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7/25/2019 Basic Introduction to the Paint Shop
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Introduction to the Paintshopand its products
Paintshop Basics
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What is a Paint Shop?
The Paint Shop
is a specialized
area in the
production of anautomobile
The Paint Shop
is a specialized
area in the
production of anautomobile
Paintshop Basics
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What Does a Paint Shop Do?
The Paint Shop
Receives the
Body-in-White and
Returns a FinishedPainted Body to
the Trim and
Assembly Areas
The Paint Shop
Receives the
Body-in-White and
Returns a FinishedPainted Body to
the Trim and
Assembly Areas
To Produce the
Protective Paint
Finish Seen on an
Automobile,Several Layers are
Applied
To Produce the
Protective Paint
Finish Seen on an
Automobile,Several Layers are
Applied
Paintshop Basics
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Body-in-White
Paintshop Basics
Bare steelbody Body-in-white
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Phosphate LayerPaintshop Basics
Chemically developed surface coating
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Electrocoating layer
Paintshop Basics
Corrosion-protection-Paint coating
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Primer Layer
Paintshop Basics
Primer paint coating
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Basecoat Layer
Paintshop Basics
Colored paint coating
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Clearcoat Layer
Paintshop Basics
Clear paint coating for protection against elements
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Paintshop Basics
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Supplier
Durr
Client
Innovation
Space
available
Know how
Budget
Preferredmethods
Experience
Paint
suppliers
Design
parameters
Chemistry
Paintshop Basics
How is a process, how chart, layout developed?
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Conveyors
Paintshop Basics
Monorail
Skid
Ro-dip
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Bodies are Moved Through the PaintShop and Between Floors with Conveyors
Paintshop Basics
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Overview of aPhosphate System
Also calledpretreatment system
Paintshop Basics
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What Is Phosphate?
Phosphate is a chemically
developed surface coating
It helps shield metal from air,
moisture, etc.
This increases corrosion
resistance
And simultaneously provides a
roughed-up surface for the next
paint layer to adhere to.
Paintshop Basics
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What does a Phospathe System do?
It throughly rinses, washes nad clean the body
It deposits a phosphate coating on the body Improves paint adhesion
Prevents underfilm corrosion
Helps shield metal from air and moisture
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Remember, the reason behind the
Phosphate system is to prepare the body
for subsequent paint layers. Some of the stages in the Phosphate
system are:
Degreasing
Rinsing (various)
Activation
Zinc Phosphate
Passivation
Paintshop Basics
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Exhaust Air
Supply Air
Phosphate EnclosurePhosphate Enclosure PaintShopAir
PaintShop
Air
SupplyFan
Ventilation System
The phosphate enclosure air flow is negative in an
attempt to contain the steam and chemicalsgenerated in the process.
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Overview of an
Electro Coating System
or E-coat System
Paintshop Basics
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Why do we have an E-Coat Process?
Electrocoating provides corrosion
protection to the vehicle.
A uniform, protective coating isapplied to all the paint vehicle parts.
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+++
++++
-
The negatively charged
vehicle is dipped into a tank
of positively charged paint.
-
How is E-Coat Paint Applied?
--
--
++ ++
Paintshop Basics
Paintshop Basics
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The Electrochemical Reaction
Since opposites attract, the positively charged
paint is drawn to the negatively charged body.
This process continues until a continuous and
even film coats the entire surface of the body.
The process stops itself when the film is almost
equal on all its surfaces.
Paintshop Basics
Paintshop Basics
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Typical spray ring
configuration
The E-Coat System not only consists of the E-Coat
Paint, but successive stages to rinse excess paint
off of the bodies.
These stages can consist of:
Cream Coat Rinses
Ultrafil trate Dips and Sprays R.O. Water Dips and Sprays
Deionized Water Sprays
Paintshop Basics
Paintshop Basics
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Overview of a Spray Booth
Paintshop Basics
Paintshop Basics
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Paintshop Basics
Spraybooth Cross Section
supply
plenum
enclosure
scrubber
exhaust
Five major
components
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What is a Spray Booth?
Paintshop Basics
Spray Booths have been engineered and installed
as separate enclosures within the Paint Shop
For the purpose of applying paints to the body:
Prime Coat
Base Coat
Clear Coat
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The application of the various paint
layers requires that the exact
environmental conditions be
maintained in order to achievemaximum quality
Paintshop Basics
Paintshop Basics
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A Filtered Environment is required to Minimize Dirt
and Dust in the spray Booth
Paintshop Basics
SPRYBOOTH FILTRATION
AIR FLOW
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Containment of PaintOverspray
a s op as cs
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Maintaining
Specific Temperatureand Humidity
p
24 C - 1C
75% RH - 5%RH
Paintshop Basics
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Air Flow Balance Zone to
Zone
and Air Flow Down Drafts
p
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Isolation of theSpraying Process
from the Remainder
of the Plant
p
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Different types of operations occur inthe Spray Booth.
Each operation takes place in an areacalled a zone.
Some zones are: a blow off or feather duster zone
a solvent / water wipe zone
a tack-off zone
manual paint application zones
automatic paint application zones
flash-off zones
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Supply air for the Spray Booth comes from
air supply houses located on a mezzanine orpenthouse level above the booth
G l A bl
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HumidifierFilter-unit:
For Air c leaning
Cooling-/heating-
section:
For the temperature of
the air in the region of
the paint window
Silencer:
to adsorb sound
Humidifier:
for theconditioning of the
air to the
necessary
humidity
Fan:For intake of the air
General AssemblyFilter-unit F5 Cooling- / Heating section
Filter-unit F7Fan
Sound absorber
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The supply air is ducted tovarious zone plenums and
introduced into the booth through
distribution filter media whichmakes up the booth ceiling.
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The paint laden air is then pulled
down the throat of the scrubber.
Paintshop Basics
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SCRUBBER
BAFFLE
FLOOD PAN FLOOD PAN
WATER RETURN
TROUGH
WATER DISTRIBUTION TROUGHWATER DISTRIBUTION TROUGH
Paint
particles
collide with
the water
particles
Scrubbed Air Out
Paint Laden Air
Booth Air Downdraft
Paint Solid Laden Water
Scrubber Pressure Drop is
Adjusted to Achieve Desired
Efficiency
Cross-Section of
Drr Mini-Baffle
Scrubber System
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Supporting Cast:
Sludge System
Paint Circulation System
Humidification System
Powder Paint System
Building HVAC System
Paintshop Basics
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Spraybooth
Filterhouse
Carbon RotorRegenerative
ThermalOxidizer (RTO)
Air From theSpray Booth
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Overview of an Oven
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What is aPaintshop Basics
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What is a
"Conventional" Oven?
WORK
Radiant
Bring-UpZones
Convection
Heat-UpZones
Convection
HoldZones
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Purpose of the
Bring-Up Radiant Zones
Add Heat to the Work to
Bring all Parts up to the
Target Temperature
Add Heat in a Uniform,
Controlled and Dirt-Free
Fashion
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Purpose of the Heat-Up Convection Zones
Add Heat to Low Heavy
Metal Components of the
Job
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Purpose of the Hold Convection Zones
Maintain Temperature on
the body
At Time Specified for Proper
Cure
Historically Circulating air
is Used
Indirect Fired Heaters
Q: What Does a Heater Do?Paintshop Basics
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Flexible
Connection
Flexible
Connection
OvenOven
HeaterHeater
DuctDuct
A: The Heater Supplies Heated Air to the Oven
1- Positioned near the oven, the heater uses a natural
gas burner to heat air (either directly or indirectly).
111
222
2- Heated air is supplied to Oven to maintain
specified temperature.
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What Do We Mean By
"Direct-Fired"or " Indirect-Fired"?
Oven heaters
Direct Fired Heater Operation
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M
RETURN
DUCT
EXHAUST TOATMOSPHERE
RECIRC.
FAN
COMBUSTION
BLOWER
FRESH AIR
SUPPLY
DUCT
FRESH
AIR
Direct-Fired Heater Operation
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Indirect-Fired Heater Operation
M
RETURN
DUCT
SUPPLY
DUCT
RECIRC
FANFRESH
AIR
COMBUSTION
BLOWER
FRESH AIR
Air through
th O
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the Oven
OvenOven
Regenerative
ThermalOxidizer (RTO)
Paintshop Basics
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J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D
Order Received
Engineering and P/E
Site Work & BuildingInstallation
Start-Up / Facility Launch
Turn Over to Production
1998 1999 2000
Typical Project as it Flows Throughthe Company
Where are you involved?
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Paintshop Basics
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Turnkey PaintshopTurnkey Paintshop
Site
PreparationManufacturing
Building
Erection
Process
InstallationLaunch SOP
Facility Support
Services
P d t LiP d t Li
Paintshop Basics
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OvensPhos/EC BoothsPaint
Circ / PipingFacilit y / Layout
Product LineProduct Line
P d t LiP d t Li
Paintshop Basics
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Product LineProduct Line
EnvironmentalAppl ication
EquipmentRobotics
Conveyors/Material Handling
Controls