Cyclone separator
The cyclone separator uses centrifugal force to remove foreign matter, such as iron particles, which have a high specific gravity, from the processing fluid. It is mainly implemented in the pre-washing and degreasing processes where there are many iron particles.
The processing fluid from which foreign matter has been removed flows out of the upper discharge port, and the foreign matter is collected at the bottom of the system. The system is designed to discharge the foreign matter periodically and, as a result, eliminates the need for spare parts such as filters that are typically required for filtration.
Micro bubble system
The positive charge of oil is attracted to the negative charge of micro bubbles through electrostatic attraction, removing oils such as rust inhibitor oil and press oil from the body.
Adding micro bubbles to the degreasing tank lowers the alkali concentration and reduces the amount of degreaser replenished per vehicle to about one-third of the regular amount.
Metal oxide film
This treatment method coats the surface with a film to prevent corrosion of the coated workpiece and improve the coat adhesion. Using zirconium as the main component in the conversion process reduces the amount of sludge to about one-tenth that of conventional phosphate conversion fluids.
By lowering the amount of sludge, less sludge adheres to the coated workpiece's surface, and the need for a surface treatment process to remove iron particles is eliminated.
Optimization of e-coating tank nozzle layout and agitation flow rate with flow analysis
The optimum layout of nozzles, etc., can be reviewed by using fluid analysis to determine fluid movement in the e-coat tank in advance.
Measuring the flow and speed of the fluid in the e-coat tank ensures optimal nozzle placement and agitation flow rate (flow rate at the top of the e-coat tank). As a result, excessive adhesion of paint and contaminants can be prevented, and the painting quality can be improved.
E-coat Tank Internal Magnetic Screen
A screen consisting of a magnet and magnetized wire mesh is directly installed at the body entrance tank, with a high concentration of iron particles. The screen efficiently captures iron particles without disrupting the flow in the tank without impairing the flow in the tank.
With a magnetic bug filter installed outside the system, the range of the magnetic force is narrow, and iron particles that cannot be captured accumulate in the e-coat tank.
In contrast, with the magnetic screen, iron particles on the circulating flow in the tank can be efficiently captured by the screen with a large surface area, leading to a higher iron particle removal rate.
2-Stage UF system
In a typical e-coat painting process, the paint is carried out to the water-washing process. A filter generated with a UF system is used to recover the paint in the e-coat tank.
With the 2-stage UF system, two stages of UF films are installed to improve the paint recovery rate. This helps reduce the amount of paint used.
The fluid separated from the paint is returned to the water-washing process, where it can be used instead of pure water. This helps reduce the amount of pure water used and contributes to reducing costs and the environmental impact.
Warm water-washing after e-coating
The water used for water-washing after e-coating is heated to activate the thermal movement of the water. The thermal movement reduces the surface tension of the rinsing water and effectively discharges the washing water that has entered the coated workpiece's crevices.
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