summit.engr@summitengineers.net

Automated Coating System

Application of adhesive chemicals on the “Metal Substrates” before molding rubber has been one of the trickiest issues for “Metal To Rubber Bonding” industry. There have been various issues related to this activity,


Our Breakthrough Solutions

We at Summit Engineers & Consultants Ltd, have developed & patented automated machines for spraying primer & adhesive onto the metal components, either inside or outside surface, to the required specifications.

The machines are capable of handling different sizes and shapes of the metal components & are being used for last 8 years by many companies in this industry such as

  • Innova Rubbers, Nashik,
  • Varroc Elastomers, Aurangabad,
  • Suyog Rubbers, Nashik,

And many smaller ones.

These machines have only improved over the time.

Technical Specifications & Videos

Parameters Specifications
Input Electric Supply 3- phase 440 volt
Input pneumatic Supply 5-7 bar
Dryer With or without heater/ dryer with temp. control
Machine Output Single/double coating of one type/ two types of adhesive of 15 to 50microns on cylindrical/ flat components.
Cycle time per
component
And No. of
components
per 8hr shift
ID Spraying Single Station
(Either primer or final coat)
6 sec/job *
4800jobs/shift

View Video Single Station ID Spray

View Video Single Station Canopy ID Spray

ID Spraying 2- Station Conveyorised (Both coats) 2 sec/job *
14500 jobs/shift
View Video 2 Station ID Spray
OD Spraying Single Station
(Either primer or final coat)
2 sec/job
14500jobs/shift
View Video OD Single Station Non Convey
OD Chemlok Spray with X and Y axis   View Video OD Chemlok Spray with X and Y axis
Verticle ID Chemlok Spray Machine   View Video Verticle ID Chemlok Spray Machine
OD Spraying Single Station
Conveyorised (Either primer
or final coat)
1 sec/job **
30000 jobs/shift
View Video Single Station Conveyorised OD Spray
OD Spraying 2- Station
Conveyorised (Both coats)
1 sec/job **
30000 jobs/shift

View Video 2 Station OD Convey Spray Machine

View Video 2 Station OD Spray Conveyorised

Legend: * Depends on length of components Max spray length 150mm

** Depends on length of components Max spray length 450mm

OD Spraying : Coating outside surface of the metallic component

ID Spraying : Coating Inside surface of the metallic component

Coating Machines

Salient Features & Advantages

Productivity:
  • Automated, hence reduces manpower requirement many-folds.
  • Cycle time/component < 5 Sec.
  • Excellent reliability and operational security of the complete system.
  • Advanced Alarm & warning systems.
  • Durable & efficient clamping system.
Mistake Proofing:
  • No adhesive: machine stops: If the level of adhesive ( either primer or final) goes below 10% the machine stops. Warning alarm for operator at 20% for both level & with alarm display on HMI.
  • No rotation of jobs: Machine stops with alarm display on HMI.
  • Spray Gun choked: Machine stops with alarm display on HMI.
  • Main Air pressure too low: Machine stops with alarm display on HMI.
Diagnostics:
  • Live temperature read outs on the panel HMI
  • Live digital pressure displays for main air supply pressure & Spray Gun Back pressures.
  • Hooter with 3 colour tower lamp.
  • Precise identification with clear alarms on HMI for errors on various sensors & reed switches.
Easy Maintenance:
  • Easy access: All control & electrical equipment on one side of the machine.
  • Separate control cabinet for all pneumatic controls.
  • Separate junction boxes for Station 1 & Station 2 Control wiring & electrical wiring.
Safety:
  • Option to opt for Flameproof motors & fittings
  • All moving parts barriered.
  • Operator Friendly: Localised & effective mist extraction.
  • Improves worker safety
  • Advanced Spray Gun: No loose parts & uses high quality chemical resistant sealing materials.
  • Safe heaters with no exposed heating coils, no possibility of solvent rich flammable vapour travelling to red hot heaters
  • Automatic Temperature control of heaters.
  • Heater/ or heater fan failure: Machine stops with alarm display on HMI.
Convenience Savings:
  • Easy integration – systems are compact and portable
  • Easy installation and operation – compact unit requires just a few minutes for set-up.
  • Reduces waste of costly coating chemicals.
  • Rugged design & hence low maintenance quick change spray guns which can be easily removed from the coating station.
  • Spray nozzle gets very close to metal surface, very low misting & wastage.
  • Custom built tooling & fixtures as per component. Modular design of the complete system.
  • Even surfaces, easy to clean.
Quality:
  • Uniform and accurate product coating.
  • Wide range of flow rates, spray angle and drop size to suit costumer requirement
  • Ensures quality with air and liquid control; eliminates quality problems due to uneven application of the spray solution due to changes in spray pattern or drop size
  • Variety of other controllable parameters to get desired results.
  • Quality problems due to coatings that are too hot or too cold are eliminated through the use of closed-loop temperature control
The Summit Service:
  • We are only a phone call or an Email away, wherever you are in India.
  • Full support for Commissioning & Operator Training
  • Easy to use Operations Manual complete with drawings, line diagrams, maintenance & fault finding guidance.
  • While individual bought out components carry their own warranty, we provide one year full service warranty for any manufacturing defect.
  • Summit machines are well proven, tough, specially built for the harsh adhesive paint application environment. They provide a series of benefits to the customer and are now considered a standard in the coating industry.
Comparison Between Manual Adhesive Coating & Automated Coating
      Traditional Manual
Coating (Single Coat)
Single Station
non-conveyorised m/c
(Primer or final Coat)
2-Station Conveyorised m/c
For both primer & final coat
on the same m/c
Coating of Inners Productivity per person Per Job 30 sec/job 4 to 8 sec/job about 2 sec/job*
Ave. Jobs per hour 120 600 1800
Ave. Jobs per 8 hr. Shift 960 4800 14500
Coating of
Outers/
Flat jobs
Productivity
per person
Per Job 15 sec/job 2 sec/job about 1 sec/job*
Jobs per hour 240 1800 3500
Jobs per 8 hr. Shift 1900 14500 30000
For all Quality Coating Thickness Uneven Even Even
Coating Consistency Not assured Assured Assured
Bond Strength Not assured Assured Assured
Coating Thickness Control Not possible Possible Possible
Other
Savings
Drying time High due to uneven coating minimal based on viscocity minimal based on viscocity
Adhesive Spillage uncontrolled Controlled Controlled
Space High due to large no. of
manpower involved
2 sq. meter including
one operator
3 sq. meter including
bowl feeder
Health & Safety Unavoidable exposure to
a large no. of personnel
Limited & controlled by
exhaust ducts
Limited & controlled by
exhaust ducts
Industry /Application Picture Commonly used Chemlok Grades Order Description Our Spraying Machine
Bush: Inner Cylindrical Pipes. Coating from outside. Diameter & length varies Ch205 PRIMER CH220, 252X, 6108, 6411 OD Spraying Machine Product Code SEA0200, SEA0410, SEA0510
Bush: Outer Cylindircal Pipes. Coating from inside.Diameter & length varies. Ch205 PRIMER CH220, 252X, 6108, 6411 ID Spraying Machine Product Code SEA0100, SEA0310
Mount: Top Bottom flat plates Flat components of different sizes & shapes Ch205 PRIMER CH220, 252X, 6108, 6411 OD Spraying Machine Product Code SEA0200, SEA0410, SEA0510
Oil Seal Circular metal rings of different diameter for sealing purpose Ch202 A/B, TS-167-13HS – NBR 607/ 608 – Silicone 5150, 5151- FKM OD Spraying Machine Product Code SEA0200, SEA0410, SEA0510
Rollers Horizontal metal cylinders build with rubber as per application. Ch205 , TS-1677-13HS – NBR 205/236A. 234BNW, 252X, NR, EPDM, CSM. 608- Silicone 219/218: PU OD Spraying Machine Product Code SEA600
2-wheeler stay guard Zn-plated component for tail light indicator. Ch250- EPDM 481#44 – TPE OD Spraying Machine Product Code SEA0200, SEA0410, SEA0510
Solid Tyres- Metal Different Dia Metal Bands. Size varies from 6 inch to 21 inch diameter CH205/220 – NR/SBR 219/218 OR CH213 for PU OD Spraying Machine Product Code SEA0200, SEA0410, SEA0510
Rubberised Wheels (Plastic core) Plastic center cores of diameter 4 inches to 8 inches. CH205/220 or 250- NR/SBR OD Spraying Machine Product Code SEA0200, SEA0410, SEA0510
Crawlers Crawlers have metal inserts of shape ==U== CH205/220 – NR/SBR OD Spraying Machine
Product Code SEA0200, SEA0410, SEA0510
Diamond Bead Small beads of dia 5mm. CH213-PU OD Spraying Machine Product Code SEA0200, SEA0410, SEA0510

Contact us

Summit Engineers And C2-wheeler stay guardonsultants Pvt. Ltd.

F- 93, MIDC, Ambad , Nashik - 422010,

Maharashtra, India

+91-8087074417

+91-8237007190

+91-253-6640562 / 72 / 74

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