SprayVision: What You See Matters, Not Just Where You Look

 

SprayVision: It's Not What You Look At, It's What You See

SprayVision offers technology that performs pattern analysis, evaluates that pattern, and conducts thickness measurement without waiting for the system. SprayVision technology has been developed based on the needs of the coating industry to analyze spray gun patterns (manual, pneumatic, bell, etc.), spray applications performed with these guns, and to optimize the results after application. While this technology can be used with all types of paint, it can be easily installed with any type of wet spray system. SprayVision consists of hardware (Figure 1) that analyzes in three dimensions the image of paint applied to a special film or tape, and software (Figure 2) that evaluates this data.

How does SprayVision work?

As a first step, a pattern test is performed or a sample part is painted (Figures 3-4). If a pattern test is performed, the pattern must be applied to the special film both statically and dynamically; if a sample part is being painted, analysis strips must be applied to the part (Figures 5-6). With the special strips applied to the part, detailed analysis of robot movements (trajectory) and thickness distribution can be performed. After paint application, the next step is to place the special film or strip into the SprayCapture device. It should be noted that measurement is possible even in the wet state without drying the paint. Thickness, volume and other outputs are recalculated with a deviation below 5% on the dry surface (Figure 7). It is possible to perform all these operations without waiting for the part to pass through the entire paint line. Because the image of the pattern or special strip is captured, you can immediately begin analysis and evaluation. The most important functions are explained and shown in the photograph below (Figure 8). 1. Capturing the Pattern Image - Transmitting data from SprayCapture 2. Evaluating Basic Measurements - Pattern Dimensions - Calculation of Applied Paint Volume - Evaluation of Transfer Efficiency - Paint Distribution - 2D analysis on X and Y axes 3. 3D model of pattern - Better Understanding of Effective Area - Examination of Paint Distribution on Z Axis - Use for Advanced Analysis 4. Pattern Comparison - Comparison of Patterns and Volumes - Identification of Pattern with Better Transfer Efficiency 5. Application Settings - Display of Spray Parameters for the Determined Pattern SprayCapture - Contains basic analysis of the pattern and initial evaluation results including thickness, volume, three-dimensional model and cross-section information.

2D/3D - Pattern Comparison

Dynamic patterns are very important for evaluating paint transfer during robot programming and for analyzing robot movements. SprayVision enables evaluation of SB50 (unit of measurement for trajectory distance) from the dynamic pattern and calculation of transferred paint volume. Based on this information, it is possible to determine which spray parameters provide better transfer efficiency and atomization. This process can also be performed with the special strip placed on the part. Figure 9 shows the change in a sample dynamic pattern applied in painting interior plastic parts by reducing the fan air from 3 bar to 2.5 bar. As you can see, the volume has increased significantly. You can spray many patterns and decide which best suits your purpose by using the pattern with the best transfer efficiency. This reduces the amount of paint you use and provides savings.

Process control

This module is a tool for objectively evaluating patterns. It is important to determine the required pattern for your project and verify that the pattern is still as desired before moving to series production or after making various changes to the system (air cap change, application values, etc.). A pattern test is applied and then placed into SprayCapture. Within a few minutes, the user receives an objective evaluation of shape, volume, width and height match. If there is any abnormality in the process, you can detect it and based on the results identify the actual problem that needs correction. - Comparison of the pattern during production with the established standard pattern. - Fully automatic comparison and data output for the user. - Independent comparison of dimensions, shape and volume. - Error detection with alert option.

Path connections

This module provides the ability to control the relationship between the coating trajectory and the homogeneity of the paint layer. When using multiple spray guns or air caps, you can easily make comparisons and analyze each individual spray application. In Figure 10 on the next page, you can see the results of each individual spray gun on the horizontal line. Although the spray parameters in the control unit are completely identical, the spray outputs of the guns are completely different. When comparing robot applications as well, it has frequently been found that even identically operating robots show differences in their applications that require correction.

Figure 6 shows the strip applied on the buffer, while the graph in Figure 11 shows the thickness distribution of this application on the buffer.

Thickness measurement

The paint thickness values of the painted part are obtained from the wet film before drying. No more waiting for hours! Especially if you have new projects waiting to be implemented. The procedure is applied in the following order: The desired part is painted using a point or surface strip belonging to SprayVision, the strip is removed at flash-off, placed into SprayCapture, and within minutes the expected dry thickness values on the part are displayed. Precise measurement values are always obtained even if the paint's viscosity or solid content changes.

Offline programming

Allows creating a highly realistic program without wasted parts or time spent in the paint booth. All data can be processed before the paint dries. First, it is important to find the right parameters with the highest transfer efficiency, good atomization and the required pattern size. After these parameters are set, it will be possible to design the dynamic pattern. With the dynamic pattern test, you will instantly know what the thickness on the main surface of the parts will be. This feature provides savings of many hours that would be spent on the paint line. Additionally, applications added to the existing program and problem areas on the part can be identified and resolved. By using SprayVision you can obtain innovative and effective technology and also achieve unmatched quality, efficiency and financial savings. Kemalcan Süzen - Technical Sales Manager - Latro • Financial - Determining transfer efficiency, - Optimization of spray parameters, - Process control, - Reduction of scrap parts. • Efficiency - Increase in transfer efficiency, - More advanced process control. • Quality - Establishment of standard production, - Better interpretation of spray application, - Immediate detection of spray-related errors. • Environment - Reduction of paint used, - Reduction of VOC. • General - Quick detection of any errors, - Overview and detailed filterable database, - Ergonomic positioning (close to spray line).