Powder Coating I Automation concepts

Sweden – A Pioneer in
the Field of Automation
Sweden is responsible for any number of innovations which range from Viking longboats,
dynamite and ball bearings through to the SLR camera. The Scandinavians also take a progressive
approach to powder coating and have introduced modern technologies and high levels ofautomation into the process. The three examples below demonstrate the intelligent uses ofautomation in Swedish industry.

off the production line and are exported
all over the world.
Since installing a MagicCylinder powderbooth, TMHMS has relied on Gema’s fast
colour change system. The company has
three production lines dating back to theperiod from 2001 to 2006, each of which
was originally equipped with two paint-ing robots and robotic guns. A lack ofspare parts for the electronic systems led
to the need to replace the robots. TMHMS
took this opportunity to install a new application system and modern conveyors
on all three lines.
Two MagicCylinder powder booths areused to apply black coatings. These are© GemaToyota Material Handling Manufacturing
Sweden AB (TMHMS), which is part of
the Toyota Material Handling Group, is
one good example of the innovative ability of Swedish companies. Forklifts andother industrial trucks have been manufactured at its plant in Mjölby in Sweden
since 1946. Every year 85,000 units roll

The high level of automation allows a much greater variety of parts to be coated cost-effectively..
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IST International Surface Technology 1 I 18© Husqvarna© TMHMSThe use of a new powder gun has produced a much more consistentfinish on forklift trucks.

equipped with MagicControl system control units, fluidising hoppers and AP01
pumps. During the course of the project,Gema launched the new GM03-R powder gun for robots, which TMHMS immediately installed on production line 1.
The result was a very consistent finish
and improved flow compared with theold guns.
A variety of colours is applied on production line 3. This booth was fitted withan OptiCenter, together with OptiSprayAP01 application pumps, which allows
TMHMS to process special colours for individual customers quickly and cost-effectively.
The comprehensive retrofitting programme has future-proofed the boothsand enabled them to coat a variety of different parts at an affordable cost. The reliability of the AP01 application pumps
and the consistent, reproducible coating
results that can be achieved with the robotic guns make an essential contribution to achieving the high standards ofquality that are characteristic of the TMHMS brand.

Contour detection using lasers
Quality Powder Coating (QPC), a company based in the Swedish town of Nassjö, provides high-quality powder coating

Powerful chainsaws are the trademark of the well-known Swedishcompany Husqvarna. Up to 13,000 parts are produced and coated every
day in its main plant in the town of Husqvarna.

and corrosion protection services. Coatings are applied on two lines both withand without primers, depending on customers’ requirements.
In order to meet its customers’ needs both
now and in future, QPC invests in the latest technology. When it was time to replace
its ten-year-old primer booth, QPC looked
for a colour change solution which offered
the highest possible levels of flexibility, efficiency and cost-effectiveness. During a visit to another company, QPC’s production
manager noticed the OptiSpray AP01 application pump from Gema. Tests were thencarried out in Gema’s lab and QPC became
convinced of the benefits of the AP01 andwas also impressed by how easy the OptiCenter powder centre was to use.
During the tests, Gema also presented
the new UA04 gun axis. This system uses laser detection to automatically position each individual gun vertically. In thecase of QPC the guns can be moved toa depth of 300 mm. This is the perfectsolution for coating the inside of housings and complex parts. QPC is the firstcompany in Scandinavia to use this newproduct from Gema. The PCC mode of thecontrol units has been largely responsible
for the improved quality of the metallic
coatings in particular.
The new colour change system from Gema allows QPC to provide an even morereliable, flexible and efficient service toits discerning customers. For this reason in the summer of 2017 the top coatline was also replaced by a MagicCompact EquiFlow colour change system with
UA04 gun axes.

From die casting directly to powder
coating with the help of robots
Husqvarna is famous for its powerfulchainsaws and disc cutters which areused all over the world. In its main plantin the Swedish town of Husqvarna, up
to 13,000 parts for these products are
manufactured and coated every day overthree shifts.
In 2016 Husqvarna launched a project toincrease the level of automation in its production facilities. Robots were installed
to sort the die cast components and automatically hang them on the conveyor.
As part of this project the powder coating shop was also evaluated with the aimof speeding up colour changes, reducing
the need for operator interventions andensuring the highest levels of availability. Tests carried out by Gema persuaded the production managers and experienced powder coaters to choose the MagicCompact EquiFlow booth with a dual
OptiCenter and OptiSpray AP01 application pumps.
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A newly developed gun axis is the ideal solution for coating the insidesof housings and complex parts. This system automatically positions
each individual gun vertically.

© GemaThe robotic guns produce a consistent, reproducible coating.

© Gema© GemaPowder Coating I Automation concepts

In order to increase the automation level of its powder coating process, Husqvarna invested in the very latest equipment. The result is fast colourchanges, a reduction in operator interventions and high availability.

As 80 percent of the parts are coated in
the company’s traditional orange colour,
this powder is pumped straight from aBigBag (FPS16) to the OptiCenter. Because space is in short supply in theplant, Gema suggested suspending thereciprocators to allow for more freedomof movement.
Husqvarna is certain that the MagicCompact EquiFlow colour change system isthe ideal means of meeting its automation targets. Previously three employees
were needed in this area and now only
one powder coater is responsible for allthe tasks. The production process is high32

IST International Surface Technology 1 I 18

ly reliable, which is an important factor,
together with the robots in the three-shiftoperation. Husqvarna was also impressedby the suspended reciprocators, the short
implementation period and the fast commissioning process.

Bold investments that have paid off
In all three cases, companies in Sweden
have invested in modern technologies andhave been brave enough to play a pioneering role. Their appetite for innovation has
allowed them to keep their production facilities in this high-wage country and toremain competitive into the future. Perhaps other companies should adopt theirapproach and invest in new, efficient andreliable technologies? In the long term thisis a much more promising strategy thanmoving production to low-wage countries. //Contact
Gema Switzerland GmbH
CH-St. Gallen, Tel. +41 71 313 83 00
info@gema.eu.com
www.gemapowdercoating.com