ROBODRY SPRAYTRON

ROBODRY RETROFIT

TEchNIcAl DATA

Measures and dataRobodry Retrofit code:Robodry Spraytron code:Booth width:Booth length:Booth Height:Weight:Maximum size of objects which can be painted:Time for installation:Warranty:

Compressed airLine pressure:Connection tube size:

Motors

Overhead crane

Rails

20002001

min 3,90 mt - max 4,50 mtmin 7,00 mt - max 10,00 mt

min 2,70 mt350 kg

2 x 6 x h 2 mth 32

12 months

min 12.7 - max 14.7 ftmin 22.9 - max 32.8 ft

min 8.8 ft771.6 lb

6.5 x 19.6 x h 6.5 ft

8 bar8x10 ØixØe mm

All drive motors are ATEX-certified 24V DC motors equipped with ENCODERS for continuous position control.

The gantry structure of the overhead crane accom-modates all motor drives, installations and sensors required for robot operation. The gantry structure is made up of:two motor-driven side carriages that slide on alu-minium runways installed in the booth.A frame connecting the two motor-driven carriag-es for the sliding movement of the vertical lamp units.Two rails for motor-driven carriage of horizontal lamp.Shape Record Scanner.

Robodry has its own framework with 4 legs and an aluminium rail on each side of the booth that bear the full weight of the robot without damaging or affecting the booth structure.

Robodry is perfect for large-volume body shops.This is a fully automated robot and should be operated by skilled painters. It can perform a complete paint-and-dry job in half an hour and up to 14 jobs a day.In other words, it saves you one and a half hour per job on average, compared to your normal routine.

Control boxComputer:Touch screen:Supply voltage:Frequency:Controls voltage:Installed power (power input during first 3’:30”):

Control box

Pc and electronics

Approval and QualityApproval:

Laser temperature control sensor

Automatic laser shape system

19.6x36.6”

2.7 lb/h

16.4 lb/h

PC EMBEDDED15 “

400 V~ - 230 V~50/60 Hz

24 V~11,3 kW

EU: CE - ATEX II 3 G X Au: Compliant to Australian safety standards

AS/NZS 4114.1:2003 – AS 3814.1:2009US: cETLus Listed - Intertek 5000803

Robodry 2K9 EvoPlus can be configured with the control panel on the right or left side of booth doors. All power, gas and air connections will be on the same side as the panel. The Robodry’s con-trol panel features a 15” touch screen to allow for data.

It features an industrial PC with Windows Embed-ded operating system.

Robodry features 3 laser sensors for dynamic temperature detection, one on each lamp unit.The LTC (Laser Temperature Control) sensor is ATEX certified and has been specifically developed and designed at Symach’s in-house research laboratory to avoid reflection and deterioration when measuring temperature on water base, metallic paint and different colours.

The SRS is a laser system that performs a preliminary scan of thevehicle or part to be dried. This system acquires and stores the object shape, which will be used to keep the horizontal lamp unit parallel to and at the proper distance from the painted surface as it moves around the object during the dry-ing cycle. As a result, Robodry can dry vehicles and objects of any shape and size. This horizontal lamp automatically adjusts to the shape of the vehicle and remains parallel to and at the proper distance from the surface, and can move around objects of any shape and dry vertical, sloping or horizontal surfaces perfectly.

GasNo. of lamps:Dimensions:Power output:Hourly consumption - LPG (G31) at 12 mbar:Hourly consumption - Natural gas(G20) at 12 mbar:Power consumption (3’:30” only):Catalyser life:Implant power output:Hourly consumption - LPG (G31)at 12 mbar:Hourly consumption - Natural gas(G20) at 12 mbar:LPG gas (G31) / natural gas (G20)line pressure:Operating pressure LPG gas (G31)-Natural Gas (G20):Fitting size:

Control gas unit

Gas pipelines

6500 x 930 mm

16,4 kW

1,24 kg/h

1,66 cu.m./h1,88 kW

5000 hours - 30000 drying cycles98,4 kW

7,44 kg/h

9,96 cu.m./h

20/25 mbar

12 mbar1”G

The DrytronicPlus lamp can run on LPG or natural gas with no difference in performance.Gas pressure for proper operation is 25 millibar for LP G and natural gas. The gas unit is installed out-side the booth and includes 1 main solenoid valve, 3 NC (Normally Closed) solenoid valves - one per lamp unit - and a safety pressure valve that main-tains proper pressure.Gas is never present inside the booth where the Robodry is installed, because it is only delivered to the lamps when drying is activated. Connection to customer’s plant mains is ensured by a 1” pipe.

All gas pipes are certified flexible stainless steel corrugated pipes for moving applications and are guaranteed for continuous rotation in cable drag chains. The pipes are jointless and are robot laser welded at the manufacturer’s factory.

LOOK AT THE FUTURE

Software

Operator

Language

Size entry and lamp unit selection

Horizontal lamp with two operating modes: shape or fixed height

Enter size with the touch of a finger

Multiprogramming

The main screen allows access to the following programmes:a) Operator (selection, editing and new operator entry).b) Robot (drying treatment data entry). c) Drying formulas (formula entry and editing).d) Manual controls (to control robot movements).e) Report (treatments done and robot service state).f) Services (contains all services).g) Stop (to switch off robot and PC).

Each operator has his own registration and password.

Each operator can operate Robodry using their native language; basically, different operators in the same shop can use different display languages.

Entering the data required for the treatment is a simple, intuitive procedure: the screen shows booth layout and an independent treatment can be set for each unit using the “RH ” button for the right lamp, the “LH ” button for the left lamp, and “F” or “S” to select Fixed height mode or Shape mode for the horizontal lamp.

The horizontal lamp has two operating modes: “F” as in Fixed height mode for when you need to dry different loose parts and scanning objects with an indefinite shape might prove difficult; and “S” as in Shape mode, that provides for laser scanning of the shape of the vehicle to be dried.

Entering size is easy: at the press of a button, a bar appears on the booth layout and the operator simply needs to drag it with one finger to determine where treatment is to begin and end.Figures on the bar indicate current setting as would be measured on the metric rule attached to the rails.Treatment start and end settings (figures) determine the portion of vehicle or part that will be dried.

Multiprogramming allows the operator to select a treatment multiple times for each lamp unit, i.e. set the system to dry several parts at the same time. This function conveniently enables you to dry several parts of the same vehicle in one job. For instance, if you need to dry the rear mudguard and the front mudguard on the same side of a vehicle and then the bumper removed from the vehicle, the robot will dry only those parts that have been set in the programme and will skip the other parts found between them.

DRYTRONIcPlUS TEchNOlOGY lAMP

SOFTwARE

The Drytronic lamp generates energy by means of a catalytic chemical reaction. This reaction is achieved by using a catalyser that, once activated, can break down gas molecule and separate hydrogen from carbon. After going through the catalyser, hydrogen reaches lamp outer surface and, by getting in contact with oxygen, triggers the catalytic reac-tion that generates radiation, i.e. emitting infrared electromagnetic waves in the 0.76 and 3.5 micron wavelength spectrum.

ControllerEach lamp is fitted with an electronic controller that constantly monitors heating element and catalyser efficiency and triggers an emergency condition whenever it detects an abnormal event or depletion.

Horizontal lamp unitThe horizontal lamp unit is made up of two lamps and features an automatic pneumatic motion system that moves it up and down along the full booth height. Another drive unit rotates the lamp unit through 180° so it can follow the contour of the vehicle and keep parallel to it, at any angle, during the drying cycle.

Vertical lamp unitsThe right and left vertical lamp unit is made up of two lamps installed on two automatic carriages that move forward and backward across overhead crane width to automatically adjust lamp distance to the width of the vehicle or object to be dried.

Three independent lamp unitRobodry features 3 independent lamp units that can operate individually, two at a time or three at a time during treatment. Each lamp unit is installed on a motor driven carriage that moves it closer to or farther from the painted surface as dictated by vehicle and/or part width and according to the drying formula so as to obtain optimal drying.The lamp unit is equipped with an automatic LTC (Laser Temperature Control) system that monitors drying and adjusts temperature to suit colour, type and thickness of substrate (iron, aluminium, plastic, fibreglass, etc.) and type of paint.Proper drying management according to the set formula is provided by the “StarControl” software.

Partial treatment

Drying formula selection and set-up

Shape scanning

Treatment start screen

Manual controls

Service area

Treatment - started screen

Drying formulas

Report

Self diagnosis

Starcontrol

Variable distance

The four Starcontrol functions:

Increasing or decreasing speed

Increasing or decreasing wavelength

Gas flow

Partial treatments can also be set for one or more parts among those set in the programme. For instance, if one part among those set requires undercoat to be applied wet-on-wet, you may use this function to have the robot dry only the selected part and skip all others.

After entering treatment size, you need to select the drying formula from the database.A formula is a set of parameters and the work cycle which Robodry performs automatically developed and tested to dry a specific product. For instance, a complete drying cycle can be programmed as follows:step one: select formula for wet-on wet undercoat, if used;Step two: select water base formula.Final step: select clear lacquer formula.This means an operator can set the full drying cycle before they begin painting. When finished, they will only need to press the Start button.

After the operator has entered data, Robodry asks to perform a preliminary scan of the vehicle to acquire its shape using the SRS (Scanner Record Shape) system.This procedure takes a little longer than a minute and the shape of the scanned object is displayed immediately.

The treatment start screen offers the possibility of editing formula parameters both before and after pressing Start, while the treatment is under way. This function allows operator to easily correct a drying formula as needed, making for great flexibility. Editable parameters are as follows:formula temperature.Formula speed.Distance - changes the distance from the surface to be dried set in the formula, for objects with unusual shapes and dimensions not compatible with automatic operation using “StarControl”.

The manual controls window enables the operator to control Robodry movements for maintenance purposes.

Robodry automatically updates the preventive maintenance plan according to the number of treatments done.

The treatment-started window lets you edit all parameters of a formula. It also displays a dynamic 3D graphic model of the vehicle and any objects during the treatment.It displays a clock showing time left to end of treatment and the temperature readings of all three lamp units, for operator to monitor the job under way when needed.

Operator can use a database of preset formulas for each type and brand of paint, or enter new, customised formulas, also according to their preferences or technique.

Robodry generates reports for each drying treatment.

Robodry features a self-diagnosis section to report technical problems.

Robodry drying treatment is controlled by advanced monitoring and control software named “StarControl”. The “StarControl” software automatically controls drying treatment by coordinating the operation of all LTC (Laser Tem-perature Control) devices, of the robot system and of the Drytronic WLC (Wave Length Control) technology for fast, optimal drying, while ensuring that temperature and exposure parameters are always met.

“Variable distance” This system enables Robodry to automatically control the temperature set in the formula, making sure it is maintained throughout the treatment. The robot system adapts lamp distance automatically so as to achieve accurate, even drying.

This system controls exposure time and the acceleration ramp of paint temperature, and varies formula speed dy-namically to obtain the proper exposure for each product and brand of paint.

The WLC (Wave Length Control) system promotes or slows down the chemical reaction in the lamps to increase or decrease the energy output at varying wavelength as required.

Gas flow is controlled by the “Pop-Up” system that adjusts pressure and delivery to treatment.

AccESSORIES

Supporting beamCode:Dimensions:Beam supporting legs forbooths with size door measuring up to 6 mt.

Surcharge special leg kitCode:Legs.Leg support.Adjustable foot.For booths extension from 4 mt to 4.5 mt.

Rail extensionCode:Supporting legs.Adjustable foot.Cable conduit.Right-hand measuring label.2 mt aluminum section.10.1 mt toothed belt.Booth rails extension from 8 mt to 10 mt.

20803 mt x 2 pieces

2081

2082

9.8 ft x 2 pieces

19.6 ft

13.1 to 14.7 ft

6.5 ft33.1 ft

26.2 to 32.8 ft

Special pipes

Alarm devices safety pressure valve

Gas and solvent detector

Motor drive effort control

Control hardware and software

Booth thermostat

Gas supply pipes are flexible stainless steel corrugated pipes guaranteed to last 30,000 movements in cable drag chains, that require no on-site welding.

The gas control panel outside the booth accommodates a safety pressure valve to ensure the correct amount of gas is delivered at the right time.

A gas and solvent detector is installed inside the booth to monitor the internal environment at all times and detect any traces of gas during operation.

If a moving part hits an obstacle on its path, the robot is immediately placed in an alarm condition.

Hardware and software monitoring ensures proper operation of each and every component.

A thermostat is installed inside the booth to check for proper internal temperature.

Gas delivery only during the drying treatment

Gas nc solenoid valves

Air pressure valve

Catalyser control

Gas delivery is always cut off outside the booth, meaning that gas is only delivered when the drying treatment is in progress and all safety systems are active.

The gas control panel outside the booth features double-tier safety, with a first NC (normally-closed) main and three additional NC solenoid valves one for each lamp unit that are only activated when the drying treatment is active.

A pressure valve checks compressed air pressure to ensure the proper catalytic reaction is achieved.

Each lamp is fitted with a thermostat that monitors the proper operation of catalyser and heating element.

Safety devicesThis robot is ATEX certified, which means it has been designed to operate in environments where potentially explosive gas mixtures can develop as solvents are released by paint products during the drying process.This certification guarantees that the product and its components are designed and manufactured to operate safely in this kind of environment.

SAFETY DEvIcES

APPlIcATIONS: wATER BASE

ppg - basf - akzo Nobel

AXAlTA

APPlIcATIONS: clEAR cOAT

Drying

Drying

Drying

Drying

TOTAL TIME

TOTAL TIME

TOTAL TIME

1

1

1

3

2

2

2

4

1:30 MINUTES

1:30 MINUTES

2:00 MINUTES

1:30 MINUTES

6:00 MINUTES

4:30 MINUTES

6:00 MINUTES

1° + 2° Coat (without flash off)

1° + 2° + 3° Drop coat(without flash off)

1° + 2° Coat(without flash off)

3° Coat (Drop coat)

2:00 MINUTES

3:00 MINUTES

4:00 MINUTES

1:00 MINUTES

Symach srl - Via Cassoletta, 41/A Crespellano 40056 - Bologna - Italy

www.symach.cominfo@symach.com

Ph. +39 (0)51 963161