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Cosmetic sealingCosmeticsealingin paint shopAtlas Copco s SCA product line provideshigh-quality cosmetic sealing solutions
Meeting highestdemands in paint shopChallenges incosmetic sealingA car’s design has complex geometriesand many surface breaks where tightseals are critical, yet for reasons ofaesthetics, they should be invisible tothe eye. Areas using cosmetic sealinginclude e.g. doors, trunks and hoods,rear gutters, roof ditches, and rearlamps. These areas are often difficultto reach with precision, and applyingan endless bead can be a challenge.JET STREAMSealing and sound dampening applications in paint shop require a highlevel of quality, reliability and precision. They need to prevent corrosionin the long term and meet increasingly high demands in a car’s aestheticappearance and passenger comfort.To fulfill these high demands infunction, quality, and aesthetics,cosmetic beads can be applied withdifferent application technologies.Selecting the right applicationtechnology depends on the geometryof the car body and customerrequirements. With Atlas Copco, carmanufacturers have a partner withextensive know-how and a broad rangeof innovative solutions for cosmeticsealing.MINI FLAT STREAMEvery production line is unique,but paint shops are made up offour main processesUnderbody application(UBS/UBC)EXTRUSION / TRIM EDGEPROTECTIONInterior seam sealingHOOK NOZZLE FLAT STREAMHOOK NOZZLE JET STREAMCosmetic sealingSound deadening(LASD)1Automated solutions from Atlas Copco for cosmetic sealingEffective prevention of humidity andcorrosionAdvanced design and increasinglycomplex geometries of car partsLimited accessibility of sealing areasHigh demands in aesthetics andpassenger comfortTemperature-sensitive materialsIncreaseproductivityEnable repeatablehigh qualityAre easyto use
Application technologiesfor cosmetic sealingJet streamJet stream is a common streamingtechnology suitable for high robotspeeds and a quality surface finish. Thetool’s symmetry enables easier robotprogramming.At Atlas Copco we make sure that customers get asolution that fits their requirements perfectly whileensuring maximum productivity and quality.Applications can be customized to avariety of operational areas using nozzlesof different shapes and openings.No orientation of nozzle, easier robotteachingHigh robot speedsHighly precise applicationPressuretoo highPressuretoo ³/s]PressureRobot speed[mm/s]Distanceto part[mm]MaterialApplicationtemp. [ C]Jet stream4 – 121,5 – 2,51,5 – 10high100 – 3503–8PVC25 – 32Application parameters for reference use onlyMini flat streamExtrusionMini flat stream is a low pressure applicationwith high precision of material flow.Extrusion at trim edges (trim edgeprotection) aims to avoid corrosion on asection that is not zinc coated.The application distance to the car part isapproximately 3 – 5 mm, and the width andslot length of the nozzle determine the beadgeometry.The process is used in high-stress areassuch as wheel arches or on roof ditches.A wide variety of nozzles are available, andthey can be adapted to customers’ uniquespecifications.Specific nozzles compensate fordeviations in robot movements and carpart tolerances. They also allow for aconstant robot speed with a specific beadshape.Highly precise application, also onvarying trim edgesCustomizable nozzle openings forspecified bead shapeSmooth surface for excellentaesthetic appearanceElastic nozzle that compensates fordeviationsConstant robot cm³/s]PressureRobot speed[mm/s]Distanceto part[mm]MaterialApplicationtemp. [ C]Mini flatstream8 – 141,5 – 2,51,5 – 10low100 – 3503–5PVC25 – 32Application parameters for reference use mm]Depending on customers’specificationFlow[cm³/s]PressureRobot speed[mm/s]NozzleorificeMaterialApplicationtemp. [ C]1 – 10low100 – 150Shape ofapplicationPVC25 – 32Application parameters for reference use only
Automatedapplication systemsThe SCA product line offers complete automated application systemsfor cosmetic sealing. The selection of components and installing thesystem must focus on the high precision of the application.Material re-circulationField applicationsWhether using flat stream, jet stream or extrusion, Atlas Copcomakes sure that the application is fully tailored to individualcustomer processes.Peltier conditioningsystem (PCS)MeterApplicatorCosmetic beads are commonly used in severalsealing applications, including hem flange, roof ditch,rear gutter, rear lamp or other customer-specificapplications.Atlas Copco offers cosmetic sealing expertise inthe entire automated application process includingprocess selection, testing and process optimization.Nozzle specificationsHem flange applications for closure parts can requirea special nozzle. Customized hook nozzles andL-nozzles are available for both flat stream and jetstream applications.Customized nozzle geometry toreach application areaHighly precise nozzles to insurenozzle exchange without re-workRobotcontroller(not SCA)SystemcontrollerConsideration for customers’unique processes and cargeometriesExtensive process know-how andcustomer supportIn-house testing at Atlas System installationThe high quality requirements for the cosmetic sealingprocess determine the choice of the system and thepositioning of components. With the Atlas Copco expertisein system installation, we ensure a high temperaturestability and minimal pressure drops, long lifetimes, andeasy maintenance.Industry-proven components andvarious options ensure a superiorapplication in every condition
System componentsSystem optionsThe components or paint shop application systems are developedfor high-performance car manufacturing.Depending on the individual customer requirements, SCA system optionsincrease the productivity and quality of the cosmetic sealing process.Application controlMaterial supplyThe SCA system controller directs all main functions and componentsof the cosmetic sealing application. For easy operation, an integratedHMI and a central, external HMI are available. The connection from theSCA application controller to the robot controller can be realized with allcommon industrial field bus systems.The SCA material supply solution for sealing anddampening applications is available as 1000l/300galbarrel version. The utilized displacement pumpUP1200 is characterized by a very high volume flowand high pressure. The robust design of the UP1200enables a long lifetime and easy maintenance. In caseof long distances from the material supply to theapplication cell, the UP1200 is used as booster pump.Metering systemsThe selection of the metering unit is dependent on thecustomers’ requirements for flow, volume, and pressure.SCA metering systems are optimized for highly preciseapplications.Nozzle cleaning stationThe standalone nozzle cleaning station Borster NCS withauto switch-on functionality is Atlas Copco’s solution forpaint shops to eliminate line stops, rework and cleaningcaused by residual PVC material at the nozzle and dripson the car body.Conditioning systemsPVC is a commonly used material and its viscosity is highly sensitive totemperature fluctuations. In order to get constant application conditions, aPeltier conditioning system (PCS) can heat or cool the material regardlessof ambient temperature. The PCS is fully integrated into the applicationsystem and can be operated from the application HMI.ApplicatorsFor high-quality applications, customers can choose from avariety of rotatable, multi-nozzle applicators. A re-circulationsystem to the nozzle is usually integrated into the applicatorsto stabilize application conditions due to the dynamic viscosityof the materials. In general, different circulation systems areavailable dependent on system configuration.Tool change stationPaint shop production lines working on a variety of car models need flexiblesolutions. The SCA tool changing station allows the use of different nozzleshapes for various car designs. The whole nozzle carrier of an applicator can beexchanged automatically. Equipping the nozzle can be optimally aligned to thecar’s geometry. For different designs, diverse variants are available that can beflexibly adapted to customer requirements.Software featuresNozzlesTo achieve customer requirements inbead size, a broad range of standard andcustomized nozzles are available.The SCA online tracer is a useful application control tool to satisfyhigh quality demands in cosmetic sealing. It can be used toprecisely analyze processes during an application cycle. It is used fortroubleshooting, diagnostics and quality control. Furthermore, valuablesoftware features are automatic pre-pressure control and highly precisevolume measurement.
Sucess storyLearnmContaHow we innovateour customersct us!ore absolutio out what Atlas Cns caopcoin you n accomplishr painsca.int shopfo@a:tlascopco.comInitial situation at OEMProduction of seven models, each with fivevariants, in total 1,200 vehicles a dayOperation of two lines in three shiftsCosmetic sealing on closure parts:100 % manual applications as well as a highamount of reworkAtlas Copco is synonymous with high quality and efficiency.With operations all over the globe, we have a vital corporateculture that is built on innovation, application knowledge sharingand a strong customer focus.Individual processes require individual solutions. In our tenInnovation Centers all around the world, our experienced teamswork together with customers and suppliers to develop the bestsolution for their individual application needs. We strive to bean extension of your innovation department and to offer you thehighest value possible.We keep your systems runningAtlas Copco solutionWith over 150 service technicians around the world, we are closeby and ready to ensure the customer gets the very most from hisAtlas Copco systems, now and for many years to come.Development of a fully automatedapplication system for cosmetic sealing onclosure partsConcept development, processdevelopment and validation, nozzlespecificationTesting in validation cell and product line,roll-out for all hang-on parts in the entireproduction lineSituation todayMore than 20 Atlas Copco automatedapplication systems implemented forcosmetic sealing and hem flangeSignificantly increased productivity andquality in the entire productionManual work limited to finishing andinspectionReduction of costs and risksassociated with productionramp-upProcess optimization withoutdisrupting series productionWe connect customers, processexperts and material suppliersAccess to Atlas Copco’s processand information databaseClose proximity to customersaround the world through tenglobal Innovation CentersProcess development basedon customers’ actual, real-lifeprocesses
Atlas Copco, 9833 2128 01, 2018:1Committed to sustainable productivityWe stand by our responsibilities towards our customers,towards the environment and the people around us.We make performance stand the test of time.This is what we call — Sustainable Productivity.www.atlascopco.com
Cosmetic sealing Underbody application (UBS/UBC) Challenges in cosmetic sealing A car’s design has complex geometries and many surface breaks where tight seals are critical, yet for reasons of aesthetics, they should be invisible to the eye. Areas using cosmetic sealing include e.g. door
