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Symach srl - Via Cassoletta, 41/A Crespellano 40056 - Bologna - Italy
www.symach.com - [email protected]
Ph. +39 (0)51 963161
INDEX
4
SYMACH
SHORT
MEDIUM
DIRECT-FIRED
CONVENTIONAL
Body Filler
Primer
Water base
Clear lacquer
5
6
7
The electrical panel is located outside the booth, on the right or left side, and accommodates safety devices, counters and the
transformer.
CONTROL BOX
KeyBOaRd aNd dispLay
MONiTORiNg aNd CONTROL sysTeM
Controls are located on the robotised column. Flydry is equipped
with a membrane keyboard and a two-line display to allow for
data management by operator.
The electrical panel on the robotised column accommodates a
board with microcontroller that manages motor with encoder,
software, I/O signals and all other components.
Control BoX
The drive motors are ATEX - certified 24V DC motors equipped
with ENCODERS for continuous position control.
MotorS
All gas pipes are certified flexible stainless steel corrugated pipes
for moving applications and are guaranteed for continuous rota-
tion in cable drag chains. The pipes are jointless and are robot
laser welded at the manufacturers factory.
gaS PiPeS
overhead Crane
The Flydry overhead crane carries the robotised column and
slides along three parallel aluminium rails that span across the
whole width of the preparation area to carry out the drying cycle.
The overhead crane is made up of:
Two side carriages and a central motor-driven carriage that slide
along the aluminium rails.
Double aluminium rails connect the three carriages to form the
overhead crane that provides the sliding movement of the robot-
ised column.
Each Flydry module features three aluminium rails - two side rails
and a central one - that span across the width of the prepara-
tion area. In a configuration with several modules, the rails will be
butted up to one another.
railS
COMPONENTS FLYDRY8
Flydry features a laser sensor for dynamic temperature detection
on the lamp unit.
The LTC (Laser Temperature Control) sensor is ATEX certified and
has been specifically developed and designed at Symachs in-
house research laboratory to avoid reflection and deterioration
when measuring temperature on water base, metallic paint and
different colours.
laSer teMPerature Control SenSor
The robotised column can slide to any position along the length
and width of the preparation area while drying. This means the
vehicle or the parts to be dried can be placed in any position.
MoveMent and Work range
The DrytronicPlus lamp can run on LPG or natural gas with no dif-
ference in performance.
The gas unit is installed outside the booth or preparation area and
includes 1 main solenoid valve, 1 NC (Normally Closed) solenoid
valve and a safety pressure valve that maintains proper pressure.
Gas is never present inside the booth or preparation area where
the Flydry is installed, because it is only delivered to the lamps
when drying is activated. Connection to customers plant mains is
ensured by a 1 pipe.
gaS unit
The robotised column slides independently within the overhead
crane along the length of the preparation area and the overhead
crane slides across the width of the area.
The robotised column can rotate through 360 about its axis to
dry all sides of the vehicle.
The robotised column is equipped with a pneumatically con-
trolled arm that carries and orients the lamp unit as required by
the job. The lamp unit features 2 lamps - one at the bottom and
one at the top - each equipped with a LTC (Laser Temperature
Control) sensor for dynamic temperature monitoring during the
drying process.
The control console including display and keyboard is located on
the robotised column.
roBotiSed ColuMn
9
The robotised column can rotate through 360 about its axis and
can be set in any position to dry the four sides of the vehicle. It
features two pneumatic drive units to set the lamp arm at the
required height and angle.
The drive units allow Flydry to move the two lamps from a fully
vertical to a fully horizontal position and set them at varying an-
gles. This way, the two lamps can be set in the ideal position par-
allel to vehicle surface for flawless drying.
orientation and PoSitioning oFroBotiSed laMP ColuMn
verSion With Standard, Mid Sized and tall ColuMn
Flydry can be equipped with 3 different robotised columns to suit
the height of the preparation area. The version with the Stand-
ard Column covers the internal floor-to-ceiling height in a 2.70
to 3.10 m preparation area. Flydry cannot be installed in prepara-
tion areas less than 2.70 m high. The version with the Mid-Sized
Column covers the internal floor-to ceiling height in a 3.10 to
3.60 m preparation area. The version with the Tall Column cov-
ers the internal floor-to-ceiling height in a 3.60 to 4.00 m prepara-
tion area.
OpeRaTiON
drytroniCPluS laMP
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, hydro-
gen reaches lamp outer surface and, by getting in contact with
oxygen, triggers the catalytic reaction 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 catalyser efficiency and triggers
an emergency condition whenever it detects an abnormal event
or depletion.
laMP unit
Flydry features a unit with two independent lamps that can op-
erate individually or two at a time during treatment. The lamp
unit is equipped with an automatic LTC (Laser Temperature Con-
trol) 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 DryingControl
software developed at the Symach research laboratories, that
controls all formula parameters associated with sensors and Fly-
dry automation system.
10
ACCESSORIES FLYDRY
Rail module for Flydry expansion to serve several work stations.
COMPONENTS:
4000 mm aluminium section rails.
4000 mm aluminium section shelves:
Belt tensioner mountings.
Plenum or ModulLight clamps.
anChorage oMega kit
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SOFTWARE FLYDRY
a) Manual controls (overhead crane movements and column
movements in four directions).
b) Treatment size (start/end of treatment).
c) Lamp selection (bottom and/or top lamp).
d) Drying formulas (selected from database).
e) Drying temperature.
f) System stop (switch off when work is finished).
WORk TRAVEL SETTING
Operator can choose to enter travel lengths ranging from 0.5 m
up to the length of the vehicle or part to be dried.
LaMp seLeCTiONOperator can choose to use the bottom lamp or both lamps for
drying.
DRYING FORMuLA SELECTION AND EDITING
After entering treatment size and selecting the lamp or lamps to
be used, the operator chooses the drying formula from a data-
base. A formula is a set of parameters and the work cycle which
the robots performs automatically to dry a specific paint product,
a given portion of a vehicle or of loose parts.
Formula parameters can be edited in the screen before pressing
start. This function allows operator to edit a drying formula as
required. For instance, the operator may want to edit a formula
to dry a particularly thick coat of paint, or materials that are very
sensitive to temperature, to ensure optimal drying quality.
Editable parameters are as follows:
Temperature, for special jobs or when drying materials with spe-
cial requirements.
Speed, for harder or softer drying depending on coat thickness,
among other things.
Passes, number of passes can be modified for special drying cycles.
Formula database entry and editing.
The operator can edit or enter customised formulas, also accord-
ing to their preferences or technique.
When the operator has finished painting, pressing the Start key
starts the drying treatment in automatic mode.
TREATMENT - STARTED SCREEN
The treatment-started window displays the temperature reading
of the LTC (Laser Temperature Control) system, so operator can
monitor the job on hand continuously. The exact progress of the
treatment under way is also displayed.
sysTeM sTOpFlydry has a main switch to stop the system and an emergency
stop switch. When the system remains unused for half an hour,
automatic switch-off is activated..
LANGuAGE
The Flydry software offers many display languages to choose
from. Display language can be selected during the configuration
procedure and all messages and indications will be displayed in
the selected language.
treatMent Start
Flydry drying treatment is controlled by an advanced monitoring
and control software named DryingControl.
The DryingControl software automatically controls drying treat-
ment by coordinating the operation of all LTC (Laser Temperature
Control) devices, of the robot system and of the Drytronic WLC
(Wave Length Control) technology for fast, optimal drying.
Operation is maintained within set temperature and exposition
time at all times.
ThE TWO DRYINGCONTROL FuNCTIONS
Increasing or decreasing wavelength.
The first function of DryingControl is the WLC (Wave Length
Control) system, that promotes or slows down the chemical re-
action in the lamps to increase or decrease the energy output
at varying wavelength as required to obtain just the right paint
reticulation.
1
Gas Flow. Gas flow is controlled by the Pop-up system
that adjusts pressure and delivery to treatment.2
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13
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STANDARD SIZE OF BOOTh
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COMpONeNTs ROBOdRy16
17
OpeRaTiON
three indePendent laMP unitS
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SOFTWARE ROBODRY 19
After entering treatment size, you need to select the drying for-
mula from the database.
A formula is a set of parameters and the work cycle which Ro-
bodry performs automatically developed and tested to dry a spe-
cific product. For instance, a complete drying cycle can be pro-
grammed 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.
The treatment start screen offers the possibility of editing for-
mula 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.
20
Variable distance This system enables Robodry to automati-
cally 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.
1
Increasing or decreasing speed This system controls expo-
sure time and the acceleration ramp of paint temperature, and
varies formula speed dynamically to obtain the proper exposure
for each product and brand of paint.
2
Increasing or decreasing wavelength The WLC (Wave
Length Control) system promotes or slows down the chemical re-
action in the lamps to increase or decrease the energy output at
varying wavelength as required.
3
Gas Flow Gas flow is controlled by the Pop-up system
that adjusts pressure and delivery to treatment.4
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STANDARD SIZE OF BOOTh
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Increasing or decreasing wavelength The first function of
DryingControl is the WLC (Wave Length Control) system, that
promotes or slows down the chemical reaction in the lamps to
increase or decrease the energy output at varying wavelength as
required to obtain just the right paint reticulation.
1
Gas Flow Gas flow is controlled by the Pop-up system
that adjusts pressure and delivery to treatment.2
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COMpONeNTs dRyTRON34
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spRayTRON
BOOTH siZe
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COMpONeNTs spRayTRON38
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SP
RAY
TR
ON
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KO
MB
ITR
ON45
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FIX
STA
TIO
N
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MO
DU
LBLO
CK
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StruCture
Carriage For WheelS Being treated
This alternating sequence allows the operator to work continuously without any downtime and consequently with the max. productivity
and without a great effort.
the operator lays the first wheel on the rotating support making it spin without any friction or effort; thanks to this configuration, the wheel is under constant control.1then operator starts sanding the first wheel, the Wheel Station workstation is equipped with a compressed air connec-tion as well as with a sanding suction unit.2the operator applies the filler on the first wheel and pushes it on the rail inside the drying station, where the drytronic furnace dries filler in 3 to 4 minutes. once the drying process is completed, furnace turns automatically off, then the cooling phase starts and lasts for approx. another 3 minutes.3While product is being dried, the operator starts repairing the second wheel as the two supports exactly allow him/her working continuously without any downtime. 4the operator inserts the second wheel inside the furnace and takes the first one back to sand the filler, then he/she sprays the undercoat and pushes the wheel again inside the furnace to be dried. the drying process lasts another 3-4 minutes plus approx. 3 minutes necessary for cooling.5after having inserted the second wheel inside furnace, the operator sands the undercoat of the first wheel and, once finished, sprays the water base and inserts the wheel again inside furnace to be dried for 2 minutes and, after other 2 minutes necessary for cooling, the wheel is ready for clear lacquer application.6
after having inserted the second wheel inside the furnace, the operator applies the clear lacquer on the first wheel and inserts it inside furnace to be dried for 4-5 minutes. now the first wheel is ready to be refitted onto vehicle.7
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CU
RTA
IN
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WIN
DO
W E
XT
RA
CT
ION
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SYM
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H C
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TOM
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SERVICES
Consulting and design
Symach employs experienced process engineers who are capable
of designing operational processes and layouts for our customers
body shops, offering consulting services and organizational and
management advice for the establishment of a body shop or exist-ing one.
Technical assistance
Every country in which we operate is home to a technical assistance
center that offers training for local technicians, as well as spare
parts kits for customers, which allow for all types of repairs to be
performed in just in a few hours.
Training
Our technicians and training staff are highly experienced in the
fields of painting and repair processes, and travel around the
world to train our customers staff and managers for the proper
use of the Fixline process and the SPAP cycle.
