Automating Paint Shop Quality Control
Improving E-Coat Quality Through Pneumatic Automation
Exotic partnered with Parker and an automotive OEM to develop and install an automated pneumatic system that removes excess E-Coat from vehicle lift gates before curing, helping reduce defects and eliminate manual rework without adding production cycle time.
Challenge
An automotive assembly plant was experiencing an ongoing quality issue in its paint shop following the E-Coat spray process. As vehicles moved toward the curing oven, excess E-Coat droplets would drain and collect along the bottom of the rear lift gate. When baked in the oven, the droplets hardened into bubbles that created both cosmetic and functional defects.
The issue required two full-time operators to sand and buff affected areas before sending vehicles back through the E-Coat process. Some defects also escaped inspection and required additional rework after vehicles reached dealerships. Previous attempts to address the issue with in-house blowers and air deflectors had been unsuccessful. The customer needed an automated solution that could accommodate two different chassis lengths, remove the E-Coat droplets before the oven, and operate without adding cycle time.
Solution
Exotic brought in Parker’s Pneumatic team to help develop a solution. Exotic and Parker worked directly with the customer to evaluate the application and design an automated pneumatic system using Parker components and supporting accessories supplied by Exotic.
The turnkey system incorporated rodless cylinders, pneumatic valves, air nozzles, tubing, flexible air hose, and other components into a custom-designed assembly. Exotic’s Engineering Team provided the system drawings, bill of materials, and documentation, while Parker and Exotic supported installation, troubleshooting, and testing during scheduled production shutdowns.
The system is designed to integrate with the conveyor PLC logic, automatically activating the cylinders and air nozzles when a vehicle reaches the designated position before entering the oven. The fully automated process operates without human intervention and does not add cycle time to the paint process.
Benefits
The automated system is designed to significantly reduce E-Coat-related quality defects and eliminate the need for two full-time operators to perform manual rework. Those employees can be reassigned to other areas of production where additional resources are needed. Automating the process also helps reduce the risk of defects reaching customers and the associated costs of post-sale rework.
By accommodating both chassis lengths and integrating directly into the existing conveyor controls, the solution provides a repeatable process that improves quality without slowing production.
Featured Products
- Parker OSPP Rodless Cylinders: Compact pneumatic actuators designed for reliable linear motion in a variety of automation applications.
- Parker Viking Solenoid Valves: Durable pneumatic valves designed to control and direct compressed air in automated systems.
- Parker GDL Rail & Cassette: Linear guidance components designed to provide smooth, reliable movement and support for pneumatic applications.
- Parker Air Tubing & Connectors: Pneumatic components used to connect, route, and distribute compressed air throughout a system.
- 80/20 Extrusion System Frame: Modular aluminum framing used to build durable, customizable structures for automation and equipment applications.
