Customer Case Study——Leading Forklift Manufacturer Implements Automated Electrostatic Powder Coating Booth, Achieving Quality Enhancement, Efficiency Boost, and Comprehensive Eco-Smart Upgrade!

Project Implementation and Highlights

Addressing the client company's requirements and pain points, along with the unique characteristics of forklift structures, Junhe Design developed and manufactured automated powder coating equipment through multiple rounds of technical discussions and validation. This solution delivers the following benefits:

(1) Enhanced automatic spray coverage, reducing manual touch-up requirements.

(2) Optimized program control with dual automatic spray systems, enabling flexible production for both chassis and mast components.

(3) Enhanced coating process quality through the integration of a buffer zone between manual and automated spray sections, significantly improving overall coating consistency.

[Highlight: Utilization of Two Ultra-Long Multi-Functional Intelligent Spraying Systems]

The automated powder coating line employs Junhe's newly customized and designed ultra-long multi-functional spray booth series PX01. This booth features workpiece buffer zones in both the automatic spraying section and the preceding/subsequent manual spraying sections. This allows workpieces in the manual sections to pause for spraying without impacting overall production rhythm and efficiency. Compared to manual spraying, coating quality improves by 35%. The ergonomic design reduces operator fatigue and enhances work efficiency.

This spray booth features two buffer stations and spans approximately 20 meters in length, demanding high standards for uniform airflow distribution throughout. Through computational fluid dynamics (CFD) analysis combined with practical field experience data, an advanced airflow distribution design was implemented. This enables more rational exhaust ventilation configuration, enhancing both spraying efficiency and the working environment for operators.

1) Mast Spray Booth Highlights

Each mast level is equipped with two telescopic U-axis motion mechanisms, totaling six telescopic spray units. Each unit employs a high-precision servo control system for exceptional operational stability. The transmission mechanism utilizes ultra-quiet rack-and-pinion gears with low friction coefficients, minimizing maintenance costs.

For the workpiece sides, R01 series lightweight 2D sprayers are employed. Due to the low clearance at the bottom of the third mast layer relative to the operating surface, manual touch-up spraying is challenging. Therefore, KP-02 series bottom-tracking 2D sprayers are installed. Both the X-axis and Z-axis utilize high-precision servo control systems to enhance bottom coating quality. This booth also accommodates spraying of guardrails and other small components.

2) Frame Spray Booth Highlights:

Features a multi-stage synchronized drive system with MU-Z axes + U axes, with each spray machine equipped with 3 MU-Z axes and 4 U axes. This system fully accommodates diverse frame structures of varying dimensions, eliminating the need for program updates when expanding applications for new customer products. This booth offers cost-effective construction, rapid commissioning, and exceptional value. It shortens engineering debugging time while accelerating production deployment.

Workpiece side surfaces are coated using R01 series lightweight 2D spray machines.

Highlight: Laser Dynamic Profile Recognition System

Using a laser scanner to capture the contour information of workpieces requiring spraying, this data undergoes computer processing before being transmitted to the PLC. The PLC then drives the servo controller, which in turn operates the corresponding spray gun to perform contour-following spraying, thereby achieving maximum automation in the spraying process.