Patent Publication Number: US-2021172083-A1

Title: Coating system and method for e-coating and degasification of e-coat fluid during e-coat

Description:
TECHNICAL FIELD 
     Various embodiments of the disclosure relate to coating technologies for vehicles. More specifically, various embodiments of the disclosure relate to energy efficient electrocoating (e-coating) and degasification of electrocoat e-coat fluid during e-coat of complex metal parts of a vehicle for enhanced binding of paint coat to the complex metal parts of the vehicle. 
     BACKGROUND 
     With the advancements in the field of coating technologies, various processes to coat complex metal parts have been adopted in recent years at an industrial scale in the vehicle production pipeline. The e-coat process may be considered a combination of electroplating and painting, where a metal part is immersed in an e-coat fluid containing resin and binder. Conventional e-coat processes are time-consuming, susceptible to hydrogen-gas formation, and often require additional resin and binder added to the mixture when the component settles to the bottom of the bath. Thus, an e-coating system and method that overcomes these drawbacks is desired. 
     Further limitations and disadvantages of conventional and traditional approaches will become apparent to one of skill in the art, through comparison of described systems with some aspects of the present disclosure, as set forth in the remainder of the present application and with reference to the drawings. 
     SUMMARY 
     A coating system and method for e-coating and degasification of high-viscosity coating fluid during e-coat is substantially shown in, and/or described in connection with, at least one of the figures, as set forth more completely in the claims. 
     These and other features and advantages of the present disclosure may be appreciated from a review of the following detailed description of the present disclosure, along with the accompanying figures in which like reference numerals refer to like parts throughout. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates an operational environment of a coating system for e-coat and degasification of a coating fluid during e-coat, in accordance with an embodiment of the disclosure. 
         FIG. 2  is a block diagram that illustrates various exemplary components or systems of the coating system of  FIG. 1 , in accordance with an embodiment of the disclosure. 
         FIG. 3A  illustrates a view of an exemplary e-coat tank for e-coat and degasification of a coating fluid during e-coat, in accordance with an embodiment of the disclosure. 
         FIG. 3B  illustrates an enlarged view of a zone-of-interest in the e-coat tank of  FIG. 3A , in accordance with an embodiment of the disclosure. 
         FIG. 3C  illustrates a view of an exemplary e-coat tank of  FIG. 3A  during the e-coat process, in accordance with an embodiment of the disclosure. 
         FIG. 4A  illustrates a carrier frame for supporting a metal part of a vehicle, in accordance with an embodiment of the disclosure. 
         FIG. 4B  illustrates a view of a vehicle body mounted on the carrier frame of  FIG. 4A , in accordance with an embodiment of the disclosure. 
         FIG. 4C  illustrates an exemplary trajectory of the vehicle body of  FIG. 4B  within an e-coat tank of the coating system of  FIG. 1 , in accordance with an embodiment of the disclosure. 
         FIG. 5  illustrates a view of an exemplary e-coat tank for e-coating a metal part and degasification of an e-coat fluid solution, in accordance with an embodiment of the disclosure. 
         FIG. 6  illustrates a diagram for a process of contactless rupture of bubbles semi-submerged within a coating layer formed on a metal part of the vehicle, in accordance with an embodiment of the disclosure. 
         FIG. 7A  illustrates a plot of acoustic pressure distribution versus time on a surface of a metal part based on a center-to-center distance between two acoustic sources, in accordance with an embodiment of the disclosure. 
         FIG. 7B  illustrates a plot of acoustic pressure distribution versus time on a surface of an acoustic source, in accordance with an embodiment of the disclosure. 
         FIG. 8A  illustrates a diagram for development of a wave front on a surface of a metal part based on a distance of acoustic sources from the surface of the metal part, in accordance with an embodiment of the disclosure. 
         FIG. 8B  illustrates a plot of acoustic pressure distribution versus time on the surface of the metal part of  FIG. 8A , in accordance with an embodiment of the disclosure. 
         FIG. 9A  illustrates a plot of conventional acoustic pressure distribution versus time on a surface of a metal part for a unidirectional acoustic source. 
         FIG. 9B  illustrates a plot of acoustic pressure distribution versus time on a surface of a metal part for an omnidirectional acoustic source, in accordance with an embodiment of the disclosure. 
         FIG. 10  is a flowchart that illustrates an exemplary method for e-coating and degasification of a coating fluid during e-coat, in accordance with an embodiment of the disclosure. 
         FIG. 11  is a flowchart that illustrates an exemplary method for performing degasification of dissolved gases in an e-coat fluid solution and e-coating on a metal part of a vehicle, in accordance with an embodiment of the disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The following described implementations may be found in the disclosed coating system and method for degasification of a coating fluid during electrocoat (e-coat). The disclosed coating system includes an e-coat bath that is filled with an e-coat fluid. The coating system further includes a plurality of ultrasonic transducers that are suitably positioned in the e-coat bath in a zone-of-interest. A plurality of acoustic waves from the plurality of ultrasonic transducers are directed in the zone-of-interest within the e-coat bath when a metal part of a vehicle is dipped in the e-coat fluid within the e-coat bath. The plurality of acoustic waves are directed at a defined ultrasonic operating frequency and at a first intensity in the zone-of-interest such that removal of gases, such as hydrogen gas, from the e-coat fluid is significantly accelerated during e-coat of the metal part of the vehicle. The application of the plurality of acoustic waves at the defined ultrasonic operating frequency accelerates the reaction time, decreasing the time to form the e-coat. It also removes trapped air bubbles or air pockets around the complex metal part, such as a vehicle body, thereby increasing the e-coat surface finish and ultimately the final paint finish. 
     Further, in conventional systems, the e-coat pigment or resin particles present in the e-coat fluid typically settle at the bottom of the e-coat bath after a certain time period both during e-coat and after e-coat. The sedimentation of such e-coat pigment or resin particles at the bottom of the e-coat bath increases the maintenance of the bath at the required proportions of resin, binder, and water, and also increases the cleaning effort of the e-coating bath. This adversely impacts the throughput and overall turn-around-time in vehicle production. The disclosed coating system reduces sedimentation of the e-coat pigment and resin at the bottom of the e-coat bath, leaving the bottom surface of the e-coat bath cleaner and requiring less maintenance time. The disclosed coating system also decreases the time needed to e-coat a vehicle or vehicle part. 
       FIG. 1  illustrates an operational environment of a coating system for e-coat and degasification of a coating fluid during e-coat, in accordance with an embodiment of the disclosure. With reference to  FIG. 1 , there is shown an operational environment  100  for a coating system  102 . The coating system  102  may include an e-coat tank  104  and a sonication system  106 . The sonication system  106  may include a plurality of ultrasonic transducers  108  suitably within or outside of the e-coat tank  104 . There is further shown a carrier frame  110  and a metal part  112  that may be mounted on the carrier frame  110 . The metal part  112  may be a single metal component of a vehicle or an assembly of metal components of the vehicle. The e-coat tank  104  may store an e-coat fluid solution  114  in which the metal part  112  may be immersed to deposit an e-coat layer on the metal part  112 . 
     The coating system  102  may comprise suitable logic, circuitry, and interfaces that may be configured to control different parameters associated with a degasification of dissolved gases from e-coat fluid solution  114  and a deposition of the e-coat layer on the metal part  112  of the vehicle. For example, the parameters may be a temperature of the e-coat fluid solution  114 , an acoustic intensity, and an ultrasonic frequency of acoustic waves. The coating system  102  may be a centralized or a decentralized system with different system components, such as the sonication system  106 , operational in accordance with control signals from a dedicated control device or a distributed network of control devices. For example, the dedicated control device may be a local server for a paint unit in a manufacturing and/or assembling plant for vehicles or vehicle components. 
     The e-coat tank  104  may be a storage tank for storage of the e-coat fluid solution  114 . The e-coat tank  104  may include a network of pipes and fluid eductors that may be used to fill up the e-coat tank  104  and/or remove the e-coat fluid solution  114  from the e-coat tank  104 . The e-coat tank  104  may further include different components, such as electrodes, temperature sensors, and heat exchangers, to monitor and control electrophoretic coating (as part of electrophoretic deposition (EPD) in a painting process of a paint unit of the manufacturing and/or assembling plant) on the metal part  112 . The e-coat tank  104  may be made of stainless steel or a suitable material that may be resistant to acoustic pressure and/or chemical degradation from acoustic waves and the e-coating process. 
     The sonication system  106  may be configured to generate a plurality of acoustic waves at an ultrasonic frequency (or different ultrasonic frequencies) and with an acoustic intensity (or different acoustic intensities). The sonication system  106  may include the plurality of ultrasonic transducers  108 . The plurality of ultrasonic transducers  108  may operate when immersed in liquid, such as the e-coat fluid solution  114 . In some embodiments, an ultrasonic frequency generator may be integrated with each of the plurality of ultrasonic transducers  108 . Alternatively, the ultrasonic frequency generator may be a separate device connected to each of the plurality of ultrasonic transducers  108 . 
     The sonication system  106  may be an electronically-controlled acoustic source that includes the plurality of ultrasonic transducers  108  within a zone-of-interest  116 . The zone-of-interest  116  may correspond to a maximum gassing region in the e-coat tank  104 , where a maximum amount of dissolved gases are present. The zone-of-interest  116  in the e-coat tank  104  may also correspond to an active reaction zone in which maximum gas build-up in the e-coat fluid is observed during the e-coat process. In certain embodiments, the zone-of-interest  116  may extend to substantially the length of the e-coat tank  104 . 
     The plurality of ultrasonic transducers  108  may be mounted at a bottom portion the e-coat tank  104 . The placement of the plurality of ultrasonic transducers  108  may be based on a size, a shape, or a structure of the metal part  112  to be e-coated and the capacity or volume of the e-coat tank  104 . Alternatively stated, the placement of the plurality of ultrasonic transducers  108  within the e-coat tank  104  may be based on several factors, such as the volume of the e-coat fluid in the e-coat tank  104 , a geometric layout of the e-coat tank  104 , and different load sizes of the parts of the ultrasonic transducers or other parts installed in the e-coat tank  104 . Also, the plurality of ultrasonic transducers  108  may be at the bottom portion of e-coat tank  104  such that a plurality of acoustic waves from the plurality of ultrasonic transducers  108  is directed uniformly in different directions throughout a volume of the e-coat fluid solution  114  in the zone-of-interest  116 . 
     The plurality of ultrasonic transducers  108  may be immersible ultrasonic transducers mounted in the e-coat tank  104  such that omnidirectional acoustic waves are directed throughout the volume of the e-coat fluid solution  114  in the zone-of-interest  116 . The plurality of ultrasonic transducers  108  may be placed at the bottom level to have a smoother pressure build-up from omnidirectional radiation, as compared to larger spatial non-uniformities in pressure from a conventional unidirectional radiation. Also, the plurality of ultrasonic transducers  108  may be at the bottom level to ensure that a surface of the metal part  112  immersed in the e-coat fluid solution  114  is in a direct acoustic range of the plurality of ultrasonic transducers  108 . Also, the acoustic pressure from the directed acoustic waves may cause acoustic cavitation in different regions within a volume of the e-coat fluid solution  114  that corresponds to the zone-of-interest  116 . The acoustic cavitation may lead to a controlled and uniform degassing of the e-coat solution in the zone-of-interest  116 . 
     In certain embodiments, at least one of the plurality of ultrasonic transducers  108  may be a non-immersible ultrasonic transducer mounted on the bottom of the e-coat tank  104  from outside. The non-immersible ultrasonic transducer may be also mounted on sides of the e-coat tank  104 . The non-immersible ultrasonic transducer may be mounted on the bottom of the e-coat tank  104  in a contained layer, so as to not come into contact with the e-coat fluid solution  114  in the e-coat tank  104 . Alternatively, instead of mounting the non-immersible ultrasonic transducer on the bottom of the e-coat tank  104  in a contained layer, they are instead mounted on the inside of the e-coat tank  104  but above a level of the e-coat fluid solution  114 . This may be preferred to effectively remove gas build-up on the metal part  112 , i.e. entrapped bubbles on the e-coat layer. The bottom or side mount of the plurality of ultrasonic transducers  108  may reduce certain debris and foreign material which may settle on the top of each of the plurality of ultrasonic transducers  108 . Conventionally, the debris and foreign material when settled on the top of each the plurality of ultrasonic transducers  108  usually reduces the effectiveness or performance of the sonication system  106 . 
     The carrier frame  110  may be an electronically steerable assembly that may have one or more support portions to support and hold onto the metal part  112  of the vehicle. The carrier frame  110  may include guide rails that may be mounted on top of the e-coat tank  104 . The metal part  112  may be mounted as a carriage on the guide rails of the carrier frame  110 . The height and horizontal displacement of the metal part  112  from the carrier frame  110  may be adjusted at different points along the length of the e-coat tank  104 . 
     The e-coat fluid solution  114  may include of an e-coat pigment, a resin, and a deionized (DI) water. Alternatively, the e-coat fluid solution  114  may have a different composition under a different proportion for different types of metal parts of the vehicle. The e-coat pigment and the resin may be mixed with the deionized water to form the e-coat fluid solution  114 . 
     In operation, the metal part  112  may undergo a pre-treatment process before the metal part  112  undergoes the e-coating process. The pre-treatment process may ensure that the metal part  112  remains clean and prepared for the e-coating process. Also, the pre-treatment process may prevent bubbles in the e-coat tank  104  to adhere to the metal part  112  while the metal part  112  is immersed in the e-coat tank  104 . The pre-treatment process may include, but is not limited to, a cleanup of the metal part  112  by cleaner solutions, such as an alkaline cleaner, a rinse operation, an acid etch, and a dip in a wetting agent. 
     The pre-treated metal part (also referred to the metal part  112 ) may be moved for immersion in the e-coat tank  104 . Also, prior to an initialization of the e-coat process, the e-coat tank  104  may be filled with the e-coat fluid solution  114 . The coating system  102  may be configured to use fluid eductors and the network of pipes in the e-coat tank  104  to automatically pour the e-coat tank  104  with a pre-determined volume of the e-coat fluid solution  114  to a pre-determined level of the e-coat tank  104 . The coating system  102  may be configured to monitor a temperature and other parameters, such as pH, and viscosity, to ensure that the e-coat fluid solution  114  has achieved conditions that is required (optimum) for the e-coat process. 
     In the e-coat tank  104 , the e-coat fluid solution  114  may include a first amount of dissolved gases, such as hydrogen (H 2 ) gas. The dissolved gases and associated effects on a deposition of an e-coat pigment on the metal part  112  may be maximum within the zone-of-interest  116 . Conventionally, as the metal part  112  is immersed in the zone-of-interest  116 , the dissolved gas may prevent the e-coat pigment or the paint emulsion in the e-coat fluid solution  114  to condense evenly on different regions of the metal part  112 . In such cases, the e-coat pigment on the metal part  112  may deposit such that there may be localized regions on the metal part  112  where the e-coat pigment may not have condensed suitably, and thereby leads to coating defects in the metal part  112  (i.e. an e-coated metal part). 
     In order to prevent such defects, a process of a controlled acoustic cavitation may be implemented in the zone-of-interest  116 . The controlled acoustic cavitation may cause a development of positive and negative pressure regions that may lead to generation of vacuum bubbles that may entrap a portion of the dissolved gases. The entrapped portion of the dissolved gases in the bubbles may rise to the surface of the e-coat fluid solution  114 , coalesce, and implode to release the entrapped portion of the dissolved gases from the e-coat fluid solution  114 . This process may be referred to as a controlled degasification of the first amount of the dissolved gases over a defined time period. This process may ensure that the deposition of the e-coat pigment or the paint emulsion is uniformly applied onto the surface of the metal part  112 . 
     The coating system  102  may be configured to control the plurality of ultrasonic transducers  108  (immersed in the zone-of-interest  116 ) to direct a plurality of acoustic waves at an ultrasonic frequency in the zone-of-interest  116  of the e-coat tank  104 . The directed plurality of acoustic waves at the ultrasonic frequency may cause the controlled degasification of the first amount of the dissolved gases from a volume of the e-coat fluid solution  114  that corresponds to the zone-of-interest  116 . The coating system  102  may be further configured to control a first intensity of the directed plurality of acoustic waves over the defined time period for a control over the deposition of the e-coat pigment over the metal part  112  of the vehicle. The metal part  112  may be immersed in the e-coat fluid solution  114  at a specific height from a bottom level of the e-coat tank  104 . The specific height may be decided based on an acoustic range of the plurality of ultrasonic transducers  108 , an angle of incidence on the surface of the metal part  112 , a smoothness of buildup of pressure near the surface of the metal part  112 , spatial and time-dependent pressure variations on the surface of the metal part  112 , and other factors. 
       FIG. 2  is a block diagram that illustrates various exemplary components or systems of the coating system of  FIG. 1 , in accordance with an embodiment of the disclosure.  FIG. 2  is explained in conjunction with elements from  FIG. 1 . With reference to  FIG. 2 , there is shown the coating system  102 . The coating system  102  may include the sonication system  106 , a power system  202 , and a temperature control system  204 . The temperature control system  204  may include a temperature sensor  206 , a heating system  208 , and a cooling system  210 . The e-coat tank  104  may store the e-coat fluid solution  114 . The coating system  102  may further include a control section  212  and the carrier frame  110  associated with the e-coat tank  104 . The control section  212  may include a memory  214 , control circuitry  216 , an input/output (I/O) device  218 , and a network interface  220 . In some embodiments, the coating system  102  may also include one or more non-immersible ultrasonic transducers, such as a non-immersible ultrasonic transducer  222 . 
     The power system  202  may supply power to various components of the coating system  102 . Further, the power system  202  may regulate supply of electric current or voltage to various components in the e-coat tank  104 . When a metal part (such as a vehicle body) is dipped in the e-coat fluid solution  114  of the e-coat tank  104  from an overhead conveyor or shuttle (such as the carrier frame  110 ), the vehicle body may act as a cathode and one or more plates within the e-coat tank  104  may act as the anode. The control section  212  may be configured to electronically control the power system  202  based on a set of control signals over the defined time period of the e-coating process. 
     The temperature control system  204  may include the temperature sensor  206 , the heating system  208 , and the cooling system  210 . The temperature control system  204  may comprise suitable logic, circuitry, and interfaces that may be configured to continuously monitor temperature levels within the e-coat tank  104  using the temperature sensor  206 . The heating system  208  and the cooling system  210  may comprise suitable logic, circuitry, and interfaces that may be configured to receive control signals from the control circuitry  216  to regulate the temperature within the e-coat tank  104  in a specified temperature range for the e-coating process. In cases where the temperature within the e-coat tank  104  reaches beyond a specified temperature threshold, a temperature alarm may be raised, and the cooling system  210  may be activated to cool down the e-coat fluid solution  114  in the e-coat tank  104 . The heating system  208  may be used to heat the e-coat fluid solution  114  in the e-coat tank  104  for a time period such that temperature of the e-coat fluid solution  114  is between a specified temperature range, such as “70° F.” to “95° F.”. Electrical resistance during from electrophoretic deposition, friction of free radicals in the e-coat fluid solution  114 , and acoustic cavitation caused by acoustic signals may be the major factors that may be causing a rise in the temperature of the e-coat fluid solution  114 . In some embodiments, one or more heat exchangers may be used to manage high temperatures resulting from electrophoretic deposition, i.e. during the e-coat process. The heat exchanger may enable an optimal control of the temperature during the controlled degasification of the e-coat fluid solution  114 . 
     The control section  212  may include the memory  214 , the control circuitry  216 , the I/O device  218 , and the network interface  220 . In some embodiments, the control section  212  may be provided or integrated on the outer periphery of the e-coat tank  104 . In some embodiments, the control section  212  may be a separate device communicatively coupled to the various components, such as the sonication system  106 , the power system  202 , and the temperature control system  204 , of the coating system  102 . 
     For example, the operations of the control section  212  may be implemented on at least one of a cloud server, a local server in the manufacturing and/or assembling plant for painting operations, a distributed control system (DCS), an industrial control system (such as a Programmable Logic Controller (PLC), a Supervisory Control and Data Acquisition (SCADA), or a Proportional-Integral-Derivative (PID) controller), or a combination thereof. 
     The memory  214  may comprise suitable logic, circuitry, and/or interfaces that may be configured to store a set of instructions executable by the control circuitry  216 . For example, different settings and configurations to control a trajectory of the metal part  112  of the vehicle within the e-coat tank  104  may be stored in the memory  214 . Examples of implementation of the memory  214  may include, but are not limited to, Electrically Erasable Programmable Read-Only Memory (EEPROM), Random Access Memory (RAM), Read Only Memory (ROM), Hard Disk Drive (HDD), Flash memory, Solid-State Drive (SSD), and/or CPU cache memory. 
     The control circuitry  216  may comprise suitable logic, circuits, interfaces, and/or code that may be configured to automatically (i.e. programmatically) control one or more components or systems, such as the sonication system  106 , the power system  202 , and the temperature control system  204 , of the coating system  102 . Examples of the control circuitry  216  may include, but are not limited to, a microcontroller, a Reduced Instruction Set Computing (RISC) processor, an Application-Specific Integrated Circuit (ASIC) processor, a Complex Instruction Set Computing (CISC) processor, a microcontroller, a central processing unit (CPU), a state machine, and/or other processors or control circuits. 
     The I/O device  218  may comprise suitable logic, circuitry, interfaces, and/or code that may be configured to receive the one or more user inputs and provide one or more corresponding outputs to a user who may manage the operations associated with the e-coat process. Examples of the input devices may include, but are not limited to, a touch screen, a microphone, a human machine interface (HMI) for the e-coat process, a motion sensor, a keyboard, or a dedicated user interface. Examples of the output devices may include, but are not limited to, a display, a temperature alarm bell, or a speaker. 
     The network interface  220  may comprise suitable logic, circuitry, interfaces, and/or code that may be configured to communicate with other components and systems of the coating system  102 , via a wired or wireless communication channel. The network interface  220  may be implemented by application of known technologies to support wired or wireless communication among different components of the coating system  102  and other devices in and around the vehicle manufacturing and/or assembling plant. 
     The non-immersible ultrasonic transducer  222  may be a stepped-plate high-directional transducer or a push pull ultrasonic transducer. The non-immersible ultrasonic transducer  222  may include one or more radiating plates, which may generate acoustic waves at an ultrasonic frequency, for example, “25 kHz”. In some embodiments, the non-immersible ultrasonic transducer  222  may also be provided in the coating system  102  in addition to the plurality of ultrasonic transducers  108 . The non-immersible ultrasonic transducer  222  may be configured to output a highly directional acoustic wave to rupture a plurality of bubbles semi-submerged within a coating layer formed on the metal part  112  of the vehicle. The non-immersible ultrasonic transducer  222  may be activated based on control signal(s) received from the control circuitry  216 . 
       FIG. 3A  illustrates a view of an exemplary e-coat tank for e-coat and degasification of a coating fluid during e-coat, in accordance with an embodiment of the disclosure.  FIG. 3A  is explained in conjunction with elements from  FIGS. 1 and 2 . In  FIG. 3A , there is shown a view  300 A of an e-coat tank  302 . The e-coat tank  302  may be same as the e-coat tank  104 . The e-coat tank  302  includes a plurality of anode panels  304  on side walls of the e-coat tank  302 . The e-coat tank  302  further includes a network of pipes  306  and a network of fluid eductors  308  at a bottom portion  310  of the e-coat tank  302 . There is further shown a plurality of ultrasonic transducers, such as a first set of ultrasonic transducers  312  and a second set of ultrasonic transducers  314  in a zone-of-interest  316  of the e-coat tank  302 . Although not shown, there may be watertight (i.e. insulated and grounded) cables routed along walls and in between the plurality of anode panels  304  of the e-coat tank  302 . Such cables may power the first set of ultrasonic transducers  312  and the second set of ultrasonic transducers  314  in the zone-of-interest  316 . 
     In the e-coat tank  302 , the first set of ultrasonic transducers  312  and the second set of ultrasonic transducers  314  may be mounted to the bottom portion  310  of the e-coat tank  302  and within the zone-of-interest  316 . Each of the first set of ultrasonic transducers  312  and the second set of ultrasonic transducers  314  may be configured to generate omnidirectional acoustic waves as the corresponding ultrasonic transducer resonates at a high wave amplitude. The generated omnidirectional acoustic waves may correspond to cyclic positive pressure waves and negative pressure waves within the e-coat fluid solution  114  at an ultrasonic frequency, for example, “25 kHz”. The details of the first set of ultrasonic transducers  312  and the second set of ultrasonic transducers  314  is described, for example, in  FIGS. 3B and 3C . 
       FIG. 3B  illustrates an enlarged view of a zone-of-interest in the e-coat tank of  FIG. 3A , in accordance with an embodiment of the disclosure.  FIG. 3B  is explained in conjunction with elements from  FIGS. 1, 2, and 3A . With reference to  FIG. 3B , there is shown an enlarged view  300 B of the zone-of-interest  316  of the e-coat tank  302 . 
     In the enlarged view  300 B, the first set of ultrasonic transducers  312  and the second set of ultrasonic transducers  314  may be mounted on the bottom portion  310  of the e-coat tank  302  in the zone-of-interest  316  such that a first position of the first set of ultrasonic transducers  312  staggers from a second position of the second set of ultrasonic transducers  314 . The stagger in the first position and the second position may be represented by a distance  318 . The first position may stagger from the second position for an inhibition of at least one dead fluid zone in the zone-of-interest  316 . In other words, the stagger in the first position and the second position may help to minimize a development of at least one dead fluid zone in the e-coat fluid solution  114 . The dead fluid zone may correspond to a specific volume of the e-coat fluid solution  114  which remains unaffected by the acoustic energy generated by the first set of ultrasonic transducers  312  and the second set of ultrasonic transducers  314 . Also, a minimum effect of the degasification and acoustic cavitation (i.e. a release of the dissolved gases from implosion of bubbles at surfaces) may be observed in the dead fluid zone. 
     In certain embodiments, each of the first set of ultrasonic transducers  312  and the second set of ultrasonic transducers  314  may be a push-pull ultrasonic transducer, with a free vibrating end and a fixed end. The free vibrating end may be mounted on a support mounting bracket (not shown). Similarly, the fixed end may be mounted on a fixed bracket (not shown). The entire fixture that includes the first set of ultrasonic transducers  312  and the second set of ultrasonic transducers  314  may be firmly secured to an L-channel in the e-coat tank  302  with chains (not shown). Additionally, mats (not shown) may be placed below the free vibrating end and the fixed end of each of the first set of ultrasonic transducers  312  and the second set of ultrasonic transducers  314  to absorb vibrations from the acoustic energy generated from acoustic waves. The mats may be made of plastic, stainless steel, or of a suitable material that may efficiently absorb the vibrations. 
       FIG. 3C  illustrates a view of an exemplary e-coat tank of  FIG. 3A  during the e-coat process, in accordance with an embodiment of the disclosure.  FIG. 3C  is explained in conjunction with elements from  FIGS. 1, 2, 3A, and 3B . With reference to  FIG. 3C , there is shown a view  300 C of the e-coat tank  302  during the e-coat process. The details of the e-coat process are described herein. 
     Initially, the control circuitry  216  may be configured to transfer the e-coat fluid solution  114  to the e-coat tank  302 , via the network of pipes  306  and the network of fluid eductors  308  at the bottom portion  310  of the e-coat tank  302 . The e-coat fluid solution  114  may fill up the e-coat tank  302  up to a specific level  320  that may depend on a height of the e-coat tank  302  and an acoustic range at a specific height of the metal part  112  from the first set of ultrasonic transducers  312  and the second set of ultrasonic transducers  314 . 
     The e-coat fluid solution  114  may include a first amount of dissolved gases (for example, a hydrogen (H 2 ) gas) that may be at a first pressure. The solubility of a gas (i.e., the amount of dissolved gas in the e-coat fluid solution  114 ) may be proportional to a partial pressure of the dissolved gases. Thus, the solubility of the dissolved gases, such as the H 2  gas, in the e-coat fluid solution  114  may be reduced by placing the e-coat fluid solution  114  under a reduced pressure. 
     In some embodiments, the control circuitry  216  may be configured to control the temperature of the e-coat fluid solution  114  within a range of temperature values that may be required for a deposition of the e-coat pigment in the e-coat fluid solution  114  on the metal part  112  of the vehicle. The e-coat fluid solution  114  in the e-coat tank  302  may be heated for a defined time period. The control circuitry  216  may be configured to communicate a first control signal to the heating system  208  to heat the e-coat fluid solution  114  in the e-coat tank  302  for the defined time period to maintain the temperature of the e-coat fluid solution  114  within the range of temperature values, such as “70° F. to 95° F.”. The temperature within the e-coat tank  302  may be continuously monitored using the temperature sensor  206 . In cases where the temperature reaches beyond a specified temperature threshold, for example, “95° F. or 100° F.”, a temperature alarm may be raised, using the temperature alarm bell of the I/O device  218 . The cooling system  210  may be activated concurrently to cool down the e-coat fluid solution  114  within the e-coat tank  302 . In accordance with an embodiment, the control circuitry  216  may be configured to monitor a plurality of parameters, such as pH level of the e-coat fluid solution  114 , a concentration ratio of the e-coat pigment or resin to the deionized water, and a total pressure of the dissolved gases in the e-coat fluid solution  114 . 
     In some embodiments, the control circuitry  216  may be further configured to control an immersion of the metal part  112  to be e-coated in the e-coat fluid solution  114 . The control of the immersion of the metal part  112  may include an adjustment of a trajectory of the metal part  112  across a length of the e-coat tank  302 , a height of the metal part  112  at different points in the trajectory, and a speed of movement of the metal part  112  across the length of the e-coat tank  302 . The details of the control of the trajectory is described, for example, in  FIGS. 4A to 4C . 
     The control circuitry  216  may be further configured to control a plurality of ultrasonic transducers, i.e. the first set of ultrasonic transducers  312  and the second set of ultrasonic transducers  314 , to direct a plurality of acoustic waves at an ultrasonic frequency in the zone-of-interest  316  of the e-coat tank  302 . The directed plurality of acoustic waves at the ultrasonic frequency may cause a controlled degasification of the first amount of the dissolved gases from a volume of the e-coat fluid solution  114  that corresponds to the zone-of-interest  316 . In some embodiments, the ultrasonic frequency may be between “20 kilohertz (KHz) to 50 KHz”. In some embodiments, the ultrasonic frequency may be between “25 to 40 KHz”. In other embodiments, the ultrasonic frequency may be one of “25 KHz” or “40 KHz”. The ultrasonic frequency may be controlled such that a distribution of the acoustic energy is uniformly spread-out over the volume in the e-coat fluid solution  114  that corresponds to the zone-of-interest  316  in the e-coat tank  302 . 
     It may be observed that when the plurality of acoustic waves are directed or applied at the ultrasonic frequency, for example, “25 KHz or 45 KHz”, desired chemical reactions that pertains to electrophoretic deposition on the metal part  112  may be accelerated and undesired chemical reactions may be avoided in the e-coat tank  302 . For example, the first set of ultrasonic transducers  312  and the second set of ultrasonic transducers  314  may be configured to generate the plurality of acoustic waves at the ultrasonic frequency of “25 kHz” and a defined power per cubic meter in a range of “10 to 100 Watts/Gallon”. At such ultrasonic frequency, the plurality of acoustic waves may exhibit longer wavelength that may be insufficient to adversely affect a molecule to induce any unwanted chemical change in the e-coat fluid solution  114 . Such an inert behavior of the plurality of acoustic waves for the radicals or molecules in the e-coat fluid solution  114  may be suitable for the controlled degasification (and/or de-agglomeration) of e-coat particles, such as the e-coat pigment and resin particles. 
     The control circuitry  216  may be further configured to control an electric voltage generator (not shown) of the power system  202  to apply a suitable electric voltage to the metal part  112  for a deposition of a coating layer of the e-coat pigment on the surface of the metal part  112 . The thickness of the coating layer may be controlled based on the applied voltage. 
     The plurality of ultrasonic transducers may be in the zone-of-interest  316  such that the plurality of acoustic waves are directed uniformly in different directions throughout the volume of the e-coat fluid solution  114  in the zone-of-interest  316 . Alternatively stated, the plurality of acoustic waves may be directed as omnidirectional acoustic waves as the corresponding ultrasonic transducer resonates at a high wave amplitude. The omnidirectional acoustic waves may correspond to cyclic positive pressure waves and negative pressure waves that occur at the ultrasonic frequency, for example, “25 kHz”. 
     In a negative pressure phase (or a low pressure phase), molecules within the e-coat fluid solution  114  experience a physical force that leads to generation of vacuum nuclei that grows continuously up to a specific size. The specific size may be proportional to the ultrasonic frequency of the plurality of acoustic waves. The vacuum bubbles entrap a portion of the first amount of the dissolved gases, such as the H 2  gas. In the positive pressure phase (or a high pressure phase of the half cycle), the bubbles that entrap the dissolved gases reach the surface of the e-coat fluid solution  114  and implode. The implosion of the bubbles leads to a degasification of the portion of the dissolved gases from the e-coat fluid solution  114 . The energy released from the implosion (caused by the acoustic cavitation) may raise the temperature of the e-coat fluid solution  114  beyond the range of temperature values required for the deposition of the e-coat pigment on the metal part  112 . Thus, the control circuitry  216  may control the temperature control system  204  to regulate the temperature of the e-coat fluid solution  114  within the range of temperature values. 
     As shown, the surface of the e-coat fluid solution  114  may comprise a first region  322 , a second region  324 , and a third region  326 . The second region  324  and the third region  326  may correspond to the zone-of-interest  316 . The first region  322  may correspond to the region on the surface of the e-coat fluid solution  114 , other than the zone-of-interest  316 . The first region  322  may be a less active gassing region as compared to the second region  324  and the third region  326 . Also, the first set of ultrasonic transducers  312  may lie below the second region  324  and the second set of ultrasonic transducers  314  may lie below the third region  326 . The effect of the acoustic cavitation and the control degasification may be visible from almost negligible or few bubbles in the second region  324  and the third region  326 . In absence of the acoustic cavitation and the control degasification, the first region  322  is shown to have a plurality of bubbles on the surface. 
     The control circuitry  216  may be further configured to control a first intensity of the directed plurality of acoustic waves over a defined time period for a control over a deposition of the e-coat pigment of the e-coat fluid solution  114  over the metal part  112  of the vehicle. The first intensity may correspond to an acoustic intensity of the plurality of acoustic waves in the e-coat fluid solution  114 . The control of the first intensity of the acoustic waves may correspond to a rate of a removal of the first amount of the dissolved gases from the e-coat fluid solution  114  of the e-coat tank  302 . Alternatively stated, as the acoustic intensity increases (or decreases) at a given ultrasonic frequency, the acoustic cavitation, i.e., a rate of bubble formation and implosion also increases (or decreases) and thereby leads to an increase (or a decrease) in the removal of the first amount of the dissolved gases over the defined time period. 
     The application of the plurality of acoustic waves may accelerate a removal of gases, such as the hydrogen gas, in the e-coat fluid solution  114  by breaking intermolecular interactions. In some embodiments, the plurality of acoustic waves may be applied in addition to a controlled stir (e.g., by a mechanical stirrer or agitator) under a reduced pressure. The addition of the controlled stir may enhance an efficiency of the degasification of the e-coat fluid solution  114 . Also, the directed plurality of acoustic waves may disperse and push the e-coat pigment evenly in different physically reachable and unreachable regions of the metal part  112 . As a result, the deposition of the e-coat pigment on the metal part  112  may be uniform, with a minimum (or even zero) number of spots that have either no or poor deposition of the e-coat pigment. 
     In the zone-of-interest  316 , the metal part  112  may be immersed in the e-coat fluid solution  114  at a specific height from a bottom level of the e-coat tank  302 . The specific height may be selected based on a required acoustic pressure or a sound pressure level (in dB) on the surface of the metal part  112 . Also, the specific height may be further selected to obtain a stable conical wave front between the metal part  112  and the first set of ultrasonic transducers  312  and the second set of ultrasonic transducers  314 . The acoustic pressure may be a function of the specific height of the metal part  112  from the bottom portion  310  of the e-coat tank  302  and an angle of incidence of the plurality of acoustic waves onto the surface of the metal part  112 . Thus, in some embodiments, the control circuitry  216  may be further configured to control an orientation of the metal part  112  in the e-coat fluid solution  114 . The orientation may be controlled to cause a change in an angle of incidence of the plurality of acoustic waves on the surface of the metal part  112 . The change in the angle of incidence may cause a change in the acoustic pressure on the surface of the metal part  112 . In such cases, the acoustic pressure may correspond to the controlled first intensity of the directed plurality of acoustic waves within the zone-of-interest  316 . 
     Conventionally, there may be larger spatial and time-dependent pressure variations on the surface of the metal upon an increase in the specific height of the metal part  112 . Such larger spatial and time-dependent pressure variations may lead to development of pressure islands dispersed around the surface of the metal part  112 . This may lead to a non-uniformity in the deposition of the e-coat pigment around different regions on the surface of the metal part  112 . 
     In some embodiments, the deposition of the e-coat pigment on the metal part  112  may be further based an acoustic range of each ultrasonic transducer of the plurality of ultrasonic transducers (such as the first set of ultrasonic transducers  312  and the second set of ultrasonic transducers  314 ) from the metal part  112 . The acoustic range may correspond to the specific height of the metal part  112  from the bottom level of the e-coat tank  302 . More specifically, the acoustic range may depend on factors such as, a speed of sound as a function of the temperature and a composition of the e-coat fluid solution  114 , a wavelength of the acoustic waves, an attenuation values of acoustic waves for the ultrasonic frequency, a sound radiation pattern, an amplitude of a return echo, and a sound pressure level (in dB). The amplitude of the return echo may depend on the specific height of the metal part  112 , a geometry of the surface of the metal part  112 , and a size or an area of the surface of the metal part  112  exposed to the plurality of acoustic waves. The control circuitry  216  may be configured to select a specific sound pressure level (in dB) at the ultrasonic frequency for the plurality of ultrasonic transducers (such as the first set of ultrasonic transducers  312  and the second set of ultrasonic transducers  314 ). For example, at “25 kHz”, the sound pressure level may be “55 kPa”. Based on the sound pressure level, the acoustic range may be selected to be around “1.2” meters. 
     Conventionally, the e-coat pigment (and/or resins) may agglomerate into lumps throughout the volume of the e-coat tank  302 . The agglomeration of the e-coat pigment (and/or resins) may affect a rate of the deposition of the e-coat pigment (and/or resins) and a deposition amount of the e-coat pigment (and/or resins) on the metal part  112 . Also, the e-coat pigment in the e-coat fluid solution  114  may stick to the side walls and the bottom portion  310  of the e-coat tank  302 . This may cause the e-coat pigment (and/or resins) to remain on the side walls and the bottom portion  310  as the e-coat fluid solution  114  is drained out from the e-coat tank  302 . 
     In accordance with an embodiment, the control circuitry  216  may be configured to control at least the first intensity or the ultrasonic frequency of the directed plurality of acoustic waves over the defined time period to cause a dispersion or a de-agglomeration of the e-coat pigment in the e-coat fluid solution  114 . At least the first intensity or the ultrasonic frequency of the directed plurality of acoustic waves may be controlled such that particles of the e-coat pigment unstick to walls of the e-coat tank  302 . This may be achieved from the localized cyclic pressures and temperatures that may be exerted due to the acoustic cavitation in the e-coat fluid solution  114 . Such pressures and temperatures may loosen up agglomerated blobs of the e-coat pigment from the walls and the bottom portion  310  of the e-coat tank  302  and within the e-coat fluid solution  114 . This may further render the walls and the bottom portion  310  of the e-coat tank  302  microscopically clean for a reuse. 
     In accordance with another embodiment, the control circuitry  216  may be configured to communicate one or more control signals to the plurality of ultrasonic transducers (such as the first set of ultrasonic transducers  312  and the second set of ultrasonic transducers  314 ). The one or more control signals may be communicated to control a gradual or a periodic increase of the first intensity of the directed plurality of acoustic waves over the defined time period to reduce a sedimentation or agglomeration of the e-coat pigment or the resin at the bottom portion  310  of the e-coat tank  302 . 
       FIG. 4A  illustrates a carrier frame for supporting a metal part of a vehicle, in accordance with an embodiment of the disclosure.  FIG. 4A  is explained in conjunction with elements from  FIGS. 1, 2, 3A, 3B, and 3C . With reference to  FIG. 4A , there is shown a carrier frame  400 A that may act a supporting mount and a guiding apparatus for the metal part  112  of the vehicle. In  FIG. 4A , there is shown a start point  402  (i.e. a location) indicative of a center coordinate of the carrier frame  400 A with respect to a vehicle coordinate system (represented by X, Y, and Z coordinates). The carrier frame  400 A may include a guide rail  404  that may be used to guide the metal part  112  through the e-coat fluid solution  114  and across the length of the e-coat tank  104  using movable arms  406 A and  406 B of the carrier frame  400 A. 
     The metal part  112 , such as a vehicle body or other complex metal parts of the vehicle, may be mounted on the carrier frame  400 A. The movable arms  406 A and  406 B of the carrier frame  400 A may be configured to hold or movably affix the metal part  112  (such as the vehicle body or other complex metal parts of the vehicle) for translation and rotational motion along different axes of the vehicle coordinate system. The movable arms  406 A and  406 B of the carrier frame  400 A may be configured to move the metal part  112  in accordance with a defined trajectory through the e-coat fluid solution  114  in the e-coat tank  104 . All the kinematics (translation and rotation) of the metal part  112  may be defined with respect to a reference coordinate, such as a center location of the carrier frame  400 A. 
       FIG. 4B  illustrates a view of a vehicle body mounted on the carrier frame of  FIG. 4A , in accordance with an embodiment of the disclosure.  FIG. 4B  is explained in conjunction with elements from  FIGS. 1, 2, 3A, 3B, 3C, and 4A . With reference to  FIG. 4B , there is shown a view  400 B of an exemplary complex metal part of a vehicle, such as a vehicle body  408  mounted on the carrier frame  400 A. The vehicle body  408  may be mounted on the carrier frame  400 A before the vehicle body  408  is immersed in the e-coat fluid solution  114 , stored within the e-coat tank  104  for the e-coat process. The movement of the carrier frame  400 A may be controlled based on instructions from the control circuitry  216 . The control circuitry  216  may be configured to adjust a z-position (i.e. a height) of the vehicle body  408  within the e-coat tank  104 . Also, the control circuitry  216  may be configured to adjust an x-position and a y-position (i.e. a forward displacement and a sideways displacement) of the vehicle body  408  in the e-coat tank  104 . 
       FIG. 4C  illustrates an exemplary trajectory of the vehicle body of  FIG. 4B  within an e-coat tank of the coating system of  FIG. 1 , in accordance with an embodiment of the disclosure.  FIG. 4C  is explained in conjunction with elements from  FIGS. 1, 2, 3A, 3B, 3C, 4A, and 4B . With reference to  FIG. 4C , there is shown the start point  402  (i.e. a center location of the carrier frame  400 A) and an end point  410  of an exemplary defined trajectory  412  in which the vehicle body  408  is traversed through the e-coat tank  104  for the e-coat process. There is further shown the zone-of-interest  414  in the e-coat tank  104 . It may be observed based on experimentation that the zone-of-interest  414  is the mid portion of the e-coat tank  104  in which the vehicle body  408  remains completely immersed in the e-coat fluid solution  114 . The zone-of-interest  414  may correspond to a chemically active zone in the e-coat tank  104 . In some embodiments, the zone-of-interest  414  may extend substantially along the length of the e-coat tank  104 . In other embodiments, the zone-of-interest  414  may include any region in which the vehicle body  408  remains fully submerged in the e-coat tank  104 . It may be further observed that a build-up or concentration of the dissolved gases, particularly hydrogen gas, remains maximum in this zone-of-interest  414  as compared to other zones or regions of the e-coat tank  104 . 
     The control circuitry  216  may be configured to control the defined trajectory  412  of the metal part  112 , such as the vehicle body  408 , through the e-coat fluid solution  114  within the e-coat tank  104 . The metal part  112 , such as the vehicle body  408 , may be mounted on the carrier frame  400 A. The control circuitry  216  may be further configured to control the carrier frame  400 A to guide the metal part  112 , such as vehicle body  408 , across the length of the e-coat tank  104 , in accordance with the defined trajectory  412 . The e-coat pigment may deposit on the surface of the metal part  112 , such as the vehicle body  408 , while the metal part  112  is guided across the length of the e-coat tank  104  in accordance with the defined trajectory  412 . 
       FIG. 5  illustrates a view of an exemplary e-coat tank for e-coating a metal part and degasification of an e-coat fluid solution, in accordance with an embodiment of the disclosure.  FIG. 5  is explained in conjunction with elements from  FIGS. 1, 2, 3A, 3B, 3C, 4A, 4B, and 4C . With reference to  FIG. 5 , there is shown a view of an e-coat tank  500  as part of the coating system  102 . 
     The e-coat tank  500  may be one of the exemplary embodiments for the e-coat tank  104 . The e-coat tank  500  may include a plurality of ultrasonic transducers  502 A,  502 B,  502 C,  502 D,  502 E, and  502 F in a zone-of-interest  504  of the e-coat tank  500 . The plurality of ultrasonic transducers  502 A,  502 B,  502 C,  502 D,  502 E, and  502 F may include a first set of ultrasonic transducers  502 A,  502 B, and  502 C and a second set of ultrasonic transducers  502 D,  502 E, and  502 F. The first set of ultrasonic transducers  502 A,  502 B, and  502 C and the second set of ultrasonic transducers  502 D,  502 E, and  502 F may be coupled on a first side wall and a second side wall of the e-coat tank  500 , respectively, in accordance with a sidewall configuration. The e-coat tank  500  may store the e-coat fluid solution  114  up to a specific level  506  with respect to a bottom of the e-coat tank  500 . The e-coat tank  500  may further include a carriage mount  508  to support a carrier frame, such as the carrier frame  400 A. The position of the first set of ultrasonic transducers  502 A,  502 B, and  502 C and the second set of ultrasonic transducers  502 D,  502 E, and  502 F on the first side wall and the second side wall of the e-coat tank  500  may help to disperse the e-coat pigment in the e-coat fluid solution uniformly across a volume that corresponds to the zone-of-interest  504 . In certain embodiments, the sidewall configuration may be used along with a non-immersible ultrasonic transducer to effectively degas the dissolved gases from the zone-of-interest  504  and to accelerate deposition of the e-coat pigment on the metal part  112 . 
       FIG. 6  illustrates a diagram for a process of contactless rupture of bubbles semi-submerged within a coating layer formed on a metal part of the vehicle, in accordance with an embodiment of the disclosure.  FIG. 6  is explained in conjunction with elements from  FIGS. 1, 2 ,  3 A,  3 B,  3 C,  4 A,  4 B,  4 C, and  5 . With reference to  FIG. 6 , there is shown a coating surface  602  of the vehicle body  408 , a coating layer  604 , and a plurality of bubbles  606  in the coating layer  604 . 
     At  608 , a uniform distribution of the plurality of bubbles  606  within the coating layer  604 , is depicted before or during application of an acoustic wave on the coating layer  604 . At  610 , some of the plurality of bubbles  606  appear to rise to a surface of the coating layer  604 , during application of the acoustic wave on the coating layer  604 . At  612 , some of the plurality of bubbles  606  are shown as semi-submerged within the coating layer  604  formed on the coating surface  602  of the vehicle body  408  (i.e. a complex metal part). There is also shown a radiating plate  616  of a non-immersible ultrasonic transducer  618  positioned in parallel to the coating surface  602  of the vehicle body  408 . In some embodiments, instead of the use of the plurality of ultrasonic transducers  108 , one or more non-immersible ultrasonic transducers, such as the non-immersible ultrasonic transducer  618 , may be used for a contactless rupture of the plurality of bubbles  606  semi-submerged within the coating layer  604 . 
     For example, when the vehicle body  408  is taken out or emerges from the e-coat tank  104 , the control circuitry  216  may be configured to control the non-immersible ultrasonic transducer  618  to direct an acoustic wave from the radiating plate  616  of the non-immersible ultrasonic transducer  618  towards the coating surface  602  of the vehicle body  408 . The acoustic wave with an ultrasonic frequency, for example, “25 KHz” or “40 KHz”, may be directed to rupture the plurality of bubbles  606  semi-submerged within the coating layer  604  on the vehicle body  408 . This additional application of the acoustic wave may ensure that no gas bubble is entrapped within the coating layer  604  both during and after the e-coat process. In some embodiments, the rupture of the plurality of bubbles  606  semi-submerged within the coating layer  604  may be done within the e-coat tank  104  by use of the non-immersible ultrasonic transducer  618 . Thus, the coating layer  604  on the coating surface  602  of the vehicle body  408  may be devoid of gas bubbles. 
     At  614 , the coating surface  602  of the coating layer  604  is shown with almost no bubbles after the contactless rupture of the plurality of bubbles  606 . As the coating layer  604  remains devoid of the plurality of bubbles  606 , an additional paint coat may be applied on the coating layer  604 . The paint coat may then form a strong bond with the vehicle body  408  and result in an improved paint finish. The complete degasification of the coating layer  604  may enhance aesthetic characteristics, corrosion protection, and an appearance and a durability of the vehicle body  408 . 
       FIG. 7A  illustrates a plot of acoustic pressure distribution versus time on a surface of a metal part based on a center-to-center distance between two acoustic sources, in accordance with an embodiment of the disclosure.  FIG. 7A  is described in conjunction with elements from  FIGS. 1, 2, 3A, 3B, 3C, 4A, 4B, 4C, 5, and 6 . With reference to  FIG. 7A , there is shown a plot  700 A. The plot  700 A represents an acoustic pressure distribution versus time on a surface of the metal part  112  based on a center-to-center distance between two acoustic sources, such as two ultrasonic transducers. The plot  700 A further represents the acoustic pressure distribution versus time for an optimal center-to-center distance (e.g., “550 mm”) between two adjacent ultrasonic transducers of the plurality of ultrasonic transducers  108 . In cases where the center-to-center distance is equal to the optimal center-to-center distance, a smoother pressure build-up may be observed on the surface of the metal part  112 . In cases where the center-to-center distance increases (or decreases) beyond the optimal center-to-center distance, larger spatial non-uniformities in the pressure may be observed in a plot of the acoustic pressure distribution versus time on the surface of the metal part  112 . 
       FIG. 7B  illustrates a plot of acoustic pressure distribution versus time on a surface of an acoustic source, in accordance with an embodiment of the disclosure.  FIG. 7B  is described in conjunction with elements from  FIGS. 1, 2, 3A, 3B, 3C, 4A, 4B, 4C, 5, 6, and 7A . With reference to  FIG. 7B , there is shown a plot  700 B. The plot  700 B represents an acoustic pressure distribution versus time on a surface of ultrasonic transducer of the plurality of ultrasonic transducers  108 . The plot  700 B of the acoustic pressure distribution versus time may be based on a center-to-center distance between two acoustic sources, such as two ultrasonic transducers. The plot  700 B further represents the acoustic pressure distribution versus time for an optimal center-to-center distance (e.g., “550 mm”) between two adjacent ultrasonic transducers of the plurality of ultrasonic transducers  108 . In cases where the center-to-center distance is equal to the optimal center-to-center distance, a smoother pressure build-up may be observed on the surface of the ultrasonic transducer. In cases where the center-to-center distance increases (or decreases) beyond the optimal center-to-center distance, larger spatial non-uniformities in the pressure may be observed in a plot of the acoustic pressure distribution versus time on the surface of the metal part  112 . 
       FIG. 8A  illustrates a diagram for development of a wave front on a surface of a metal part based on a distance of acoustic sources from the surface of the metal part, in accordance with an embodiment of the disclosure.  FIG. 8A  is described in conjunction with elements from FIGS.  1 ,  2 ,  3 A,  3 B,  3 C,  4 A,  4 B,  4 C,  5 ,  6 ,  7 A, and  7 B. With reference to  FIG. 8A , there is shown a diagram  800 A. 
     In the diagram  800 A, there is shown a surface  802  of the metal part  112  and a plurality of ultrasonic transducers (such as a first ultrasonic transducer  804 A, a second ultrasonic transducer  804 B, and a third ultrasonic transducer  804 C). The surface  802  and the plurality of ultrasonic transducers are immersed in the e-coat fluid solution  114 . The surface  802  of the metal part  112  may be at a specific height  806  in the zone-of-interest  116 . There is further shown a plurality of acoustic waves that form a conical wave-front  808  between the surface  802  and the plurality of ultrasonic transducers. 
     As shown, the specific height  806  for the surface  802  may be an optimal height, for example, “800 mm”. The specific height  806  may be selected to ensure that a smoother pressure builds up on the surface  802 . The development of the conical wave-front  808  may be indicative of smoother and uniform pressure build up on the surface  802 . In cases where the specific height  806  increases (or decreases) as compared to the optimal height, larger spatial and time-dependent pressure variations may be observed on the surface  802 . Also, instead of the conical wave-front  808 , a group of dispersed pressure islands may be observed around the surface  802  of the metal part  112 . 
       FIG. 8B  illustrates a plot of acoustic pressure distribution versus time on the surface of the metal part of  FIG. 8A , in accordance with an embodiment of the disclosure.  FIG. 8B  is described in conjunction with elements from  FIGS. 1, 2, 3A, 3B, 3C, 4A, 4B, 4C, 5, 6, 7A, 7B, and 8A . With reference to  FIG. 8B , there is shown a plot  800 B. The plot  800 B represents an acoustic pressure distribution versus time on the surface  802  of the metal part  112  based on a distance (i.e. the specific height  806 ) of the metal part  112  from the acoustic sources, such as the plurality of ultrasonic transducers. The plot  800 B further represents the acoustic pressure distribution versus time for an optimal height (e.g., “800 mm”) for the surface  802  of the metal part  112 . 
     In cases where the specific height  806  is equal to the optimal height, a smoother pressure build-up may be observed on the surface  802  of the metal part  112 . In cases where the specific height  806  increases (or decreases) as compared to the optimal height, larger spatial non-uniformities in the pressure may be observed in a plot of the acoustic pressure distribution versus time on the surface  802  of the metal part  112 . 
       FIG. 9A  illustrates a plot of conventional acoustic pressure distribution versus time on a surface of a metal part for a unidirectional acoustic source. With reference to  FIG. 9A , there is shown a plot  900 A. The plot  900 A represents a conventional acoustic pressure distribution versus time on a surface of the metal part  112  for a unidirectional acoustic source. The unidirectional acoustic source may radiate a plurality of acoustic waves only in an upward direction. As shown, the plot  900 A includes multiple closely spaced positive and negative peaks that may be indicative of larger spatial non-uniformities in the pressure from the unidirectional radiation of the plurality of acoustic waves. 
       FIG. 9B  illustrates a plot of acoustic pressure distribution versus time on a surface of a metal part for an omnidirectional acoustic source, in accordance with an embodiment of the disclosure.  FIG. 9B  is described in conjunction with elements from  FIGS. 1, 2, 3A, 3B, 3C, 4A, 4B, 4C, 5, 6, 7A, 7B, 8A, and 8B . With reference to  FIG. 9B , there is shown a plot  900 B. The plot  900 B represents an acoustic pressure distribution versus time on a surface of the metal part  112  based on an omnidirectional acoustic source, such as the plurality of ultrasonic transducers  108 . The omnidirectional acoustic source may generate an omnidirectional radiation of acoustic waves in the e-coat fluid solution  114 . The omnidirectional acoustic source may resonate at a very high wave amplitude and thereby generate cyclic positive and negative pressure waves at the ultrasonic frequency. As shown, the plot  900 B includes smaller positive and negative peaks for the acoustic pressure distribution with a relatively larger time gap as compared to the plot  900 A. This may be indicative of a development of a smoother pressure build-up from the omnidirectional radiation of the plurality of acoustic waves. 
       FIG. 10  is a flowchart that illustrates an exemplary method for e-coating and degasification of a coating fluid during e-coat, in accordance with an embodiment of the disclosure.  FIG. 10  is explained in conjunction with elements from  FIGS. 1, 2, 3A, 3B, 3C, 4A, 4B, 4C, 5, 6, 7A, 7B, 8A, 8B, and 9B . With reference to  FIG. 10 , there is shown a flowchart  1000 . The operations, implemented in the coating system  102 , may begin at  1002  and proceed to  1004 . 
     At  1004 , a plurality of parameters of the e-coat fluid solution  114  may be monitored. The control circuitry  216 , in conjunction with the temperature control system  204 , may be configured to monitor the plurality of parameters of the e-coat fluid solution  114 . The plurality of parameters may include, but are not limited to, a pH level of the e-coat fluid solution  114 , a concentration of the e-coat pigment or resin, pigment to binder ratio, and an acoustic pressure, and a partial pressure of the dissolved gases in the e-coat fluid solution  114 . 
     At  1006 , a trajectory of the metal part  112  may be controlled in the e-coat fluid solution  114  within the e-coat tank  104 , using the carrier frame  110 . The control circuitry  216  may be configured to control the trajectory of the metal part  112  in the e-coat fluid solution  114  within the e-coat tank  104 , using the carrier frame  110 . An example of the control of the trajectory of the vehicle body  408  within the e-coat tank  104 , has been shown and described in the  FIG. 4C . 
     At  1008 , the plurality of ultrasonic transducers  108  may be controlled to direct a plurality of acoustic waves at the ultrasonic frequency in the zone-of-interest  116  of the e-coat tank  104 . The control circuitry  216  may be configured to control the plurality of ultrasonic transducers  108  to direct the plurality of acoustic waves at the ultrasonic frequency in the zone-of-interest  116  of the e-coat tank  104 . 
     At  1010 , a first intensity of the directed plurality of acoustic waves may be controlled over a defined time period for a control over the deposition of the e-coat pigment of the e-coat fluid solution  114  over the metal part  112  of the vehicle. The control circuitry  216  may be configured to control the first intensity of the directed plurality of acoustic waves over the defined time period for the control over the deposition of the e-coat pigment of the e-coat fluid solution  114  over the metal part  112  of the vehicle. In accordance with an embodiment, the control circuitry  216  may be further configured to control an electric voltage generator (not shown) of the coating system  102  to apply a suitable electric voltage to the metal part  112 . The application of the suitable electric voltage may cause a deposition of a coating layer of an e-coat pigment on the metal part  112 . The thickness of the coating layer may be controlled based on the applied voltage. Control passes to end. 
       FIG. 11  is a flowchart that illustrates an exemplary method for performing degasification of dissolved gases in an e-coat fluid solution and e-coating on a metal part of a vehicle, in accordance with an embodiment of the disclosure. With reference to  FIG. 11 , there is shown a flowchart  1100 . The flowchart  1100  is described in conjunction with elements from  FIGS. 1, 2, 3A, 3B, 3C, 4A, 4B, 4C, 5, 6, 7A, 7B, 8A, 8B, 9B, and 10 . The method for performing degasification of dissolved gases in the e-coat fluid solution  114  and e-coating on the metal part  112  of a vehicle, begins at  1102  and proceeds to  1104 . 
     At  1104 , the metal part  112  of the vehicle may be pre-treated to prepare for an e-coat process in the e-coat tank  104 . For example, the metal part  112  of the vehicle may be cleaned, followed by acid-etching and rinsing before the e-coat process to obtain a cleaner reaction surface on the metal part  112 . The cleaner reaction surface facilitates an efficient deposition of a coating layer of the e-coat pigment on the metal part  112  during e-coat process. 
     At  1106 , the e-coat fluid solution  114  in the e-coat tank  104  may be heated over the defined time period. The heating system  208  may be configured to heat the e-coat fluid solution  114  in the e-coat tank  104  for the defined time period such that a temperature of the e-coat fluid solution  114  is between a specified temperature range, such as “70° F. to 95° F.”. In some embodiments, the e-coat fluid solution  114  in the e-coat tank  104  may be heated periodically to raise a defined level of temperature of the e-coat fluid solution  114  over a certain duration. The temperature within the e-coat tank  104  may be continuously monitored using the temperature sensor  206 . In cases where the temperature within the e-coat tank  104  is beyond a specified temperature threshold, a temperature alarm may be raised and the cooling system  210  may be activated to cool down the e-coat fluid solution  114  within the e-coat tank  104 . 
     At  1108 , the metal part  112  of the vehicle may be immersed at the specific height in the e-coat fluid solution  114  from a bottom level of the e-coat tank  104 . At  1110 , the trajectory of the metal part  112  may be controlled in the e-coat fluid solution  114 , using the carrier frame  110 . 
     At  1112 , a plurality of acoustic waves may be directed at the ultrasonic frequency in the zone-of-interest  116  of the e-coat tank  104  by controlling the plurality of ultrasonic transducers  108  mounted in the zone-of-interest  116 . The first amount of dissolved gases in the e-coat fluid solution  114  may be reduced or removed as bubbles from a surface of the e-coat fluid solution  114  based on the directed plurality of acoustic waves. It may be observed that at the time of application of the plurality of acoustic waves, large bubble islands may be dispersed on the surface of the e-coat fluid solution  114 . In some cases, small bubbles may coalesce to form larger bubbles and sufficiently large bubbles may rupture on the surface of the e-coat fluid solution  114 . 
     At  1114 , the deposition of the e-coat pigment of the e-coat fluid solution  114  may be controlled over the immersed metal part  112  of the vehicle by controlling the first intensity of the plurality of acoustic waves over the defined time period. Also, the first intensity of the directed plurality of acoustic waves may be controlled over a defined time period to accelerate a dispersion (or de-agglomeration) of the e-coat pigment present in the e-coat fluid solution  114 . Control passes to end. 
     In a conventional e-coating process, the e-coat operation may be followed by a recovery operation of e-coat materials, such as the e-coat pigment and/or resin, in the e-coat fluid solution  114 . Typically, mechanical agitators may be used to disperse the e-coat pigment. In case of the coating system  102 , as a result of the increase of the first intensity of the directed plurality of acoustic waves over a defined time period to accelerate the dispersion of the e-coat pigment present in the e-coat fluid solution  114 , there is no deposition of residue at the bottom of the e-coat tank  104 . Rather, the e-coat pigment is dispersed by the plurality of ultrasonic transducers  108  even in the absence of any mechanical agitators. The recovery process of the e-coat solids is fast compared to the conventional e-coating process, and the inner surfaces of the e-coat tank  104  remains clean. Thus, an additional time-consuming cleaning step is not required. In some embodiments, a curing of the coating layer may be performed. The curing time and temperature may vary based on the type of e-coat pigment and resin used in the e-coat fluid solution  114 , size, and geometry of the metal part  112  of the vehicle that is to be e-coated. 
     In a conventional e-coat process, an e-coat pigment may be deposited on a metal part (such as the entire vehicle body, the hood, or a side fender) of the vehicle, without an application of acoustic energy in a conventional e-coat fluid solution that includes the dissolved gases. It may be noted that the deposition of e-coat pigment on the metal part using the conventional e-coating process may result in one or more coating defects. The e-coated metal part may be susceptible to coating defects around corners, hard-to-reach areas, or other areas on the surface of the metal part. Such one or more coating defects may occur due to agglomeration of e-coat materials, such as e-coat pigment, in the e-coat fluid solution and dissolved gases in the e-coat fluid solution. This may also lead to a non-uniform coating layer, especially in areas that may have less surface area exposed directly to the e-coat fluid solution. The one or more coating defects may exhibit almost negligible or a thin layer of e-coat pigment that may be susceptible to damage and may wear off in subsequent manufacturing or quality test stages. 
     On the contrary, in the disclosed e-coat process, the application of the plurality of acoustic waves at the controlled first intensity and the ultrasonic frequency causes a uniform and accelerated deposition of the e-coat pigment in the e-coat fluid solution  114  across the surface of the metal part  112  of the vehicle. On the metal part  112 , there may be no coating defects. Such absence of coating defects may help to resist corrosion or other chemical or physical damages to the metal part  112  of the vehicle. Also, the body paint may adhere efficiently with the metal part  112  due to absence of coating defects, which otherwise may cause the body paint to wear out over a specific usage or test time period. In some cases, the surface of the metal part  112  may be inverted to have the surface placed concave relative to a surface of the plurality of ultrasonic transducers  108 . 
     Various embodiments of the disclosure provide a coating system (such as the coating system  102 ). The coating system may include an electro-coat (e-coat) tank (such as the e-coat tank  104 ) that stores an e-coat fluid solution (such as the e-coat fluid solution  114 ) having a first amount of dissolved gases and a plurality of ultrasonic transducers (such as the plurality of ultrasonic transducers  108 ) mounted in a zone-of-interest (such as the zone-of-interest  116 ) of the e-coat tank. In accordance with an embodiment, at least one of the dissolved gases in the e-coat fluid solution is hydrogen gas (H2). The coating system may further include control circuitry (such as the control circuitry  216 ). The control circuitry may be configured to control the plurality of ultrasonic transducers to direct a plurality of acoustic waves at an ultrasonic frequency in the zone-of-interest of the e-coat tank. The directed plurality of acoustic waves at the ultrasonic frequency may cause a controlled degasification of the first amount of the dissolved gases from a volume of the e-coat fluid solution. The volume of the e-coat fluid solution may correspond to the zone-of-interest. The control circuitry may be further configured to control a first intensity of the directed plurality of acoustic waves over a defined time period for a control over a deposition of an e-coat pigment of the e-coat fluid solution over a metal part (such as the metal part  112 ) of a vehicle. The metal part may be immersed in the e-coat fluid solution at a specific height from a bottom level of the e-coat tank. 
     In accordance with an embodiment, the plurality of ultrasonic transducers may be mounted to a bottom portion of the e-coat tank and within the zone-of-interest. The plurality of ultrasonic transducers may be in the zone-of-interest such that the plurality of acoustic waves are directed uniformly in different directions throughout the volume of the e-coat fluid solution in the zone-of-interest. 
     In accordance with an embodiment, the plurality of ultrasonic transducers may include at least one push-pull ultrasonic transducer. The plurality of ultrasonic transducers may include a first set of ultrasonic transducers (such as the first set of ultrasonic transducers  312 ) and a second set of ultrasonic transducers (such as the second set of ultrasonic transducers  314 ). The first set of ultrasonic transducers and the second set of ultrasonic transducers may be mounted on a bottom portion (such as the bottom portion  310 ) of the e-coat tank in the zone-of-interest such that a first position of the first set of ultrasonic transducers staggers from a second position of the second set of ultrasonic transducers. The first position may stagger from the second position for an inhibition of at least one dead fluid zone in the zone-of-interest. 
     In accordance with an embodiment, the coating system may further include a carrier frame (such as the carrier frame  110 ). The metal part may be mounted on the carrier frame. The control circuitry may be further configured to control a defined trajectory (such as the defined trajectory  412 ) of the metal part through the e-coat fluid solution within the e-coat tank. The control circuitry may be further configured to control the carrier frame to guide the metal part across a length of the e-coat tank in accordance with the defined trajectory. 
     In accordance with an embodiment, the control circuitry may be further configured to control at least the first intensity or the ultrasonic frequency of the directed plurality of acoustic waves over the defined time period to cause a dispersion or a de-agglomeration of the e-coat pigment in the e-coat fluid solution. At least the first intensity or the ultrasonic frequency of the directed plurality of acoustic waves may be controlled such that particles of the e-coat pigment unstick to walls of the e-coat tank. 
     In accordance with an embodiment, the control of the first intensity of the acoustic waves corresponds to a rate of a removal of the first amount of the dissolved gases from the e-coat fluid solution of the e-coat tank. The first intensity may correspond to an acoustic intensity of the plurality of acoustic waves in the e-coat fluid solution. 
     In accordance with an embodiment, the control circuitry may be further configured to control an orientation of the metal part in the e-coat fluid solution. The orientation may be controlled to cause a change in an angle of incidence of the plurality of acoustic waves on a surface of the metal part. The change in the angle of incidence may cause a change in an acoustic pressure on the surface of the metal part. The acoustic pressure may correspond to the controlled first intensity of the directed plurality of acoustic waves. 
     In accordance with an embodiment, the deposition of the e-coat pigment on the metal part may be based an acoustic range of each ultrasonic transducer of the plurality of ultrasonic transducers from the metal part. The acoustic range may correspond to the specific height of the metal part from the bottom level of the e-coat tank. 
     In accordance with an embodiment, the coating system may further include a non-immersible ultrasound transducer (such as the non-immersible ultrasonic transducer  222 ) that may include a radiating plate (such as the radiating plate  616 ). The control circuitry may be further configured to control the non-immersible ultrasound transducer to direct an acoustic wave from the radiating plate to rupture a plurality of semi-immersed bubbles within a coating layer (such as the coating layer  604 ) of the e-coat pigment on the metal part of the vehicle. The radiating plate of the non-immersible ultrasound transducer may be parallel to a surface of the metal part. 
     Various embodiments of the disclosure may be found in a method for performing degasification of dissolved gases in an e-coat fluid solution and e-coating on a metal part of a vehicle. The method may include a step of immersing the metal part of the vehicle at a specific height in the e-coat fluid solution from a bottom level of an e-coat tank. The method may include another step of directing a plurality of acoustic waves at an ultrasonic frequency in a zone-of-interest of the e-coat tank by controlling a plurality of ultrasonic transducers mounted in the zone-of-interest. The directed plurality of acoustic waves at the ultrasonic frequency may cause a controlled degasification of a first amount of dissolved gases from a volume of the e-coat fluid solution. The volume of the e-coat fluid solution may correspond to the zone-of-interest. The may further include another step of controlling a deposition of an e-coat pigment of the e-coat fluid solution over the immersed metal part of the vehicle by controlling a first intensity of the directed plurality of acoustic waves over a defined time period. 
     The present disclosure may be realized in hardware, or a combination of hardware and software. The present disclosure may be realized in a centralized fashion, in at least one computer system, or in a distributed fashion, where different elements may be spread across several interconnected computer systems. A computer system or other apparatus adapted for carrying out the methods described herein may be suited. The present disclosure may be realized in hardware that comprises a portion of an integrated circuit that also performs other functions. It may be understood that, depending the embodiment, some of the steps described above may be eliminated, while other additional steps may be added, and the sequence of steps may be changed. 
     While the present disclosure has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed, but that the present disclosure will include all embodiments that fall within the scope of the appended claims. Equivalent elements, materials, processes or steps may be substituted for those representatively illustrated and described herein. Moreover, certain features of the disclosure may be utilized independently of the use of other features, all as would be apparent to one skilled in the art after having the benefit of this description of the disclosure. 
     As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any contextual variants thereof, are intended to cover a non-exclusive inclusion. For example, a process, product, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements, but may include other elements not expressly listed or inherent to such process, product, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive or and not to an exclusive or. For example, a condition “A or B” is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B is true (or present). 
     Although the steps, operations, or computations may be presented in a specific order, this order may be changed in different embodiments. In some embodiments, to the extent multiple steps are shown as sequential in this specification, some combination of such steps in alternative embodiments may be performed at the same time. The sequence of operations described herein can be interrupted, suspended, reversed, or otherwise controlled by another process. It will also be appreciated that one or more of the elements depicted in the drawings/figures can also be implemented in a more separated or integrated manner, or even removed or rendered as inoperable in certain cases, as is useful in accordance with a particular application.