Solutions for Paint Shops
A Chinese car manufacturer uses Turck’s BL compact stations, connectivity products, and proximity switches in its new paint shop
Harsh ambient conditions in the paint line
The extremely harsh conditions of the automotive industry present the integrator and automation components with several challenges, such as the the multi-stage painting process. The central task of the project was to automate the transport system of the paint line, which is based on an automated skid conveyor system. The autonomous and safe control of the skids on the rails requires the use of many position measuring points, sensor signals, and motor control signals.
Open standard
The customer’s specifications included the alignment and control of the paint robot as well as the flexible integration of the conveyor belt systems, while maintaining a constant level of production efficiency in full operation. The responsible engineers wanted an automation system that was based upon an open protocol which could be implemented with standard cabling.
The decision was made to move forward with DeviceNet. This fieldbus standard is an open protocol that provides the level of flexibility to optimally meet the requirements of the paint shop. Due to the size of the plant Turck’s BL compact stations were installed, which route all inputs further via the bus cable to the next I/O station and then on to the master. Turck’s BL compact DeviceNet modules with protection to IP67 are fitted on the steel support of the transport system along the entire length of the paint line. They are also installed next to the motor controller which coordinates the entire transport of the skids.
The customer uses BL compact stations with 16 digital inputs (BL CDN-8M12S-8DI-P) and the smaller version with eight digital inputs (BLCDN-4M12S-8DI-PD). They form the backbone of the entire bus system in the paint line.
Extremely robust
The compact stations are fully encapsulated in epoxy resin in order to achieve their tremendously robust design and IP69K protection. The thermal performance of the block modules is also impressive: They can withstand temperatures from -40 to +70 °C. Despite the high temperatures, the paint line does not effect the modules. The extensive diagnostic functions of the I/O stations enable the customer to increase availability and the required level of reliability. LEDs on the module provide workers with reliable status indication of the inputs locally in the field. The matching Y junction cables and all of the bus cables also come from the Turck portfolio.
Turck offers BL compact modules for analog signals, switch signals for connecting RFID read/write heads, and more. Individual BL compact stations were fitted with signal processors to meet the customer’s special application requirements in order to save costs on stations and cables. The system is perfectly matched to the application, is easy to maintain, and also includes proximity switches from the Turck portfolio as well as fieldbus stations and connectivity products.
- Automotive
- Body Detection in Automobile Production
- Reliable Skid Detection in Automotive Production
- RFID Bus Mode Ensures Quality of Lithium-Ion Batteries
- Level Measurement in Dip Coating Line
- Level Control in Central Lubrication System
- Quality Assurance on the Gluing Robot
- Tilt angle sensor accelerates platform alignment
- IP67 Hybrid Module Processes Safety Signals
- Decentralized monitoring of cooling stations
- Robot welding cells networked with Ethernet
- Monitoring the cooling circuit on welding clamps
- Flow monitoring in drum washers
- Press Shop
- Body Shop
- Paint Shop
- Final Assembly
- Powertrain
- Item-level Detection with UHF RFID
- Supply of cooling lubricant in machine tools
- Controlling hydraulic pressure in pressing plants
- Measuring process pressure on scissor lifts
- Success Stories - Automotive
- Laser Sensor Detects Black Bumpers in Assembly Cell
- Decentralized Safety Technology for Modular Production
- Modular Conveyor System
- RFID and I/O modules for Safe Tool Changes
- RFID in an Automated Guided Vehicle
- Muffler Production Wired with IO-Link Junction Boxes
- Workpiece Carrier Identification in Rear Vent Production
- Weld Nut Sensing
- RFID Traceability
- RFID in Engine Production
- Bumper Production with Identification
- Solutions for Paint Shops
- Welding and Assembly Sensors
- Angle Sensors for Assembly Systems
- Tool Identification
- Unique Products on the Conveyor Belt
- RFID in the Body Shop
- IO-Link Eases Differential Gear Production
- Chemical
- Decentralized Automation in Ex Areas
- RFID Control of Tube Connections in the Ex Area
- Ethernet Signal Connection in the I&C Room
- Ethernet-based Automation of Modular Skids
- Detection of Pigs
- Remote Signal I/O
- Easy Connection of Field Devices
- Signal Processing with System I/O in the Control Cabinet
- Signal Separation with Interface Technology in the Control Cabinet
- Identification of Hose Connections
- Efficient Monitoring of Cabinets in the Field
- Monitoring of Quarter Turn Actuators
- Planning and Assembly of System Solutions
- Success Stories
- I/O System Excom Creates Space in the I&C Rooms
- Zone 2 and 22 RFID
- Efficient Testing Control
- Intrinsically Safe Field Communication
- Process Control System Partnership
- Hazardous Area Remote I/O
- Dual Valve Position Feedback
- Flexibility with Fieldbus
- Asset Management with Remote I/O
- Correct Positioning with RFID in Carbid Production
- Fast conversion in restricted space
- Energy
- Food and Beverage
- Dough Thickness Control in Rolling Machines
- Identification of Food Containers
- Detection of Valve Position
- Detection of Pipe Elbows
- Identification of Chocolate Molds
- Success Stories
- Grist for the Mill
- Decentralized Control Modules in Coldstore
- Track and Trace in Meat Production with RFID
- Contact-free Encoder in Potato Production
- UHF RFID in Food Distribution Center
- RFID for Chocolate Production
- Distributed I/O for Food Equipment
- Remote I/O for Distilleries
- RFID and Autoclaves
- Transparency in Chocolate Manufacturing
- IP67 Power Supplies for Conveyors
- Identification in Food Product Storage
- Logistics
- Tracking Big Bags with RFID
- Access Control for Protected Areas
- Decentralized Muting of Electro-sensitive Protectice Equipment
- Preventive Maintenance on Conveyor Belts
- Detection of Transport Containers
- Level Detection in Vessels
- Identification of Cryovessels
- Identification of Mobile Containers with Handheld Devices
- Identification of Food Containers
- Tier 1 – Bumper Identification
- Collision Protection on Reach Stackers
- Success Stories
- RFID Enables Unmanned Store at Major Building Site
- I/O and Safety Modules Increase Throughput in Intralogistics
- Shipment Tracking for Raw Materials
- RFID-based Shipment Control Minimizes Errors
- RFID-based Tracking of Inbound and Outbound Materials
- Decentralized UHF RFID Solution
- Contact-free Encoder in Potato Production
- Decentralized Control Modules in Coldstore
- IP67 Power Supplies for Conveyors
- Modular Conveyor System
- RFID Solution for Warehouse
- RFID Guides AGV in Suspension Production
- RFID Identifies Pharmaceuticals
- UHF RFID in Food Distribution Center
- Mobile Equipment
- Condition Monitoring Sensor Automates Climate Control
- Automatic Slope Compensation
- Distribution Lines for Field Sprayers
- Angle Measurement on a Field Sprayer
- Determining the Boom Angle Position
- Two-Axis Tilt Measurement on a Combine Harvester
- Collision Protection on Reach Stackers
- Success Stories
- RFID Solution with Smart Forklifts in Automobile Production
- Safe Remote Maintenance of Irrigation and Drainage Pumps
- Access Control with RFID System
- Selective Asparagus Harvester
- Position Measurement with RFID and Encoder
- RFID in an Automated Guided Vehicle
- Block I/O Modules on Super Yacht
- Wear-free encoder on hopper dredger
- I/O for Dust Suppression
- Cabinet Cooling
- Quick Disconnect Connectivity
- Automation Solutions for Extreme Cold
- Remote I/O for Cranes
- Rugged Heavy Metal Lifting
- Rollercoaster Positioning
- Mobile Machinery Solutions
- Exact Height Positioning
- Critical Angle Sensing
- Angle Indicator
- Oil and Gas
- Packaging
- Decentralized RFID Package Verification
- Identification of Printing Color Cartridges
- Reliable Operation of Machines
- Monitoring of Caps in Filling Lines
- Monitoring Changeover Processes
- Identification of Test Bottles
- Level Monitoring of Ground Coffee
- Level Detection in Vessels
- Detection of Transport Containers
- Success Stories
- Pharmaceutical
- End-to-End Sample Tracking with RFID
- Automate Modular Skids
- Pharmaceutical Skids with Decentralized I/O Technology
- Ex Isolation in Modular Process Plants
- Control of Valve Interfaces
- Monitoring of Quarter Turn Actuators
- Detection of Pipe Elbows
- Remote Signal I/O
- Planning and Construction of Super Skids
- Easy Connection of Field Devices
- Identification of Cryovessels
- Identification of Mobile Containers
- Identification of Mobile Containers with Handheld Devices
- Identification of Hose Connections for Precursors
- Identification of Hose Connections in Sterile Areas
- Identification of Hose Connections in Ex Zone 1
- Identification of Big Bags and Bioreactors
- Identification of Single-Use Applications
- Success Stories
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