SYN] Magazine
#3 | 2019

A high-speed Nozzle

In automobile production, flat stream applications are mainly used for car body sealing in paint shops. A plastisol is applied onto the raw edges, rocker panels or the entire underbody to protect these areas against corrosion and stone chips. A new nozzle developed by Atlas Copco allows even faster application.

In general, flat stream nozzles allow high flow rates with short cycle times and therefore represent a highly productive application method. The material is distributed precisely and applied with well-defined edges, ensuring a high-quality application pattern. As a general principle, high robot speeds can already be reached with conventional flat stream nozzles. However, as the speed increases, the material flow also needs to be boosted to produce the coating thickness required. As a result of the higher flow rate, the material stream spreads out and covers a wider area. The robot speed must therefore be adapted to obtain the required seam width.

Twice as fast

“Atlas Copco has now developed a new nozzle that ensures application over a constant width irrespective of the robot speed,” says Lothar Gudat, Business Development Manager with Atlas Copco IAS. “This solves the problem of varying application width with conventional nozzles and allows higher robot speeds and even shorter cycle times.” Comprehensive tests have shown that robot speeds of up to 1,200 mm/s are possible with the new nozzle, while standard nozzles only produce acceptable application results at speeds of up to 600 mm/s with the same parameters.

Saving Time on long Application Runs

The new nozzle offers considerable potential on long application runs from 300 mm, for example on rocker panels and in vehicle interiors. These distances allow the robot to accelerate and save cycle time. “By optimizing the programming of the robot, we can save up to 1.4 seconds per meter. We expect the new nozzle to reduce cycle times by between 10 and 20 percent – or even more, depending on the application and process,” says Gudat.