Sames Kremlin partnered with Emerson to optimize compressed air flow in its powder coating machines
Powder coating is a dry finishing technique that offers a more durable and environmentally friendly alternative to traditional liquid paint. It’s primarily used in automotive and appliance manufacturing. To achieve an even finish while minimizing material waste, it’s important powder coating machines feature a precise compressed air flow.
Sames Kremlin has developed powder coating solutions for high productivity since 1960. The global company recently partnered with Emerson to optimize the flow of compressed air with minimum reaction time for its powder coating machines. Through expert engineering support, Emerson helped Sames develop a valve block solution using ASCO™ï¸ 202 Preciflow proportional valves and AVENTICS™ï¸ manual regulators that provide uniform coating thickness and greater transfer efficiency while minimizing overspray and material waste.
An AVENTICS™ï¸ manual regulator.
Engineering a Valve Block with Optimal Control
In automotive applications, powder coating is applied to wheels, frames, trim pieces, engine components and other car parts for a durable, chip-resistant finish. In appliance manufacturing, powder coating is used on washing machines, dryers, refrigerators, dishwashers and other appliances due to its excellent resistance to scratches, corrosion and heat. Achieving a level powder coating application requires high-performance equipment with optimal control.
Sames Kremlin spray guns, pumps and atomizers are designed to deliver an optimal powder coating application. These tools include sophisticated control systems with fast proportional valves and compact blocks, electrical systems and air flow settings to manage the air pressure carrying the powder, ensuring proper delivery and minimizing overspray.
When building powder coating solutions, it can be a challenge to optimize compressed airflow with minimum reaction time. Without this level of control, the coating thickness may not be uniform and transfer efficiency – the amount of powder adhering to the object being sprayed – may be low. The resulting overspray can waste powder material.
The control of a powder coating machine — and the quality and efficiency of the application — depends on the performance of the valve block. This is why the design team at Sames Kremlin came to Emerson with specific goals when developing a valve block for its powder coating machine. It wanted a compact valve block with optimum control that could achieve high transfer efficiency to minimize overspray of powder, as well as uniform coating thickness to minimize coating defects.
It’s important to understand how poor valve control affects coating thickness and transfer efficiency. In a valve block, the proportional valve acts like a conductor for the powder. It receives an electronic signal from the control panel and adjusts the opening accordingly. When an operator activates a powder coating machine, a compressed air stream carries the electrostatically charged powder particles toward the object being coated. This allows for precise control over the amount of powder flowing into the spray gun.
If the air flow is poor, it results in uneven flow and slow or sluggish air. Uneven flow can lead to areas with too much or too little powder, resulting in an inconsistent coating thickness. A thin and uneven coating offers less protection, while a thick coat can be wasteful and prone to defects like dripping or sagging. Slow or sluggish air may not carry the powder particles effectively, causing them to fall short or drift off course. This reduces transfer efficiency and increases waste.
Precise airflow control can help minimize overspray, reducing material waste and lowering overall coating costs. A well-directed air stream focuses powder on the object, minimizing the chance of it drifting off as overspray. Additionally, minimizing reaction time in the airflow control system allows for quicker adjustments to maintain consistent air pressure and prevent imperfections.
A few factors cause overspray, including longer response time in the proportional valve flow, pressure change requirements, inaccurate pressure adjustments into the valve blocks and incorrect voltage of the machine that charges the powder material, as well as the distance and angle of the spray gun to the work piece.
One requirement the Sames team stipulated was the valve block’s size. Having a compact valve block is important because the size of the powder coating machine is restricted. The valve block must be installed in tight spaces along with other components inside the machine to reduce the distance between powder material to the spray equipment.
Powder Spray Precision with Fast Response Times
Emerson used its proportional valve expertise and innovative technology to help Sames Kremlin engineer a compact valve block with optimum control to precisely manage the powder coating patterns in its machine.
Emerson and Sames developed and tested possible valve block solutions that met the optimal flow and pressure requirements with high response sensitivity. Together, they chose ASCO 202 Preciflow proportional valves and an AVENTICS manual regulator.
Ideal for high-precision flow control, ASCO Series 202 Preciflow proportional valves feature low hysteresis, excellent repeatability and high sensitivity. With an operating pressure of up to 145 psi (10 bar), Series 202 Preciflow valves have a compact, lightweight, frictionless architecture that saves valuable space, resulting in smaller valve blocks in powder coating machines.
Acting as a valve block, ASCO 202 Preciflow proportional valves and the AVENTICS manual regulator together maintain an ideal airflow that allows the powder to pass via the spray gun in the optimized pattern. By precisely controlling the powder flow, the Series 202 Preciflow valve achieves the desired coating thickness, while the AVENTICS manual regulator adjusts compressed air pressure in the main line.
With this combination of technologies, the Sames valve block is a compact, lightweight, high-performance solution with faster response time than tested competitor products.
An ASCO™ï¸ 202 Preciflow proportional valve.
Valve Block Offers a Competitive Edge and Sustainable Solution
Its portfolio of proportional valves and industry-leading expertise made it possible for Emerson to identify, engineer and test the best valve block for the Sames Kremlin powder coating machine. Through extensive testing, the valve block provides excellent results and meets all performance requirements.
The valve block designed by Emerson for Sames Kremlin increases end user productivity and reduces waste. Featuring ASCO 202 Preciflow proportional valves and AVENTICS manual regulators, the highly precise valve block has minimum response time and low hysteresis, helping optimize compressed air flow and reduce overspray.
The support and expertise of the Emerson team gave Sames Kremlin an advantage over its competitors. By partnering with Emerson, Sames Kremlin better serves its customers and helps them achieve the outcomes that matter most. With greater powder coating performance, manufacturers can maintain product consistency and quality while reducing total cost of ownership. And, by reducing overspray, as powder material can be hazardous, the solution helps manufacturers practice sustainable production techniques.
Sames Inocart NDT complete manual powder package.
By partnering with Emerson, Sames Kremlin solved its technical challenges and achieved its goals using Emerson’s engineering expertise and portfolio of proportional valves and regulators. The valve block designed by Emerson for powder coating and paint applications offers fast response time and low hysteresis. The combined strength of Sames Kremlin powder coating technology and Emerson valve automation reduces overspray and waste, helping end users reduce material consumption and total cost of ownership.
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About the Author Sumit Kapde, Global Business Development Manager, Robotics and Proportional Valves, Emerson, is an accomplished global business development manager. Throughout his career, Kapde has helped clients from diverse industries enhance productivity through strategic implementation of tailored solutions. He holds an MBA in International Industrial Management from Hochschule Esslingen in Germany. Additionally, he earned a bachelor’s degree in chemical engineering from Nirma Institute in India. |
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About Emerson
Emerson is a global technology and software company providing innovative solutions for the world's essential industries. Through its automation portfolio, Emerson helps hybrid, process and discrete manufacturers optimize operations, protect personnel, reduce emissions and achieve sustainability goals. For more information, visit https://www.emerson.com.
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