Painting Line Research Articles

Exoskeletons for workers: A case series study in an enclosures production line

This case-series study aims to investigate the effects of a passive shoulder support exoskeleton on experienced workers during their regular work shifts in an enclosures production site. Experimental activities included three sessions, two of which were conducted in-field (namely, at two workstations of the painting line, where panels were mounted and dismounted from the line; each session involved three participants), and one session was carried out in a realistic simulated environment (namely, the workstations were recreated in a laboratory; this session involved four participants). The effect of the exoskeleton was evaluated through electromyographic activity and perceived effort. After in-field sessions, device usability and user acceptance were also assessed. Data were reported individually for each participant. Results showed that the use of the exoskeleton reduced the total shoulder muscular activity compared to normal working conditions, in all subjects and experimental sessions. Similarly, the use of the exoskeleton resulted in reductions of the perceived effort in the shoulder, arm, and lower back. Overall, participants indicated high usability and acceptance of the device. This case series invites larger validation studies, also in diverse operational contexts.

Application of Big Data technologies in downstream steel process

In steel manufacturing, the rolling step defines the major properties of final products of the steel industry which are delivered to a wide range of different industrial sectors. Modern rolling mills, to reach high degree in process supervision and efficiency, installed sensor equipment that delivers masses of data and information about the process, the product and its quality at high sample rate and at high spatial resolution. But there is a misalignment between the applied high-tech equipment and the online exploitation of such measurements to describe their impact into the product properties. To make use of the high amount of online available data, on 2018 started the RFCS project NewTech4Steel aimed to enhance process stability and product quality in steel production by exploitation of break-through technologies for real-time monitoring, control and forecasting inspired by Big Data concepts. Within this project, on the basis of the strict correlation between the cold rolled strip flatness and downstream process productivity (HDG & painting line), it has been investigated at Marcegaglia Ravenna plant the case-study of managing the massive amount of production data and making them operational by leveraging machine learning algorithm in order to optimize the global productivity. The project allows fast and online data processing and in turn fulfills the plant line needs for: prediction of defect related to manifested coil flatness imperfections and real-time prediction of process parameters during the zinc coating to avoid break/sideslip on critical conditions. The solution created in New Tech4Steel is inspired by Lambda Architecture as the unified platform for data and analytics which is composed of three layers: batch processing layer for offline data, serving layer for preparing indexes and views and speed layer for real–time processing. The work compiled the necessary measures to integrate the new technologies into the existing IT systems especially under the aspects of brown-field implementation, the connection of newly developed systems to existing ones, and the requirements for HMIs for user interaction and visualization.

Development of End Beam Obstacle Avoidance Program based on ABB Automatic Painting Programming

In order to improve the company’s production efficiency, in response to the call of the country to accelerate the industrial automation, the company’s developers have independently developed a painting line parametric automatic programming system based on ABB robot using C++ language, the automatic spraying of the main beams of the crane is realized. The automatic programming system can only spray the main beam of the end beam without end. The end beams obstacle avoidance program is optimized based on the automatic programming system, which aims to control the robot to avoid the end beam of the main beam, so that the system can spray the main beam of the crane with the end beam normally.

Study of industry 4.0 pillars and their uses in increasing productivity and reducing logistics defects

In the view of growing interconnectivity and interdependence in the modern globalized economies, it has become essential to understand and apply the concepts of Industry 4.0. It is essentially the 4th industrial revolution Industry 4.0 applied. Modern advances in the fields of IoT, IIoT, AI, Cloud computing, Data analytics, Machine Learning, Systems Biology etc. These in turn have been supported with advances in sensors, actuators, and computerization and validated with various quality tools. A thorough understanding of all these are necessary in implementing the evolving concepts and to facilitate the same with use of various technological advancements. In this paper an effort has been made to understand these concepts. Study and application of RFID based kit call off systems is done at CNH Industrial after Paint line for increasing the productivity of the smart manufacturing assembly process.

The Role of Contour Line in Painting — an Analysis of Morandi's Still Life Painting

In painting, line is one of the basic compositional elements and an important "tool" for artists to express their ideas. The combination of line and color, composition, and shape allows the viewer to feel the author's thoughts, emotions, or distinctive thinking through the picture. Foreign cave paintings, European pre-Renaissance oil paintings and modern paintings, and domestic Dunhuang murals, silk paintings of the Warring States period and cave paintings all show that the contour line has never disappeared despite its different roles in the changing times. Therefore, the artist's generalized expression of contour lines can become a characteristic of the picture that makes the artist stand out.

Implementation of a Pull System – A Case Study of a Polymeric Production System for the Automotive Industry

Abstract This work, developed as a case study, propose, describe, and evaluates an implementation of a pull system in a SME company producing polymeric components for the automotive industry. The production system of the company was based on the push paradigm, which creates high stock levels and high lead times. The main purpose was to develop a pull production system controlled by Kanbans in the painting line. To achieve this goal, this case study demonstrates the application of relevant lean tools, such as, VSM, SMED, Kanban System, Supermarkets and Leveling. Through the SMED’s application, it was possible to reduce the setup times in 38% and make annual earnings of approximately 83000€. The application of a Kanban System, Leveling and Supermarket enabled the WIP’s reduction between injection and painting in 56% and, also, between painting and expedition in 45%. Also, the lead time decreased and the value-added time increased. Thus, this is an exemplary case study for the implementation of a pull system and can be used both by practitioners and researchers interested in this theme.

Разработка методов повышения эффективности управления прикладной исследовательской деятельностью научно-производственного предприятия

The features of scientific activity of scientific and industrial enterprises are considered. The analysis of the functioning of a research and production enterprise in carrying out complex scientific research has been carried out. The contour of scientific research management is presented in the form of the main stages of the technological process of their implementation. The possibility of using the program-target approach as an effective strategy for managing research in solving complex and complex problems of a research and production enterprise is shown. An example of a matrix organizational structure of management is given as the most effective for the approach under consideration, with a description of the main stages. The use of automated information systems to improve the efficiency of research management is proposed. The diagram of the inclusion of an automated information system in the general structure of management of scientific research of the enterprise is shown. The described methods have been introduced in the NPO "Lakokraspokrytie" and are successfully used in the implementation of innovative projects for the development, design and commissioning of energy-saving painting lines, within the framework of one of which a painting line for freight cars was designed and put into operation JSC "SPC "Uralvagonzavod" in Nizhny Tagil city, which allows painting up to 16 thousand different modifications of freight cars per year

Minimizing deviations of car sequencing in a JIT production painting line

PurposeThe first in first out (FIFO) rule is an indispensable rule in the automotive industry. However, during production, the order of coming to welding operation and exiting through the painting operation is broken. Consequently, the rule of FIFO also gets broken. The purpose of this paper is to eliminate the deviations of the automotive painting process in a just in time (JIT) environment.Design/methodology/approachThe paper has been solved using observations and expert’s opinions and recorded data in the real problem area. Bypass technique and express line have been used as a real problem for the minimization of these deviations. The current process and the bypass process have been compared with simulation optimization.FindingsThis paper provides analytical insights about how to prevent delays during the JIT production painting process. Delays have been prevented by using the bypass technique and express line together. The number of delays reduced with an improvement of 129. The ratio of effect (for four months) has been founded to be 0.12. The output rate has been increased from 80% to 89%.Research limitations/implicationsThis paper focused on the number of vehicles in the cooling area of the painting process in the study; there may occur bottleneck processes or products. It does not contain station-based bottleneck processes.Practical implicationsFrom the real-case problem, one will see that the bypass technique and the express line can be applied and generalized to many similar problems and help companies conduct their assembly lines more efficiently.Originality/valueThis paper is the only example that has been used to bypass technique and express line together on the paint/cooling process in a JIT production system.

Smart and efficient system for the detection of wrong cars parking

This paper presents a smart and efficient car-parking detection system. The proposed system is comprised of two cameras connected to a mobile system that is devised with Arduino, four DC motors, and PIR sensor placed strategically to monitor parking space, especially within its painted rectangular lines of each parking lot. The mobile monitoring system is automatically responsive to any move they detected as vehicles within the parking space along the rows of parking lots. Once detected, the captured images are processed using the MATLAB software. Any improperly parked cars detected, the cameras will identify their plate numbers, and snap and record it in a database. The designed prototype of the proposed system was tested in five presumed cases. In each case, ten images were processed, thus 50 images were eventually obtained. Out of the 50 images, 48 images corresponded to correct detection whereas the other two images corresponded to wrong detection. Accordingly, the efficiency rate of the proposed smart car-parking monitoring system is 96%. This system offers suitable solution in assisting drivers to park properly within each parking lot and owners of parking area to keep it organized via remote monitoring system.

The Enigma of the Hyksos, Volume 1: ASOR Conference Boston 2017—ICAANE Conference Munich 2018—Collected Papers

The Enigma of the Hyksos, Volume 1: ASOR Conference Boston 2017—ICAANE Conference Munich 2018—Collected Papers

CED productivity improvement through conveyor jig density optimization

This project work aims the study of productivity improvement methods in AUTOMOBILE INDUSTRY’s Cathodic Electro Deposition painting line by optimizing jig density. In AUTOMOBILE INDUSTRY’s PTCED line, SM parts lifted using dedicated jigs on continuously moving OH conveyor. Present production capacity of CED line is 110 units/shift at 90% efficiency with consumption of 5.8 jigs/tractor. Objective of the project work is to improve the existing productivity by increasing jig density. Usual methods of productivity improvements mainly focusses on increasing the conveyor speed and automation introductions. Alternative method of increasing the loading capacity per jig and exploring the feasibilities of changing the existing loading patterns being adopted in this project work. The modified loading jigs and patterns observed for 2 months resulted an increase in productivity from 105 units to 141 units/shift operations.

Mobile robot painted dashed lines as road markings

Painting road markings is one of the infrastructure works that can provide road markings on roads. The fuzzy method is used as a value to determine the midpoint of the width of the road and the robot is on the middle side of the road, then produces a velocity value on the robot that is maintained by the PID method. The result is that the robot can detect the sidewalk with an ultrasonic sensor on the difference of the right sensor error 0.2 cm and the left sensor 0.5 cm through comparison of detection by the sensor and the ruler. The robot can maintain speed and the output value produced by fuzzy speed is 30, then used as input by the PID method with constant values Kp = 2.5, Ki = 0, and Kd = 0.8. The process of painting using a roll model paint tool produces a length of painting 29-31 cm and a long line breaking range of 25-27 cm with a white line width of 8.5-9 cm.

A Navigation and Augmented Reality System for Visually Impaired People.

In recent years, we have assisted with an impressive advance in augmented reality systems and computer vision algorithms, based on image processing and artificial intelligence. Thanks to these technologies, mainstream smartphones are able to estimate their own motion in 3D space with high accuracy. In this paper, we exploit such technologies to support the autonomous mobility of people with visual disabilities, identifying pre-defined virtual paths and providing context information, reducing the distance between the digital and real worlds. In particular, we present ARIANNA+, an extension of ARIANNA, a system explicitly designed for visually impaired people for indoor and outdoor localization and navigation. While ARIANNA is based on the assumption that landmarks, such as QR codes, and physical paths (composed of colored tapes, painted lines, or tactile pavings) are deployed in the environment and recognized by the camera of a common smartphone, ARIANNA+ eliminates the need for any physical support thanks to the ARKit library, which we exploit to build a completely virtual path. Moreover, ARIANNA+ adds the possibility for the users to have enhanced interactions with the surrounding environment, through convolutional neural networks (CNNs) trained to recognize objects or buildings and enabling the possibility of accessing contents associated with them. By using a common smartphone as a mediation instrument with the environment, ARIANNA+ leverages augmented reality and machine learning for enhancing physical accessibility. The proposed system allows visually impaired people to easily navigate in indoor and outdoor scenarios simply by loading a previously recorded virtual path and providing automatic guidance along the route, through haptic, speech, and sound feedback.

Design models of automatic humidity control system in flash off painting line room to reduce defect products at PT. Kubota Indonesia

The main challenge often faced by PT. Kubota Indonesia in connection with the quality of production is still a lot of level of disability in the production process, especially in the painting process. The process of painting is highly required according to the standard of both the process and condition of the room so that the results of the painting do not occur defects. Based on production data in the period from October 2018 to January 2019 there were 80% defective products with blistering defects of the total defective products, this needs a deeper analysis of the causes of product defects. Blistering defects in the form of bubbles on the surface of the painting result occur because the standard of air humidity is not achieved when the flash off process is caused because there is no tool to condition the air in the flash off the chamber. The purpose of this research is to design an automatic humidity control system model that can be used as an alternative to PT. Kubota Indonesia as a method for reducing humidity so that it can reduce the potential causes of blistering defects. Research methods include problem identification, literature study, design, and manufacture of models and testing. Problem identification is done by using the 5M + 1E method to find the root of the problem. The process of designing and making models is divided into 3 important activities namely designing 3D design concepts using solid works software, designing a control system software with Arduino Uno and designing hardware models. Tool testing is done by testing the automatic humidity control system model on the prepared test chamber model. The results obtained from this study are models of automatic humidity control systems that can condition the humidity in the test room and maintain the humidity according to the setpoint.

Tensoactive replacement analysis in the pretreatment process of steel castings 1006 of the electrostatic paint line of an engine industry

Com intuito de reduzir custos e aumentar a produtividade há uma busca incessante por melhorias nos processos industriais. A fim de minimizar os custos de operação da linha de pintura eletrostática de uma empresa de motores localizada no norte do estado do Espírito Santo, propõe-se a substituição do tensoativo utilizado na preparação do banho desengraxante para pré-tratamento das carcaças de aço carbono. O tratamento de superfície é o estágio essencial no processo de fabricação de peças que receberão um acabamento de pintura, pois o mesmo remove as sujidades promovendo então melhor aderência da tinta e consequentemente reduzindo a possibilidade de oxidação da superfície dos materiais tratados. Foram realizadas análises de custos com a finalidade de expor os possíveis ganhos com a substituição do tensoativo. Posteriormente, realizou-se teste laboratorial (teste de aderência) com o propósito de verificar a qualidade das peças após o tratamento no que tange a aderência da tinta a superfície do material. A partir da análise de custos verificou-se que a estimativa de economia é de aproximadamente 15% em relação ao processo atual. Sendo assim, a substituição do tensoativo torna-se vantajoso, pois minimiza o consumo de energia elétrica, gás natural e reduz o tempo de espera para começar a operar devido ao aquecimento do banho, além de garantir a qualidade das peças no que se referem ao atendimento à norma vigente.

Imaginary line in landscape painting of Uzbekistan

The 40–50 years of the twentieth century are one of the most interesting periods for landscape painting. It was during this period that a strong school of fine arts developed in Uzbekistan, which represented a variety of art trends. So, for example, from representatives of the avantgarde (A. Volkov, N. Karakhan, U. Tansykbayev) to realism (O.Tatevosyan, P. Benkov, Z. Kovalevskaya, R. Timurov).

Development of smart painting machine using image processing

Painting is a process in automotive industry that takes about 10% of the total time consumed per vehicle. Currently, the painting lines in several automotive industries like Toyota motors or General motors is largely being automated after implementation of robotic arms. However, according to the study done, this automation is restricted to paint main body or chassis only, the coating and painting on small vehicle parts is still done manually. This paper represents the study conducted on local Toyota motor plant located in Karachi where the need of automating the small parts painting line evolved to increase production. The designed system is based on 3axis gantry mechanism which locates the position of parts to be painted on moving conveyor through computer vision, reach the coordinates, paints autonomously and forwards it to buffer station for drying. The computer vision is introduced to minimize the human interference and make the line semi-autonomous. The system was tested for correct image processing and at the end algorithms was correctly identifying and locating 90% of the parts. Moreover, the system was tested for one week in a laboratory environment and it was observed that production rate was increased to 2% as compare to their previously available data.

New Investigations of Adhesives for Tear Repair of Canvas Paintings

ABSTRACT The thread-by-thread tear mending technique for canvas paintings represents an important field of research for the preservation of canvas paintings. This joining technology has been published and has become well established as a minimal invasive alternative for the treatment of local damage in the canvas, in contrast to the application of patches or the lining of paintings. Since then the technique has been further investigated, especially with regard to adhesive evaluation. For the first time, this paper presents the examination of five different test set-ups for the adhesive evaluation in an overall context: 1. uniaxial tensile tests on free adhesive films, 2. on mended yarns, 3. on fabric strips, 4. biaxial tensile tests, and 5. multiaxial burst pressure tests. The bonding was carried out on flax threads and canvas samples. For this purpose, single thread bonds were prepared within the specimens with a selection of different synthetic polymer dispersions and sturgeon glue modifications. Different bonding techniques were investigated, such as overlapping or butt joint mending, with and without bridging threads. The aim of the investigation was to understand the individual influencing factors in the various test series. Furthermore, the focus was on the development of a suitable test system for the evaluation of adhesives for the thread-by-thread tear mending treatment in textile painting supports. It can be stated that only the testing of several bonded threads in a fabric composite should be pursued as a long-term sensible test arrangement. This is in contrast to the previously very common set-up of testing mended single threads. Promising adhesives and adhesive modifications have been found for butt joints and overlap joints. The additional strengthening effect of bridging threads on butt joints has been proven and quantified.

Diffusible hydrogen behavior and delayed fracture of cold rolled martensitic steel in consideration of automotive manufacturing process and vehicle service environment

This study aims to elucidate the behavior of diffusible hydrogen and delayed fracture in martensitic steel with 1500 MPa strength during automotive painting process and under vehicle service conditions. A sequential process of automotive pretreatment line and vehicle service environment is simulated to evaluate the hydrogen pick up in each process. In case of the automotive painting line, the absorption of hydrogen is within the common range in the process of phosphating treatment and electrodeposition. The baking process plays an effective role for desorbing the diffusible hydrogen absorbed during the automotive pre-treatment such as zinc-phosphating, and electrodeposition process. In case of the corrosion environment under the automotive driving conditions, hydrogen induced delayed fracture is accelerated as the exposure time increases. Further, it is clarified that severe plastic deformation are the significant factors for hydrogen induced delayed fracture under with low pH value and present of chloride ion in a chemical solution parameter. In summary, hydrogen is transported constantly during electrodeposition sequential line process of automobile manufacturing below the hydrogen content of 0.5 ppm, which is not critical value for leading to hydrogen delayed fracture based on results of slow strain rate tensile tests. However, exposure to extreme conditions under service environment of vehicle, such as acidic solution and chloride chemistry solution that result in high level of hydrogen absorption, severe plastic deformation in the sheared edge, and constantly applied internal or external stresses, can cause the hydrogen induced delayed fracture in the fully martensitic steels.

Analysis of Air Flow Around the Painting Line for Dust Reduction: An Experimental and Numerical Study

The repair of paint work defects in the painting production process is done by running the parts through the painting process again. It is done together with the requisite quality control routines and involves a very large proportion of the operating costs. The dust defect which ranges between 40% to 50% is found to be the top and highest rejection at the painting line. Hence, this paper is focused to identify the effectiveness of applying Computational Fluid Dynamic (CFD) to identify the air flow and the turbulence pattern to investigate the movement and the dust particle concentration in painting line. Renormalization Group (RNG) k-? turbulence model is used in CFD to predict the particles’ movement and concentration. Five new models including the current painting line design are proposed and tested. The painting line model labelled as Model F is found to be the best model to minimize and reduce the dust particle concentration inside the painting line environment with 96.01% of percentage particle is flushed out at air velocity of 0.1 m/s. Along with results from numerical simulation using CFD, the experimental data is also collected using an air flow meter in a small-scale model painting line. Both data from experiment and CFD simulation are analysed and compared in order to measure the effectiveness of the result. The average relative error for Model F is recorded at 4.76%. The results from this study is recommended to be considered as one of the benchmarks for future design of automotive painting line.