Basic Introduction to the Paint Shop

7/25/2019 Basic Introduction to the Paint Shop

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Introduction to the Paintshopand its products

Paintshop Basics


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What is a Paint Shop?

The Paint Shop

is a specialized

area in the

production of anautomobile

The Paint Shop

is a specialized

area in the

production of anautomobile

Paintshop Basics


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What Does a Paint Shop Do?

The Paint Shop

Receives the

Body-in-White and

Returns a FinishedPainted Body to

the Trim and

Assembly Areas

The Paint Shop

Receives the

Body-in-White and

Returns a FinishedPainted Body to

the Trim and

Assembly Areas

To Produce the

Protective Paint

Finish Seen on an

Automobile,Several Layers are

Applied

To Produce the

Protective Paint

Finish Seen on an

Automobile,Several Layers are

Applied

Paintshop Basics


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Body-in-White

Paintshop Basics

Bare steelbody Body-in-white


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Phosphate LayerPaintshop Basics

Chemically developed surface coating


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Electrocoating layer

Paintshop Basics

Corrosion-protection-Paint coating


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Primer Layer

Paintshop Basics

Primer paint coating


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Basecoat Layer

Paintshop Basics

Colored paint coating


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Clearcoat Layer

Paintshop Basics

Clear paint coating for protection against elements


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Paintshop Basics


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Supplier

Durr

Client

Innovation

Space

available

Know how

Budget

Preferredmethods

Experience

Paint

suppliers

Design

parameters

Chemistry

Paintshop Basics

How is a process, how chart, layout developed?


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Conveyors

Paintshop Basics

Monorail

Skid

Ro-dip


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Bodies are Moved Through the PaintShop and Between Floors with Conveyors

Paintshop Basics


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Overview of aPhosphate System

Also calledpretreatment system

Paintshop Basics


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What Is Phosphate?

Phosphate is a chemically

developed surface coating

It helps shield metal from air,

moisture, etc.

This increases corrosion

resistance

And simultaneously provides a

roughed-up surface for the next

paint layer to adhere to.

Paintshop Basics


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What does a Phospathe System do?

It throughly rinses, washes nad clean the body

It deposits a phosphate coating on the body Improves paint adhesion

Prevents underfilm corrosion

Helps shield metal from air and moisture

Paintshop Basics


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Remember, the reason behind the

Phosphate system is to prepare the body

for subsequent paint layers. Some of the stages in the Phosphate

system are:

Degreasing

Rinsing (various)

Activation

Zinc Phosphate

Passivation

Paintshop Basics


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Exhaust Air

Supply Air

Phosphate EnclosurePhosphate Enclosure PaintShopAir

PaintShop

Air

SupplyFan

Ventilation System

The phosphate enclosure air flow is negative in an

attempt to contain the steam and chemicalsgenerated in the process.

Paintshop Basics


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Overview of an

Electro Coating System

or E-coat System

Paintshop Basics


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Why do we have an E-Coat Process?

Electrocoating provides corrosion

protection to the vehicle.

A uniform, protective coating isapplied to all the paint vehicle parts.

Paintshop Basics


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+++

++++

-

The negatively charged

vehicle is dipped into a tank

of positively charged paint.

-

How is E-Coat Paint Applied?

--

--

++ ++

Paintshop Basics

Paintshop Basics


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The Electrochemical Reaction

Since opposites attract, the positively charged

paint is drawn to the negatively charged body.

This process continues until a continuous and

even film coats the entire surface of the body.

The process stops itself when the film is almost

equal on all its surfaces.

Paintshop Basics

Paintshop Basics


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Typical spray ring

configuration

The E-Coat System not only consists of the E-Coat

Paint, but successive stages to rinse excess paint

off of the bodies.

These stages can consist of:

Cream Coat Rinses

Ultrafil trate Dips and Sprays R.O. Water Dips and Sprays

Deionized Water Sprays

Paintshop Basics

Paintshop Basics


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Overview of a Spray Booth

Paintshop Basics

Paintshop Basics


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Paintshop Basics

Spraybooth Cross Section

supply

plenum

enclosure

scrubber

exhaust

Five major

components

Paintshop Basics


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What is a Spray Booth?

Paintshop Basics

Spray Booths have been engineered and installed

as separate enclosures within the Paint Shop

For the purpose of applying paints to the body:

Prime Coat

Base Coat

Clear Coat

Paintshop Basics


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The application of the various paint

layers requires that the exact

environmental conditions be

maintained in order to achievemaximum quality

Paintshop Basics

Paintshop Basics


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A Filtered Environment is required to Minimize Dirt

and Dust in the spray Booth

Paintshop Basics

SPRYBOOTH FILTRATION

AIR FLOW

Paintshop Basics


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Containment of PaintOverspray

a s op as cs

Paintshop Basics


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Maintaining

Specific Temperatureand Humidity

p

24 C - 1C

75% RH - 5%RH

Paintshop Basics


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Air Flow Balance Zone to

Zone

and Air Flow Down Drafts

p

Paintshop Basics


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Isolation of theSpraying Process

from the Remainder

of the Plant

p

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Different types of operations occur inthe Spray Booth.

Each operation takes place in an areacalled a zone.

Some zones are: a blow off or feather duster zone

a solvent / water wipe zone

a tack-off zone

manual paint application zones

automatic paint application zones

flash-off zones

Paintshop Basics


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Supply air for the Spray Booth comes from

air supply houses located on a mezzanine orpenthouse level above the booth

G l A bl


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HumidifierFilter-unit:

For Air c leaning

Cooling-/heating-

section:

For the temperature of

the air in the region of

the paint window

Silencer:

to adsorb sound

Humidifier:

for theconditioning of the

air to the

necessary

humidity

Fan:For intake of the air

General AssemblyFilter-unit F5 Cooling- / Heating section

Filter-unit F7Fan

Sound absorber

Paintshop Basics


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The supply air is ducted tovarious zone plenums and

introduced into the booth through

distribution filter media whichmakes up the booth ceiling.

Paintshop Basics


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The paint laden air is then pulled

down the throat of the scrubber.

Paintshop Basics


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SCRUBBER

BAFFLE

FLOOD PAN FLOOD PAN

WATER RETURN

TROUGH

WATER DISTRIBUTION TROUGHWATER DISTRIBUTION TROUGH

Paint

particles

collide with

the water

particles

Scrubbed Air Out

Paint Laden Air

Booth Air Downdraft

Paint Solid Laden Water

Scrubber Pressure Drop is

Adjusted to Achieve Desired

Efficiency

Cross-Section of

Drr Mini-Baffle

Scrubber System

Paintshop Basics


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Supporting Cast:

Sludge System

Paint Circulation System

Humidification System

Powder Paint System

Building HVAC System

Paintshop Basics


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Spraybooth

Filterhouse

Carbon RotorRegenerative

ThermalOxidizer (RTO)

Air From theSpray Booth

Paintshop Basics


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Overview of an Oven


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What is aPaintshop Basics


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What is a

"Conventional" Oven?

WORK

Radiant

Bring-UpZones

Convection

Heat-UpZones

Convection

HoldZones

Paintshop Basics


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Purpose of the

Bring-Up Radiant Zones

Add Heat to the Work to

Bring all Parts up to the

Target Temperature

Add Heat in a Uniform,

Controlled and Dirt-Free

Fashion

Paintshop Basics


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Purpose of the Heat-Up Convection Zones

Add Heat to Low Heavy

Metal Components of the

Job

Paintshop Basics


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Purpose of the Hold Convection Zones

Maintain Temperature on

the body

At Time Specified for Proper

Cure

Historically Circulating air

is Used

Indirect Fired Heaters

Q: What Does a Heater Do?Paintshop Basics


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Flexible

Connection

Flexible

Connection

OvenOven

HeaterHeater

DuctDuct

A: The Heater Supplies Heated Air to the Oven

1- Positioned near the oven, the heater uses a natural

gas burner to heat air (either directly or indirectly).

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2- Heated air is supplied to Oven to maintain

specified temperature.

Paintshop Basics


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What Do We Mean By

"Direct-Fired"or " Indirect-Fired"?

Oven heaters

Direct Fired Heater Operation

Paintshop Basics


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M

RETURN

DUCT

EXHAUST TOATMOSPHERE

RECIRC.

FAN

COMBUSTION

BLOWER

FRESH AIR

SUPPLY

DUCT

FRESH

AIR

Direct-Fired Heater Operation

Paintshop Basics


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Indirect-Fired Heater Operation

M

RETURN

DUCT

SUPPLY

DUCT

RECIRC

FANFRESH

AIR

COMBUSTION

BLOWER

FRESH AIR

Air through

th O

Paintshop Basics


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the Oven

OvenOven

Regenerative

ThermalOxidizer (RTO)

Paintshop Basics


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J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D

Order Received

Engineering and P/E

Site Work & BuildingInstallation

Start-Up / Facility Launch

Turn Over to Production

1998 1999 2000

Typical Project as it Flows Throughthe Company

Where are you involved?

Paintshop Basics


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Paintshop Basics


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Turnkey PaintshopTurnkey Paintshop

Site

PreparationManufacturing

Building

Erection

Process

InstallationLaunch SOP

Facility Support

Services

P d t LiP d t Li

Paintshop Basics


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OvensPhos/EC BoothsPaint

Circ / PipingFacilit y / Layout

Product LineProduct Line

P d t LiP d t Li

Paintshop Basics


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Product LineProduct Line

EnvironmentalAppl ication

EquipmentRobotics

Conveyors/Material Handling

Controls

Date post:	28-Feb-2018
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Basic Introduction to the Paint Shop

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