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Automation and robotization of the painting line in High Voltage Hitachi Energy Czech Republic production plant

  • Client:
    Hitachi Energy Czech Republic
  • Technical specification:
    • 4× ABB IRB 5100 paint robot
    • 2× NORDSON ColorMAX3 coating booth
    • NORDSON Quick color change system ColorOnDemand
    • InSight control system
    • InSight IS software data connection to SAP information system  

Project description

To be capable of handling the rising production volume and to increase the capacity of the paintshop, an implentation of robots in the coating process came as the best solution. For any robotization process, accurate identification of products in the painting process is necessary. In this project, we replaced the entire control system of the paint line and implemented the latest version of the inSight control software.

The inSight control system and its automated scheduling function not only gives the client flexibility but also a better ability to react to changes in scheduling. The work for the planner himself is now easier and significantly faster.

In the given robotic coating implementation, in addition to the standard system of painting with the appropriate programs a system of so-called Parametric Programs was used. This system allows the use of one robotic program for multiple modifications of a given part. The modification of the part does not have to be entered by the operator, but the system is able to detect it automatically, thus significantly streamlining the entire robotic coating process.

"Robotic powder application - which is faster and more precise - now allows us to load more material onto the coating line, significantly increasing its capacity. At the same time, we have eliminated non-ergonomic activities that were strenuous and potentially dangerous for our operators." Says Zdeněk Vala, Production Manager of the High Voltage Hitachi Energy Czech Republic production plant.

His words are followed by the Head of Surface Treatment Tech Department, Mr. Václav Holeček. "The speed, precision and variability of robotic work has resulted in an increase of productivity, efficient powder application and, most importantly, a reduction of scrap rate. The combination of the control system and robotics also brings a significant reduction in waste, amount of paint consumed and amount of waste water."

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