11-station steel spray working line

Introduction to steel spray production line

Steel spray process is a kind of lean production extend from automobile manufacturing to repair. It means re-plan of steel spraying workshop, use a special way to be divided into different functional regions, and finish special works by special people. Because different process of many vehicles to be repaired will be finished by different regions and different people, it is similar to production line of factory in the type. It is called as production line.  It is classified into hardware line and process line as the realization form, and it also can be classified into beat line and non-beat line. The traditional paint repairing process can be finished completely by 1 to 2 persons, and one whole process is including more than 10 steps. But the steel spraying production line is decomposing reasonably the whole process, and making division of labor to equipments and workers as per technological process. Then, a complicated thing is simplified, and a complete paint repairing process is generally divided into 7 to 9 workstation, i.e. metal plate, scraping ash, grinding, cover, paint, primer, baking, polish and assembling. According to the processes needed, each workshop can choose the quantity of each work station. The working time of each work station of hardware line is almost the same, and each station can arrange the workers according to vertical quantity, like the production line of automobile assembling line.

l         Hardware line: a kind of production line that big scale reform to steel spraying workshop, install track and special design spray booth and primer booth. It is efficient but high cost, and suitable for big workshop. The painting workshop has to be 30 to 80m long, which needs to contain the whole line, according to vertical or horizontal vehicle distribution on the track. The integral input is so huge because of augment of track quantity, and re-build or newly added spray booth or primer room. It is always a direct and interlinked track, so it uses beat style transferring type. It including tearing down parts, metal plate, putty, polish, cover, paint, baking, polish and assembly. Each process time is fixed and the same, so the time is called as beat, such as 1 hour. The advantages of this line type include high efficiency comparing with traditional steel spray workshop, superior equipments, good environment, settled beat, and it is convenient to manage. The vehicles can be moved on the track, no need to switch on. But it also has defect. Firstly, high cost and requirements to workshop; Secondary, difficult to determine each beat time, and it is thought out by people in most cases; Thirdly, the vehicle quantity can't be guaranteed each day, so it may cause the working of whole line and people arrange break down.

l    Process line: a kind of production line type that steel spraying workshop is divided into different functional regions. According to the process time consuming, the time occupied by this station is different. The longest two processes are" atomic ash/polish" and " primer/polish" , so their time occupied is longer. And the whole production is not an exact direct line; non-beat line will be adopted almost on transfer mode. So, each process don't have time limit. Its defect is that due to the transfer time between each working process is completely "fuzzy", so you need a proficient to manage the line, otherwise it may cause inefficient.

Processes of steel spray:

1. Sheet metal correction: first of all, the workers will drive the clean car to the track. The car will move along the track to blowing ash (i.e. puttying) station after correction and disassembly.

2. Blowing ash (i.e. puttying): after the results of correction, the workers will scrap ash, bake by natural drying or infrared baking after surface treatment of work piece, and then move the work piece to polish station.

3. Polishing: choose the right sanding and polishing tool according to the process demand. Move to the next station.

4. Primer: After checking the putty and grinding quality, do primer spraying, secondary fine grinding. Move to the next station after finishing.

5. Cover: After checking the primer quality, cover the no need spraying area, and using compressed air to clean all cracks. Move to the next station after finishing.

6. Spraying: After checking the covering quality, cleaning and spraying. Move to baking oven after finishing.

7. Baking: set the time and temperature accordingly, switch on and monitor the booth. Sound-light alarming when banking finishing, move the car after cooling.

8. Polishing: After checking the baking quality, choose the wax type to do polishing and cleaning according to the quantity and size of particles on the surface of car. Move to assembly after finishing.

9. Assembly: do assembling.

 

Steel spraying production line improves the paint repair capacity by 35%, decrease the workers overtime by 90%, repair cycling shorten by 50%.