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In automotive coating, uniform paint film thickness is an important factor affecting the quality of coating. So far, extensive testing has been required when importing new models to ensure perfect spraying. Doyle has now successfully calculated the film thickness virtually and integrated the module into existing spray robot programming software to
. With newly developed simulation software, automakers can reduce the number of tests in the field. The DXQ3D.onsite software is available along with the new process simulation module. The first field beta version is in use.
Every time there is a new project in the coating workshop, for example, when importing a new model, many processes and parameters need to be precisely adjusted until the paint sprayed on any part of the body reaches the required film thickness. Before all adjustments are in place, the body goes through a complex parametric spray testing process. With Doyle's new simulation tools, automakers can now virtually simulate and optimize the process.Dr. Lars Friedrich, President and CEO of the Applied Technology Division of
Doyle Systems AG, explains that
can now reduce the number of spray tests and the number of body tests by more than 50 percent, making commissioning more efficient, reducing material costs, and reducing poor body spray quality. "
road to a digital coating workshop
the analog spraying process is one of the many important steps leading to a fully digital coating workshop. The goal is to make the spraying process more cost-effective through computer-aided product and process development while ensuring that the same high-quality products are available. Simulation technology can help even before the first prototype is put into production. With specific calculations, you can predict where problems may occur and propose remedial measures before production. In terms of film thickness, this also includes hard-to-spray body parts, such as connections to the car luggage compartment.
the DXQ3D.onsite
module is based on the three-step concept of visualization on your computer in advance. The first step involves virtually calculating the amount of paint that needs to be sprayed at any point. The software is closely integrated with the actual situation using idealized virtual spray mode for simulation. The spray scale can be scaled dynamically at different heights and widths. Users can "adjust" these two parameters to estimate and visualize the overall impact of different spray widths and flow percentages on the film thickness distribution.
in order to simulate the actual situation on the computer in advance, the software module created digital twins of all the key independent components in the form of electronic data. On the first simulation, the tool automatically converts the uploaded file format to the body's 3D digital format. This preserves all necessary additional data while deleting data that is not related to the spray operation. The benefit of this is that it reduces the storage space and computing time required, so the program can also be used directly on a laptop in the production line spray room. After the last time all relevant data is combined, a virtual spray along the robot path programmed offline is generated. It can add film thickness and is shown via a 3D feature map. This allows the team to look directly at the different optimization solutions, consider them, and make improvements before production.
the pre-optimized parameters for the first spray
the specific paint type is not taken into account when performing software simulations. Therefore, the second step after virtual optimization is to perform real-world testing in the Doyle test lab. The paint material of the customer's choice is used in the test. Use the measured values in the third (and final) step to convert the virtual parameters used in the simulation, such as spray width and flow percentage, to the parameters of the spray atomizer. During the Conversion process, the actual results are integrated into the simulator. After importing the feature map, the software automatically suggests the atomizer parameters. The body is then tested for the first real-world spray using this set of pre-optimized parameters.the real results of the
Doyle test lab are integrated into the simulation program
it takes only a few minutes to complete the simulation
the software module has a short computational time, so you can simulate the film thickness and evaluate the quality of the entire body on the traditional PC end, rather than on a mainfring computer, in a matter of minutes. "This makes it easier to evaluate film thickness quality, better demonstrate coating quality results, and optimize key areas of film thickness incosyscency." Frank Herre, head of applied technology process development at Doyle Systems, summed up these advantages.
DXQ3D.onsite simulator quantifys the thickness of the film and displays it on the body as a color gradient. The overskind coating is shown in red and the oversmed coating is shown in blue.
visual simulation shows the film thickness distribution in key areas and pre-optimizes the spray process in a targeted way.
process simulation can be used as an add-on to the DXQ3D.onsite standard software that comes with each Doyle spray robot. DXQ3D.onsite is a digital universal tool that allows path programming or parameter setting of application processes by simulating all the robots on the workstation.
.