Sabine Mewis Durr Systems AG

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LEADING IN PRODUCTION EFFICIENCY
RAI
INATED A P
USTRY
Sabine Mewis, Ke Account Manager Railway, Durr Sys
Vienna, September 25th, 2018
www.durr.com
QUIPMENT FOR

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CONTENTS
I
uation
stems
State-of-the-
I
Innovative Application
ducts, Processes, Service & Factories
Systems AG: Ecolromat, Vienna, September 25th, 2018
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INTRODUCTION: DURR GROUP- 5 GLOBAL DIVISIONS
Sales 201 7: € 3.7 billion, employees 201 7: approx. 15,000
Paint and
Final Assembly
Systems
• Paint and final
assembly systems
(t
1.2 billion
3,500
Woodworking
Machinery and
Systems
• Paint application, gluing
and seam sealing
technology; products for
industrial painting
(t
0.6 billion
2,100
• Exhaust-air purification
systems, energy
efficiency technology
(t
0.2 billion
600
• Balancing, assembly,
testing and filling
technology
(t
0.5 billion
• Machinery and plants
for woodworking
(t
1.2
billion
2,300
6,400
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SCHENCK
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IE HOMAG
Employees
Mewis , DUrr Systems AG : Ecolromat, Vienna, September 25th, 2018
(t
Sales
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INTRODUCTION
Innovation path
Behr3/6
Hydraulic painting robot
1984
EcoRP6/7
First electrical Durr
painting robot
EcoRP L/E033/133
Modular painting robot
family
1998
AG: Ecolromat, Vienna, September 25th, 2018
2005
EcoRP E043i:
World's first 7-axis painting
robot
2016
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CURRENT MARKET SITUATION
Expected market growth rates in Rail supply per region [CAGR 1) , 0/o]
2,8%
0,9%
Commonwealth of independent States
2,2%
Northern America
2,6%
Growth rail supply
market worldwide
2,3%
Latin America
1)
Compound annual growth rate 2019-2021 vs. 2013-2015
Sabine Mewis , DUrr Systems AG : Ecolromat, Vienna, September 25th, 2018
Source : Roland Berger, unite
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CURRENT MARKET SITUATION
Product Quality
t
Rroductivity
Avai lab iIity
t
Today the most of the painting activities are done manually
The trend will go for more automation and production operation management
Flexibility
t
rime-to-Market
CAPEX/OPEX
Source Picture : Deutsche Bahn AG
Sabine Mewis , DUrr Systems AG : Ecolromat, Vienna, September 25th, 2018
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STATE-OF-THE-ART APPLICATION SYSTEMS
Combined Spraying & drying booth for rail vehicles
>>Vertical ventilation, with supply air filter cover, grid and ground suction
>> Dimensions approx. 30 x 7 x 6 m, zone controlled
>>2 stroke-working platforms,
>>Guardrail in the ceiling for working on the top of the vehicle
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STATE-OF-THE-ART APPLICATION SYSTEMS
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References
Siemens St. Petersburg
Siemens Krefeld
Ural Locomotives
Vossloh Kiel
DB Paderborn
DB Fahrzeuginstandhaltung Neumunster
Dortmunder Stadtwerke
EVAG Erfurter Verkehrsbetriebe
LRS Leipzig Rail Service
Rheinbahn Dusseldorf
Stadtwerke Verkehrsgesellschaft Frankfurt
OSTRA Hannover
AG: Ecolromat, Vienna, September 25th, 2018
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STATE-OF-THE-ART APPLICATION SYSTEMS
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Disadvantages of Manual Application
>> Persons in hazardous areas
>> Less repeatability
>> Lower quality
AG: Ecolromat, Vienna, September 25th, 2018
>> Higher energy consumption
>> Less material efficiency
>> Less space efficiency
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INNOVATIVE APPLICATION SYSTEMS
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Future: Automation
.. Working area analysis
....
s AG: Ecolromat, Vienna, September 25th, 2018
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INNOVATIVE APPLICATION SYSTEMS
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Future: Automation - Installation with elevated robots
Source Video : VW Poland
s AG: Ecolromat, Vienna, September 25th, 2018
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INNOVATIVE APPLICATION SYSTEMS
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Future: Automation - Installation with elevated robots
DUr,r. Systems AG: Ecolromat, Vienna, September 25th, 2018
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INNOVATIVE APPLICATION SYSTEMS
EcoRP E/L - completely integrated application technology in arm 1, hose and cable routing
Pneumatics
terminal
HV cascade
Bulkhead plate;
hose length reduced to three meters
Drive with central hole for cable routing (axis 1 +
axis 3)
Air heater
O/E converter
Up to four
controllers
Short switching and
control times
Hose guide through the robot's central fiber
Low paint and flushing agent
consumption
AG: Ecolromat, Vienna, September 25th, 2018
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INNOVATIVE APPLICATION SYSTEMS
Paint robot and application components: One system
Color changer
Gear Pump
.I
Atomizer
»
»
»
»
»
»
»
High flexibility for all painting processes
High flexibility and performance
Low waste and fast color change
Low waste and high performance
Modular application system for all paint materials
No voltage block for waterborne
Endless dosing with gear pumps
I
Low complexity - easy maintenance - high availability
AG: Ecolromat, Vienna, September 25th, 2018
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INNOVATIVE APPLICATION SYSTEMS
Sample of application installations on the arm of the robot
1K application
1K and 2K application
2K application
AG: Ecolromat, Vienna, September 25th, 2018
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INNOVATIVE APPLICATION SYSTEMS
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Advantages of Automatic Application Systems
Improved surface quality
High transfer efficiency and less material consumption
Space-saving booth concept
Quick color changing time
High variability of spray pattern
Constant film thickness
High versatility and flexibility
Digitization
D r,ri Systems AG: Ecolromat, Vienna, September 25th, 2018
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DIGITIZATION - PRODUCTS, PROCESSES, SERVICE & FACTORIES
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EcoScreen 30-0nSite 4 and Equipment Analytics: Enabling predictive maintenance and process optimization on a local level
--
EcoScreen
Equipment Analytics
Controls
Adapter
Database
Anomaly
Detection
Visual
Analytics
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loT Connector
I
Ill
Software package
running on the HMl-PC
Connector to service
cloud, paint shop
analytics or customer
specific solutions
Automatic anomaly detection based on
smart calculation models
Benefits
>> User-friendly interface
>> High performance for graphics and simulation
>> Interface for all important CAD formats
Graphical interface for visual analytics of stored data
Database for buffering of up to 14 days of streaming data
Streaming of equipment relevant signals in real-time
DUr,r. Systems AG: Ecolromat, Vienna, September 25th, 2018
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DIGITIZATION - PRODUCTS, PROCESSES, SERVICE & FACTORIES
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EcoScreen Maintenance Assistant: Management of maintenance tasks on site
Features
>> Digital maintenance management at the system control
computer
"
>> Wear models and test functions
>> Display, grouping and logging of maintenance tasks
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VISUAL INSPECTION OF APPLICATI ON PARTS ARM 2
Preliminary work:
Maintenance task :
Check liquid seal. If it is hazed, exchange liquid and
replace shatt seal and ball-bearing of dosing pump.
Remove protective overall
Remove cover Arm 2
\
Maintenance task:
Visual inspection on tightness as well as kinks of hoses at
positions marked with a yellow arrow.
Color changervalves :
V1, PL1, RF2, F
Paint pressure
controller
,..-
Valve block with valves :
BY, V3
Benefits
>> Clear display
>> Better planning and logging
>> Simplified maintenance management
(e.g. documentation of tasks)
s AG: Ecolromat, Vienna, September 25th, 2018
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DIGITIZATION - PRODUCTS, PROCESSES, SERVICE & FACTORIES
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Mobile access using the example of the EcoPads
>> QR code scanner
>> Electronic system documentation optimized for touch control
>> Video chat with Durr hotline (Skype)
>> e learning module
DUr.r. Systems AG: Ecolromat, Vienna, September 25th, 2018
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SUMMA RY
Due to the high demand of new railway vehicles, the trend w i ll go for more
automati on and production operation management
Lower invest
Automatic Applicati on and production
operation management
Partly more flexible
>> Increaseof quality and repeatability
Manual Application
>>
>>
>>
>>
>>
>>
Lessrepeatability
Increase of efficiency
Lower quality
Reduction of running costs
Personsin hazardous areas
Higherenergy consumption
Systems AG: Ecolromat, Vienna, September 25th, 2018
>> Reductionof resources
>> Digitzation
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