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Mitsubishi Motors Introduces New Robotic "Global First" Guided Handling

Time:2011-11-08 13:33

   Mitsubishi Motors opened the factory to the news media at the same time as it announced its new plant. The reduction in manufacturing costs is achieved through three means: 1. Reduction of the number of painting robots in the intermediate and topcoat processes; 2. The introduction of new spray guns and the reduction of coating waste; 3. In the primer impregnation process, "" For the first time in the world, Mitsubishi Motors introduced the body-handling machine and shortened the production line.


   ①In terms of reduction in the number of robots, the number of 18 robots in the previous intermediate and topcoat processes was reduced to 14 units. The Yaskawa Electric robot, which is approximately 40% lighter than the original model, has been installed on the wall in a location higher than usual and has expanded the range of spraying for each robot.


   When spraying the upper part of the body, it is necessary to set one on the left and right of the conveyor line when using the original floor-standing robot. In the upper position of the wall, only one surface can be sprayed on almost the entire upper surface of the vehicle body. As the number of robots is reduced and the installation area is reduced, the length of the intermediate paint and topcoat production line can be shortened from 153m to 146m, which also contributes to the reduction of costs.


   ②The new spray gun that sprays paint on the body uses a cartridge manufactured by ABB Switzerland. In use, only the necessary amount of paint was put in the cartridge, thereby reducing the amount of wasted paint by about 60%. The original is to transport paint to the spray gun through the pipeline from the coating deployment point, and to clean the remaining paint in the pipeline when changing the paint type.


   ③The vehicle body transporter in the primer process introduces an impregnation process in which the vehicle body is immersed in a large tank filled with an aqueous epoxy solvent to perform electrodeposition in order to improve rust prevention performance. The feature of the transporter is that it can significantly change the angle in the front-rear direction of the vehicle body. Lift the front and rear of the body with an L-shaped supporter, and change the angle of the body by moving the front and rear support up and down. It was originally the use of two hanger-like supporters to lift the body, but the fulcrum of the supporter was connected to the chain that was used for the purpose of transportation, and the angle of the vehicle body could not be independently changed independently of the inclination of the track.


   By changing the angle of the car body and increasing the angle between the groove and the groove, the length of the production line can be shortened. The production line is about 30m, which is about 30% shorter than the original. In addition, it is also possible to finely adjust the angle in the tank in accordance with the shape of the vehicle body, remove the air trapped in the tank, and improve the adhesion of the solvent. In addition, by increasing the slot angle, you can also make the solvent easily "anti-sagging". The time for the body to go into the slot is about 3 minutes. The hauler was jointly developed by TAIKISHA and DAIFUKU. Epoxy solvent was made by Nippon Paint, and a voltage of about 300 V was applied to the tank.


   In order to reduce energy consumption, the factory was changed to a three-tier structure, thereby reducing the energy required for cooling. Specifically, the process of using heat such as drying and painting is set on the third floor of the factory, the process of operating large energy-consuming devices such as robots is set on the second floor, and the process of manual operation is set on the first floor. As the heat naturally rises, the process of generating heat is set on the upper floor of the factory, so that the temperature of the first floor where the worker is located can be reduced, and the use of cold air can be reduced. Takahashi Masaki, Production Technology Director of Mitsubishi Motors Manufacturing Technology Division, said confidently: “Though the idea is simple, there is no other unique spray factory that can be completely used.”


   Intermediate paint and topcoat changed to waterborne paint


   The reduction of VOCs was achieved by changing the solvent coatings in the intermediate and topcoat processes to waterborne coatings. To this end, we have adopted the "three wet technologies" that have accumulated rich experience in Mitsubishi Motors Mizushima Plant. It was originally sprayed with a solvent coating in the intermediate paint process and dried in a drying oven at 140°C. The topcoat process is also preceded by a one-time solvent coating, followed by a one-time solvent coating that extrude the surface, and a grill in a drying oven. This time, the coating used in the intermediate paint process and the paint used for the first time in the top paint process were changed from solvent paint to water paint. In order to use the water-based paint, a step of blowing hot air at about 80° C. after spraying the water-based paint was added to evaporate water. This eliminates the need for a drying oven after the intermediate paint process. In addition, in order to remove harmful substances such as formaldehyde, a heat storage type deodorizing device is newly introduced into the drying furnace. This device can heat the exhaust gas from the drying furnace to a high temperature of about 850°C, and oxidizes and decomposes the formaldehyde contained therein.


   The new construction of the spraying plant began around 2007. The factory has passed 34 years since its establishment in 1977, and its aging is serious. Moreover, after the Japanese Air Pollution Prevention Act was promulgated in 2006, it also needed to meet the requirements of the regulations.