COMAU SmartSpray

Powerlink Control of Plasma Spray Process

Comau is a leading global provider of advanced

manufacturing systems, innovative sustainable

automation and service solutions

With a strong history in the automotive industry, we

have continued to grow, and today we offer our skills

and know-how to a wide range of industries and

applications

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One team of 14,000 employees worldwide

40 years of experience

4 innovation centers

15 manufacturing plants

27 locations

15 countries

Over 110 PMI® certified project managers

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Property of Comau - Duplication prohibitedMarch2014

COMAU SYSTEMS 2013 Turnover per area (%)

COMAU GROUP 2011-13 Revenues (MIO €)

HIGH PERFORMANCE SMART TECHNOLOGY

APPLICATION FIELDS

• A complete range of innovative and reliable robots from 6

to 800 kg payload

• Reliable and powerful C5G control unit

• User-friendly programming terminal also available

in wireless version

• Process-oriented software dedicated to each

application

• A complete set of application equipments and

accessories

• Plug & play standard robotized cells for arc welding

applications

INTEGRATED ROBOTIZED SOLUTIONS

• Spot welding

• Arc welding

• Handling/palletizing

• Press-to-press automation

• Glueing

• Foundry

Robotics

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PRODUCTS

TECHNOLOGIES

FLEXIBLE SOLUTIONS

Body Structures Assembly

• Framing systems

• Accumulating pallet conveyor (APC)

• Break-away end effector

• Vision systems (Recognisense)

• Welding guns (Versagun)

• Drilling and Riveting (End Effector)

• AGV

• Laser welding / brazing / cutting

• Plasma cutting

• Roller hemming

• Aluminum joining

ADVANCED BODY STRUCTURES ASSEMBLY

• Versaroll

• Versapallet transfer system

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Powertrain Systems

MACHINING SOLUTIONS FOR:

•Transmission

•Automatic transmission

•Steering Housing

•Cylinder Block

•Crankshaft

•Cylinder Head

•Engine Accessories

ASSEMBLY SOLUTIONS FOR:

•Automatic Transmission

•Manual Gearbox

•Truck Engine

•Engine

•Power Transfer Unit

•Cylinder Head

•Piston Connection Rods

•Ancillary Machines

•Rear Differential Unit

FROM CONCEPT TO CUSTOMER CARE

TESTING SOLUTIONS

•In Process Test

•End of Line Test

•Cold Test

•Hot Test

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COMAU SMARTSPRAY

The COMAU SMARTSPRAY machine is an integrated Plasma Transferred Wire Arc (PTWA) additive manufacturing process used to apply a metal coating to internal bores.

Plasma Transferred Wire Arc (PTWA) process

COMAU SMARTSPRAY CELL

COMAU SMARTSPRAY

• COMAU NJ4-90 robots are used for handling the PTWA torch heads in the machine

• The robot program controls all critical PTWA parameters directly, improving I/O response time and protecting the core functions from inadvertent changes causing catastrophic torch failures

GAS MIXING PANEL ROBOT CONTROL PANEL

Robot Control Panel (Comau C5g) has motion control, safety input and controls gas mixing panel.

CELL PLC AND SAFETY PLC TUNTABLE VFD

Main Panel has Power Distribution, Cell Controller, Safety PLC and Turntable VFD

HMI PANEL EXTERIOR HMI PANEL INTERIOR

HMI Panel has Operator interface and I/O for Load Area

By using ETHERNET POWERLINK, COMAU was able to:• reduce the amount of wiring• reduce the amount of part number required• Better integrate the solution in Comau standard product

ADVANTAGES

• -30% in cost compared to an earlier ProfiNET based system• Fastest and better communication within the system