by real time simulation and can be assessed efficiently and constructively. That way, unpredictable effects can be reduced to a minimum during commissioning and during ongoing operation of the systems. Consequently, a sustainable system with reliable forecast values is already developed during planning phase, which predicts the output of the painting system. Furthermore, real time simulation enables the identification of bottlenecks, weaknesses and inefficient processes within the painting system already prior to commissioning, which reduces the commissioning time significantly. Precise guidelines improve the software quality (SPS) in course of project planning. The transparent consideration saves monetary resources in course of the system operation and results in reducing operational costs of the system.

 
Durchsatz 

AFOTEK Energy documents the energy consumptions of the various scenarios.

The module AFOTEK Energy enables the expansion of the real time simulation and the plant planning by the simulation of energy consumptions. This enables an individual energy analysis for the different system and production variants under consideration of the customer specifications concerning local energy and gas prices. A calculated control of the processes can reduce energy consumptions. Furthermore, to simulate and optimize the operational costs of the painting system, alternatives to reduce energy consumptions are examined (for example using the emerging waste heat) already in course of this consideration. Finally, an increased environmental awareness leads not only to cost savings for the coating company but also to an image improvement.

EnergieDetail

AFOTEK plant planning simulates not only the painting system itself but also up- and downstream processes of the system operator.

The module AFOTEK plant planning exceeds the simulation of the painting system and is not only attractive for new plants. With regard to retro fits and system expansions it also makes sense to consider all existing processes of the total plant and to simulate various system versions and expansion stages. That way various system options can be tested and the output of the total plant can be identified via simulation. Expansions and/or modifications can already be tested during planning phase without affecting ongoing production. The plant planning enables identifying best practice solutions and “What if” scenarios for the total plant. The simulation and virtual consideration of the processes can for example avoid empty bars and minimize color changes. Furthermore, they can optimize the feeding and assembly order of the products as well as the storage and outsourcing processes. These virtual optimizations shorten the throughput times of the final product through the total plant and increase the total output of the system operator.

Gesamtanlage_neu1.jpg
Example for AFOTEK plant planning including determination of energy demand.

Find out more in our product flyer about AFOTEK Paint– pdfview now!203.87 kB

Virtual process optimization of painting systems via AFOTEK Paint

3D real time simulations identify flaws early on and optimize the system throughput.

AFOTEK Paint shows the material flow of the painting system virtually in 3D via real time simulation to monitor and optimize various system and process scenarios. Moreover, all up- and downstream processes of the system can be integrated into the simulation, such as upstream assembly lines. This enables the system operator to define and optimize the material flow as well as the output of the painting system or the total plant prior to production start. 

Engl. 1 High QualiAFOTEK Paint within the company process.

AFOTEK Paint is a tool, which is adapted to the needs of the system operator and which allows the simulation of the material flow in different forms (modules).

Eng Module lowModule overview AFOTEK Paint.

The module AFOTEK real time simulation enables the virtual simulation and optimization of the system to virtually simulate, test and optimize various scenarios prior to system realization. Bottlenecks and system throughput can already be identified and optimized during planning phase. Moreover, the module AFOTEK plant planning allows the integration of the total plant into the simulation, including all up- and downstream processes, like upstream assembly lines or high bay warehouses. That way “What if” scenarios and best practice solutions can be identified to optimize not only the processes of the painting system itself but also the total plant. Both modules can be expanded by the module AFOTEK Energy. Within the simulation, this module can detect energy and gas expenses of the painting system to consider in detail heat losses, energy consumptions and thus the operation costs of the system in the context of different scenarios and to optimize them during system design.

AFOTEK real time simulation enables showing individual logistic processes via a digital plant twin.

Optimally, AFOTEK real time simulation already takes place during planning or sales phase and includes the virtual test of different system variations concerning material flow of the painting system. Different planning alternatives get tangible by real time simulation and can be assessed efficiently and constructively. That way, unpredictable effects can be reduced to a minimum during commissioning and during ongoing operation of the systems. Consequently, a sustainable system with reliable forecast values is already developed during planning phase, which predicts the output of the painting system. Furthermore, real time simulation enables the identification of bottlenecks, weaknesses and inefficient processes within the painting system already prior to commissioning, which reduces the commissioning time significantly. Precise guidelines improve the software quality (SPS) in course of project planning. The transparent consideration saves monetary resources in course of the system operation and results in reducing operational costs of the system.

AFOTEK plant planning simulates not only the painting system itself but also up- and downstream processes of the system operator.

The module AFOTEK plant planning exceeds the simulation of the painting system and is not only attractive for new plants. With regard to retro fits and system expansions it also makes sense to consider all existing processes of the total plant and to simulate various system versions and expansion stages. That way various system options can be tested and the output of the total plant can be identified via simulation. Expansions and/or modifications can already be tested during planning phase without affecting ongoing production. The plant planning enables identifying best practice solutions and “What if” scenarios for the total plant. The simulation and virtual consideration of the processes can for example avoid empty bars and minimize color changes. Furthermore, they can optimize the feeding and assembly order of the products as well as the storage and outsourcing processes. These virtual optimizations shorten the throughput times of the final product through the total plant and increase the total output of the system operator.

AFOTEK Energy documents the energy consumptions of the various scenarios.

The module AFOTEK Energy enables the expansion of the real time simulation and the plant planning by the simulation of energy consumptions. This enables an individual energy analysis for the different system and production variants under consideration of the customer specifications concerning local energy and gas prices. A calculated control of the processes can reduce energy consumptions. Furthermore, to simulate and optimize the operational costs of the painting system, alternatives to reduce energy consumptions are examined (for example using the emerging waste heat) already in course of this consideration. Finally, an increased environmental awareness leads not only to cost savings for the coating company but also to an image improvement.

Gesamtanlage_neu1.jpg
Beispiel für AFOTEK Werksplanung inkl. Ermittlung des Energiebedarfs.

Find out more in our product flyer about AFOTEK Paint– pdfview now!203.87 kB

RODAP SR 185 WF
180323 AFOTEK RODAP DSC 8915 EDIT KopieExtraction system for water circulation in paint sprayers, to discharge undesirable sludge from solvent-based and water soluble paints.

Alongside a modern spray booth, effective methods and systems for seperating paint-sludge within the water circulation are becoming increasingly important.

RODAP is an efficient extraction system for removing sludge from solvent-based and water-soluble paints in the water circulation systems of paint sprayers.

The RODAP SR 185 WF works on the principle of partial stream treatment, i. e. only a portion of the circulating water is passed through the RODAP SR 185 WF. The sedimenting sludge is continuously added to the inlet water; this way the sludge is always floating and the device is self-cleaning.

The treated water is recirculated and fed back to the paint system together with the dripping water.

Using coagulants, the paint sludge is prepared for discharge (un-sticking, flocculation). A sludge scraper dumps it into the sludge catcher, from which it can be removed easily and properly disposed of.

Find out more in our product flyer about RODAP – pdfview now!315.2 kB

Technical Information:
Capacity:                            600 l
Volumetric flow rate:           80 l/ min
Dimensions ( L x B x H):    190 x 102 x160 cm
Advantages:
  • The device discharges solvent-based and water soluble paints. With correct conditioning it can be also remove grinding dust, for example.
  • The system (discharge, water flow, and collection within the system) has been developed further consistently for more than 20 years.
  • The SR 185 WF features continuous bottom extraction of sediments in the discharge area.
  • This patented bottom extraction comes with no extra energy or effort.

Subcategories

For a good basis 
The proper and professional pretreatment of the workpieces is the basis for superior coating quality. During pre-treatment, the workpieces are first degreased and cleaned. Subsequently, a corrosion protection layer or conversion layer is applied, if necessary. Depending on the component and the required pre-treatment process, the components pass through subsequent rinsing zones and, if necessary, are passivated, phosphated and neutralized.

Our product portfolio includes not only classic pretreatment methods such as continuous spraying systems, chamber spraying systems and immersion cleaning systems, but also ionization systems, systems for flame treatment, CO2 cleaning systems and systems for snow blasting