Painting consumption is a high level of automation consumption, the production of a waste product, from the beginning of the upper part, through a series of processes such as deoiling, phosphating, cleaning, drying, powder spraying, curing and so on, until the lower part, is a systematic and connected process. The workpiece runs at an average speed on the consumption line, and there is no pause point in the middle, which is the most important part of the painting consumption line. Fundamental consumption characteristics.

It is precisely because of the above fundamental characteristics of painting consumption that the consumption of painting consumption can be more dependent on the consumption line itself. When the design plan of a painting consumption line is affirmed, especially when the chain speed of the consumption line body is affirmed, its maximum consumption ability has been affirmed fundamentally. As a result, after the speed of painting consumption is confirmed, the effective disposal time of each disposal process and the scope of related process requests on the consumption line must also be determined, and the scope of adjustment will not be too large.

In the practice of consumption, through our discussions and repeated attempts, we found some effective ways to improve the efficiency of painting consumption. After practical application, the effect is very obvious.

1. Improve the application rate of hangers by starting with painting hangers

The hangers used for painting consumption in our company can be said to have experienced the following three improvements:

(1) Set of Hangers Single Hangers

Initially, when importing the consumption line from Japan, they all copied the Japanese set. Coating hangers are also designed to fit the whole set of consumption hangers. Coating equipment, a set of air conditioning shell, can be all hung with a hanger. Painting equipment is very effective in the ideal consumption organization state, but in practice consumption, most of the work pieces can not be complete set, so hanging equipment is often idle a lot of hanging points. For this reason, we have changed the complete set of hangers into single hangers, which has improved the effective application rate of hangers.

(2) Special Hanger Dual Hanger

After changing the complete set of hangers into single-piece hangers, although the effective application efficiency of hangers has been improved, with the increase of consumption types, the frequent change of hangers in the process of consumption has quickly exposed. Considering the convenience of the application process, after a lot of design attempts, we have improved most hangers into dual-purpose hangers, which can be used in several workpieces. The problem of frequent change of hangers in sample consumption process has been well dealt with.

(3) The number of accessories: 2 4 6 8 or 16

In the process of stopping the above two improvements of the hanger, we have designed the hanger scientifically, and increased the hanging point of the single hanger under the condition of ensuring that it does not exceed the hanging point load, thus greatly improving the effective application rate of the hanger. Some even multiplied the application rate, so that the practical consumption of the painting line can greatly break the design consumption ability.

Through the improvement of the hangers of the above three lines, the consumption efficiency and consumption ability of the painting consumption line have been greatly improved, so that the painting consumption is no longer the bottleneck factor restricting the expansion of our company's consumption.

2. Use of New Pre-painting Disposal Agents

In practical consumption, we also actively adopt new pre-coating disposal agents to achieve the purpose of improving consumption efficiency. Previously, we used traditional pre-painting disposal agents, degreasing agents and phosphating agents are required to operate at temperatures above 50 degrees. Before each shift of consumption, we need to stop the heating process for a long time, especially in cold winter weather, sometimes for a long time can not reach the set temperature, affecting the normal operation of consumption.

Later, we used a new type of low-temperature phosphating agent and degreasing agent, which greatly shortened the heating process. In addition, the new phosphating agent has the characteristics of low slag, which reduces the slagging time of the liquidation tank, increases the effective working time while facilitating the consumption management, thus improving the consumption efficiency. Not only that, because of the low temperature, the new pre-coating disposal agent greatly reduces energy consumption and saves the cost of consumption. It can be said that it is a good thing to kill many birds with one stone.

3. Improve equipment and increase spare tank

In the peak consumption season, the painting consumption line also turns 24 hours a day. With the increase of production, the tank liquid in the degreasing tank and pre-degreasing tank often needs to stop changing in a few days, and the replacement tank liquid also needs to use a part of normal consumption time. In order to ensure the quality of production and not delay the normal consumption time, we stopped the modification of the thread body, and parallel a degreasing tank and a pre-degreasing tank beside the original degreasing tank and pre-degreasing tank. In this way, no matter when the tank fluid is changed, we will not affect the normal consumption time, just need to match another tank fluid in advance. This is also an effective way to improve consumption efficiency.