Model ranges and application processes are becoming more diverse. This greater variety of models painted on a line inherently leads to process inefficiencies. This is due to the fixed cycle times, which are typically based on the biggest model and the longest paint and sealer application times. If smaller or less complex car bodies could be transported faster and sealer and paint application times reduced, this would save time and increase output. However, the fixed cycle does not allow this. This was one of the many reasons that prompted Dürr to develop a radical new layout for future requirements.

“With the “Paint shop of the future Dürr is reimagining the painting process and moving beyond the boundaries of the production line,” explains Bruno Welsch, member of the Board of Management of Dürr Systems AG. “The new approach adapts to the needs of manufacturers, and enables an efficient and flexible painting process in every production scenario.”

On-demand cycle times

The general idea of the “Paint shop of the future” is based on splitting up the 120 work steps involved in a painting process into boxes and smaller sections. Instead of a fixed cycle, the process times in each box are precisely adapted to the needs of the individual body. This is made possible by processes running in parallel in the boxes and the interaction with a central high-bay storage system and the automated guided vehicle (AGV) system EcoProFleet. The fleet of AGVs is controlled by the software DXQcontrol. It intelligently guides the AGVs with the car bodies to the next processes, and in this way ensures efficient utilization of all the boxes. It enables the bodies to be sorted in anticipation of future processes, brought to and collected from the right workstation with pinpoint accuracy, and passed off to final assembly at the end in the sequence planned by the manufacturer. The concept also enables easy expansion of capacities or smooth integration of new models. The revolutionary box concept can be applied to the entire top coat and workstation area, or just to selected process steps.

Fewer resources, greater efficiency

In terms of the concrete implementation, the box concept means that three painting processes – the inner and the two outer applications – can be combined in just one booth. This patent-pending concept, the EcoProBooth, helps to save process time, since two of the usual three conveying processes are eliminated. The paint-loss during the color change process can be reduced by up to ten percent if just one paint is applied in a box, for instance the current top seller white. Splitting up the painting process into boxes shortens the overall process by tailoring the application time to the individual vehicle. These properties combine to reduce CO2 and VOC emissions.

The overall equipment availability also increases, since any malfunction only impacts the box section in question and does not affect the entire production line, in contrast to the classic line manufacturing model. The variable layout also makes integrating special processes such as a special paint supply or overspray-free two-tone painting easier and more cost efficient.

Adaptable to both large and small production

The concept of the “Paint shop of the future” is geared towards the specific requirements of various OEMs. It offers high-volume manufacturers with a high hourly capacity the opportunity to integrate new models and technologies with greater ease. It enables companies that want to limit initial investment to expand from 24 units per hour to 48 and 72 units in two steps. Newcomers to electric mobility can start their manufacturing with minimal quantities and gradually expand as demand increases. The modular concept is also Industry 4.0 capable and can be combined with the intelligent software products from Dürr’s DXQ family for various scenarios. In this way, Dürr analysis tools make painting processes more transparent and help to further increase the first run rate.

About Dürr

The Dürr Group has been established in the United States since 1970 and currently employs around 880 people. From the new Campus with a state-of-art validation, testing, and training center in Southfield, MI, Dürr USA represents four of the five divisions. Paint and Final Assembly Systems offers equipment for painting and assembly processes, while Application Technology provides paint, sealants and adhesives application systems. Dürr’s Clean Technology Systems is the global leader in air pollution abatement and energy efficient technologies. The subsidiary Schenck Trebel Corporation, based in Deer Park, New York, offers balancing machines, vibration and condition monitoring systems and services for the general industry. The customers of Dürr USA include automotive and commercial vehicle manufacturers as well as their suppliers, and a diverse group of other industries. The HOMAG Machinery North America operates the production facilities for the HOMAG Group in Grand Rapids, MI, which is also the base for sales and service company Stiles Machinery Inc. The HOMAG Group is the world’s leading manufacturer of machines and systems for the wood-processing industry and trades.

The Dürr Group is one of the world’s leading mechanical and plant engineering firms with extensive expertise in automation and digitization/Industry 4.0. Its products, systems and services enable highly efficient manufacturing processes in different industries. The Dürr Group supplies sectors like the automotive industry, mechanical engineering, chemical, pharmaceutical and woodworking industries. It generated sales of € 3.87 billion in 2018. The company has around 16,500 employees and 112 business locations in 34 countries. The Group operates in the market with the brands Dürr, Schenck and HOMAG and with five divisions:

• Paint and Final Assembly Systems:
  paint shops as well as final assembly, testing and filling technology for the automotive industry
• Application Technology:
  robot technologies for the automated application of paint, sealants and adhesives
• Clean Technology Systems:
  air pollution control, noise abatement systems and battery coating lines
• Measuring and Process Systems:
  balancing equipment and diagnostic technology
• Woodworking Machinery and Systems:
  machinery and equipment for the woodworking industry

Dürr Systems, Inc.
P: (248) 450-2225

Contact
Astrid Weisseise | Senior Marketing Manager

Dürr has confirmed its position as a market leader in China with two orders for BMW. In Dadong district in Shenyang, BMW has been operating a Dürr paint shop since 2016 and is now increasing its capacity. In Tiexi district in Shenyang, where BMW has already been using Dürr painting technology since 2013, Dürr will build a further paint shop in a new manufacturing facility. In addition, BMW is already planning a second expansion stage in Tiexi and has agreed the future expansion will be completed by Dürr. An agreement has also been made with Dürr on the construction of a paint shop in Europe, with a new BMW plant in Debrecen (Hungary) scheduled to commence production in summer of 2023.

“In Dürr, BMW has chosen an experienced general contractor for its investments in the manufacturing facilities in Asia and Europe who can deliver innovative technology for the entire painting process and whose solutions make a contribution to sustainable production,” says Dr. Jochen Weyrauch, Chairman of the Board of Dürr Systems AG, in summing up the current orders. “BMW will get three paint shops that set standards for sustainability, flexibility, and quality.”

Dürr will deliver proven technology and the latest innovations packaged in efficient plant concepts at all three sites. Successful products like the patented RoDip® rotational dip process from Dürr will create outstanding conditions in pretreatment and cathodic electrocoating for the subsequent paint application.

Efficient use of resources, from application to drying

The application step of BMW’s Integrated Painting Process (IPP) in all three paint shops will be handled by Dürr painting robots with high-rotation atomizers of the type EcoBell3. A total of 165 painting robots and 90 sealing robots from Dürr will paint and seal the BMW models in the three plants. Integrated supply systems for the paints and sealers used as well as a paint mixing room will ensure an efficient paint supply in the standard color palette. Dürr will install the EcoSupply P system for supplying special colors. Pigging systems will transport the special colors to the paint booth – with almost zero losses. The coordinated application technology will minimize paint and solvent consumption and ensure fast color changes.

BMW will use sustainable, resource-saving technology throughout the three new paint shops. The Dürr products for paint separation – EcoDryScrubber, in China and EcoDry X in Hungary – boast strong environmental credentials. EcoDryScrubber is based on paint separation using limestone powder, while EcoDry X uses cardboard filter boxes as a separating agent. The Dürr technology thus does not involve any polluting methods that use a mixture of water and chemicals. The recirculation of up to 95% of the air used in Dürr’s separation processes also enables a 60% reduction in energy consumption in the paint booth.

The EcoInCure oven, which will be used in the new plant in Tiexi as well as in Debrecen in the top coat section, will additionally boost the energy efficiency of the plant. The oven’s exhaust air can be purified using just one afterburning system of the type Ecopure® TAR. A comparable double oven with conventional continuous flow technology would need two air pollution control systems. This reduces the amount of fresh air required, and thus the energy demand. EcoInCure uses a new technology for drying: the air flowing in through the opening for the windshield heats the body parts from the inside out, resulting in uniform heat distribution and improved curing of the bodies – even special body shapes like those of electric vehicles.

Compact and scalable layouts

BMW is using an integrated skidless conveyor system for the first time in the new plants in Debrecen and Tiexi. This means that no space is required for storage of empty skids, return transport of the skids and there is no need to clean skids in the top coat section. The end result is compact and scalable layouts.

About The Dürr Group

The Dürr Group is one of the world’s leading mechanical and plant engineering firms with extensive expertise in automation and digitization/Industry 4.0. Its products, systems and services enable highly efficient manufacturing processes in different industries. The Dürr Group supplies sectors like the automotive industry, mechanical engineering, chemical, pharmaceutical and woodworking industries. It generated sales of € 3.87 billion in 2018. In October 2018, the Dürr Group acquired the industrial environmental technology business of US-based company Babcock & Wilcox, comprising the Megtec and Universal brands. Since then, it has around 16,500 employees and 108 business locations in 32 countries. The Group operates in the market with five divisions:

• Paint and Final Assembly Systems:
  – paint shops and final assembly systems for the automotive industry
• Application Technology:
  – robot technologies for the automated application of paint, sealants and adhesives
• Clean Technology Systems:
  – air pollution control, noise abatement systems and battery coating lines
• Measuring and Process Systems:
  – balancing equipment as well as assembly, testing and filling technology
• Woodworking Machinery and Systems:
  – machinery and equipment for the woodworking industry

Dürr Systems, Inc.
P: (248) 450-2225

Contact
Astrid Weisseise | Senior Marketing Manager

The 13,000th robot manufactured by Dürr is an EcoRP E043i, and will be used to paint the interior of passenger cars at GM in Changwon. The celebration of this specific robot is special for many reasons: it is the first time Dürr’s new generation three robot will be used at GM. GM relies on fully automated painting with the latest application technology. The equipment for the new paint shop, which Dürr was commissioned to build, includes a total of 78 third-generation robots. The total order is also the biggest order Dürr has received to date as a general contractor in Korea. GM will put the planned plant into in 2021, and paint the new Chevrolet Spark as well as compact SUVs using the 3-wet method.

The EcoRP E043i and 033i painting robots will handle painting the interior and exterior of the car bodies in Changwon. Seven-axis robots with the latest EcoBell3 atomizer technology will paint the interiors of the vehicle bodies with extremely high precision and flexibility. Their enhanced mobility mean they can reach even difficult-to-access places effortlessly. The exteriors will be painted using six-axis robots. Dürr’s application technology, such as the EcoBell Cleaner D2 atomizer cleaner, stands for state-of-the-art processes with low VOC emissions. The interplay of the dosing pump, color changer, atomizer, and atomizer cleaner ensures fast and efficient color changes within just 15 seconds, reducing paint loss and flushing agent consumption when changing color.

The solvents are removed from the exhaust air using an Ecopure® RTO regenerative thermal exhaust air purification system together with the Ecopure® CRC VOC concentrator from Dürr.

In the existing factory in Changwon, Dürr designed the plant to be over three levels with two painting lines for a total volume of 60 vehicles per hour. GM thought one step ahead when designing the plant by providing space for a later, two-tone painting line.

The construction of the plant also represents Dürr’s biggest order in Korea. A decisive factor for GM was the geographical proximity. Dürr is implementing the project in close cooperation between the headquarters in Germany and the Korean subsidiary in Seoul. Having contact partners directly on-site means that Dürr can provide efficient and highly qualified service locally.

“We’re proud that GM chose us for this important project. This shows the high customer benefit of the new features of the third-generation robots: top quality and availability with optimized costs,” explains Dr. Lars Friedrich, member of the Board of Management of Dürr Systems AG and responsible for the Application Technology Division.

About The Dürr Group

The Dürr Group has been established in the United States since 1970 and currently employs approximately 880 people. From the Campus with a state-of-art validation, testing, and training center in Southfield, MI, Dürr USA represents four of the five divisions. Paint and Final Assembly Systems offers equipment for painting and assembly processes, while Application Technology provides paint, sealants and adhesives application systems. Dürr’s Clean Technology Systems division is the global leader in air pollution control, noise abatement systems, and battery electrode coating lines. It has three headquarters locations in the US: Durr Systems, Southfield, MI; Durr MEGTEC, LCC, De Pere, WI; and Durr Universal, Inc., Stoughton, WI. The subsidiary Schenck USA Corporation, based in Deer Park, NY, offers balancing machines, vibration, and condition-monitoring systems and services for general industry. The customers of Dürr USA include automotive and commercial vehicle manufacturers, as well as their suppliers, and a diverse group of other industries like the chemical or wood industry. HOMAG Machinery North America operates the production facilities for HOMAG Group in Grand Rapids, MI, which is also the base for the sales and service company Stiles Machinery Inc. The HOMAG Group produces machinery and equipment for the woodworking industry.

The Dürr Group is one of the world’s leading mechanical and plant engineering firms with extensive expertise in automation and digitization/Industry 4.0. Its products, systems and services enable highly efficient manufacturing processes in different industries. The Dürr Group supplies sectors like the automotive industry, mechanical engineering, chemical, pharmaceutical and woodworking industries. It generated sales of € 3.87 billion in 2018. In October 2018, the Dürr Group acquired the industrial environmental technology business of US-based company Babcock & Wilcox, comprising the Megtec and Universal brands. Since then, it has over 16,400 employees and 108 business locations in 32 countries. The Group operates in the market with five divisions:

• • • Paint and Final Assembly Systems:
      paint shops and final assembly systems for the automotive industry
    • Application Technology:
      robot technologies for the automated application of paint, sealants and adhesives
    • Clean Technology Systems:
      air pollution control, noise abatement systems and battery coating lines
    • Measuring and Process Systems:
      balancing equipment as well as assembly, testing and filling technology
    • Woodworking Machinery and Systems:
      machinery and equipment for the woodworking industry

Contact
Astrid Weisseise | Senior Marketing Manage
P: (248) 450-2225

With a view to the market launch of the new Urus super SUV, Lamborghini modernized its long-established plant within 18 months during ongoing production. Not only was the production space doubled from 80,000 m2 to 160,000 m2, but also the overall capacity expanded to 7,000 vehicles annually. For this strategically important project for the future of the brand, Lamborghini entrusted Dürr with developing new production lines for complete vehicle assembly. This is based on a forward-looking layout in which each area can be used flexibly. That allows the line configuration to be modified at any time and adapt to changing requirements.

AGV fleet in various sizes

The conveying system with AGVs, specifically developed by Dürr for the Urus, guarantees a high degree of flexibility. The AGVs move individual components and bodies separately instead of one after another in a linear conveyor system as had been the case. They run without rails and are freely programmable like robots. This means that future model series can be manufactured on existing lines, since they can be changed over quickly to accommodate new market scenarios and varied production requirements. The AGVs at Lamborghini come in three different sizes and are suitable for line feeding tasks, the processes in the main line, and for subassembly and powertrain operations.

Ergonomically optimized workstations

In addition to the AGVs, Dürr installed other technologies that meet the demanding standards for ergonomics in the workplace. These include loading carriers (body on AGV), unloading devices (car from AGV), rotating and vertical adjustable carriers for body transport and lifting, as well as slat conveyors with a lifting table for moving the vehicle into an ergonomic position.

Overall control of the project on behalf of the Dürr Group rested with CPM, its Italian subsidiary specializing in final assembly. CPM and Lamborghini were already working together on layout design for conveyor technology, assembly lines, marriage stations, trim lines, and the end-of-line area. CPM was supported by its German colleagues from Dürr Assembly Products which supplied the x-road roll/brake test stand and adjusted it precisely to meet requirements for production of the Urus model.

Flexible line configuration for Urus assembly thanks to innovative solutions from Dürr.

About the Dürr Group

The Dürr Group has been established in the United States since 1970 and currently employs around 880 people. From the new Campus with a state-of-art validation, testing, and training center in Southfield, MI, Dürr USA represents four of the five divisions. Paint and Final Assembly Systems offers equipment for painting and assembly processes, while Application Technology provides paint application systems. Dürr’s Clean Technology Systems is the global leader in air pollution abatement and energy efficient technologies. The subsidiary Schenck Trebel Corporation, based in Deer Park, New York, offers balancing machines, vibration and condition monitoring systems and services for the general industry. The customers of Dürr USA include automotive and commercial vehicle manufacturers as well as their suppliers, and a diverse group of other industries. HOMAG Machinery North America operates the production facilities for HOMAG Group in Grand Rapids, MI, which is also the base for sales and service company Stiles Machinery Inc.

The Dürr Group is one of the world’s leading mechanical and plant engineering firms with extensive expertise in automation and digitization/Industry 4.0. Products, systems and services offered by the Group enable highly efficient manufacturing processes in different industries. Dürr supplies sectors like the automotive industry, mechanical engineering, chemical, pharmaceutical and woodworking industries. The company has 92 business locations in 31 countries. The Group generated sales of € 3.71 billion in 2017. In October 2018 Dürr acquired the industrial environmental technology business of US company Babcock & Wilcox, comprising the MEGTEC and Universal brands. Since then, the company has had over 16,000 employees and 108 business locations in 32 countries. The Group operates in the market with five divisions:

· Paint and Final Assembly Systems: paint shops and final assembly systems for the automotive industry

· Application Technology: robot technologies for the automated application of paint, sealants and adhesives

· Clean Technology Systems: exhaust-air purification systems, noise filtration systems and energy efficiency technology

· Measuring and Process Systems: balancing equipment as well as assembly, testing and filling technology

· Woodworking Machinery and Systems: machinery and equipment for the woodworking industry