panwen automation - allfi robotics inc. · robotic flaming cell —— panwen automation panwen...

FlamingEff ic iency I Eco-fr iendly I Low Cost

PANWEN Automation

PANWEN Automation

Robotic Flaming Cell —— PANWEN Automation

PANWEN Automation

PANWEN Automation Shanghai is newly established company in 2010 with the expertise’s combinations from automation a n d ro b o t i c a p p l i c a t i o n i n special field, mainly focused but not limited in robotic flaming treatment system integration.

With experiences of more than 10 years in factory automation and other robotic applications and projects, PANWEN Automation is strong and commited in building the reliable systems tailored to

the requirements from individual customers in automotive industry as well as other new-booming industry.

Our scope of supply are the system integration packages including robotic flame treatmentrobotic systems, high pressure systems, robotic, robotic gluing systems, CAD designs, fixture/jig designs, software developments, spareparts supply and after sales service.

PANWEN is setup with high caliber technical persons with open mind to absorb the expertise and latest technology in this industry, also with necessary technical support from Sweden, Germany and USA, and strives to make the best quality and competitive system

in the industry. PANWEN, a local company you can trust for robotic application in automotive industry.

PANWEN Automation are the exclusive authorized dealer in China of the FTS Technologies Inc, USA for its flaming equipment, sales and service.

PANWEN AutomationStability & Flexibility

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PANWEN Automation

Flame Treatment is a method of chemically changing the surface molecular structure of a substrate in a controlled manner to:

> Increase "Surface Energy"> Increase "Wettabil ity", and therefore compat ibi l i ty with coatings and materials

Flame treatment can be applied to any olefin based plastic or metallic component, like bumper fascias, body side moldings, wheel covers, air spoilers, air scoops, door handles, door panels, consoles, dashboards, post trims, and carpet backing.

Flame treatment of components h a s f o r y e a r s a l w a y s b e e n troublesome in a high volume product ion envi ronment . As such the common choice of manufacturing plants has been e i the r the use of Adhes ion Promoting Primers or the use of Flame Treatment, and in many cases a combination of both. Decisions on what method of surface treatment to use have always been a compromise.

With Adhesion Promoters, such concerns are env i ronmenta l (High VOC emissions and clean up costs), introductions of dirt, high maintenance costs, and

safety. Chlorinated solvents, most commonly used in Adhesion Promoters, are highly flammable a n d t o x i c w h i c h i n t u r n i s dangerous to plant and personnel alike.

Flame Treatment provides a lower cost, high quality solution for surface treatment applications. Unfortunately, this technology has fai led to keep pace with t h e a d va n c e s m a d e w i t h i n manufacturing processes used i n today 's h igh p roduc t ion environments. Considerations of manufacturing engineers as to the use of Flame as a method of surface treating have been based around cycle times, where the geometry of the part to be treated is complex, and safety considerations when using a "naked" flame within the confines of a painting system.

FTS Technologies is a company dedicated to advances in the field of surface treating technology to develop new applications and implement these technologies into high production environments. This has in part been achieved v ia the deve lopment of FTS Technologies new "Advanced Thermo-Molecular Adhesion Process" (ATmaP®) and line of "Cirqual®" Burners which take

the principles of flame treatment technology to a whole new level.

(United States Patent #: 6,716,484 B2) - Further US and Foreign Patent Applications Pending.

GM Eliminates Solvent from Suppliers’ Paint ProcessAdhesion alternative is energy efficient and practically emission free 2011-08-23DETROIT – General Motors is introducing a flame treatment technology that lets paint stick to plastic vehicle parts like instrument and door panels without using primers that contain solvents and can foul the air.

The use of solvents in paint pr imers i s an industr y-wide challenge. GM is committed to reducing emissions throughout its manufacturing operations and supply chain, so it manages tradit ional solvents through recycling, conversion to energy and superheating the gases to break them down. However, these are energy-consuming, costly processes.

This flame treatment technology instead uses an energy-efficient, ro b o t i c s y s te m to c re a te a molecular change to the surface of the plastic, making it bond with the paint. The process eliminates t h e n e e d f o r a n a d h e s i o n -promoting primer.

GM evaluated the new technology as a total business case. Not only does it improve efficiency since it’s faster than spraying primer, but the capital expense pays for itself in less than four months. It’s being used on the Chevrolet Cruze, Sonic, and Volt.

By using it on the Cruze, for example, GM suppliers:

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PANWEN Automation

Reduced solid and liquid waste (filters, cleaners, solvents and coatings) from 48 tons a year to less than one.Decreased air pollutants from 810 tons a year to 80 tons a year.Eliminated landfill waste like paint sludge and painted scrap material from 25 tons to nearly zero.GM learned about this technology through Suppliers Partnership for the Environment, a working group of U.S. automakers, their suppliers and the Environmental Protection Agency. Whitmore Lake, Mich.-based supplier FTS Technologies was striving to get its flame treatment technology implemented and approached John Bradburn, GM’s manager of waste-reduction efforts.

“Once I understood the potential of this process, we worked to connect the right GM engineers and our suppliers,” said Bradburn. “As we strive to design all of our vehicles for the environment, we can create requirements for our suppliers. In this case we were able to provide the enabling technology, making it easier for all of us.”

Said Russell Brynolf, president o f F T S : “As e n g i n e e r s an d te c h n o l o g y d e ve l o p e r s , we have the capability to improve the envi ronmental footpr int

of the manufacturing process. Technology drives us forward and it’s encouraging to see companies like GM will ing to change a process."

ENVIRONMENTAL HOT TOPICS

TOTAL ENERGY REDUCTIONS THROUGH MANUFACTURING OPERATIONS R E D U C T I O N I N C A R B O N DIOXIDE AND OVERALL CARBON FOOTPRINT. I M P L E M E N TA I O N O F N E W TECHNOLOGIES TO REDUCE ENVIRONMENTAL IMPACT AND SAVE MONEY Environmental Comparison

F T S Te c h n o l o g i e s s u r f a c e treatment technologies, such as ATmaP surface treatment, offer cl ients in the global plast ics finishing industry the benefit o f e n h a n c i n g a d h e s i o n o f coatings to polymeric substrates w i thout the use of expense and environmentally damaging adhesion promoting primers and other related environmentally unfriendly processes. With the key components of adhesion promoting primers being CPO resins, which require a substantial amount of solvents

to bring them to a sprayable viscosity (6.5lb to 7lb per gallon), a n d w i t h s o l i d c o n te n t s o f less that 10%, it is easy to see how a technology of this kind can raise many environmental c o n c e r n s . C o m b i n e d w i t h t h e c o s t s o f h a n d l i n g t h e disposal and destruction of this technologies waste products, makes this technology not only environmentally unfriendly, but incredibly costly.ATmaP® is an environmentally friendly process with no discharge of solvents (VOCs or HAP's) , eliminating the need for expensive abatement systems, or al ike. Capital and operational costs with the implementation of ATmaP surface treatment are a fraction of the cost when compared to current manufacturing processes. Emissions of solvents, use of natural gas, and dependence on government permitting, can all be substantially reduced.

The ATmaP® process may be the difference in a company being able to: • Setup a new plant where the discharging of VOC’s is not permitted;• Continue operating a plant when their environmental license has been reduced or revoked;• Inc rease the i r p roduct ion capacity when they have reached their VOC limits.

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PANWEN Automation

FTS Technologies(11084 Hi Tech DriveWhitmore Lake, MI, 48189USA) i s the global leader in surface treatments in automotive industry, located in motor city of Detroit , FTS ser ves major automotive companies like GM, FORD, Daimler-Chrisyler, NISSAN，TOYOTA，HONDA.

The CEO of FTS, Mr. RUSSEL BRYNOLF spent more than 20

years of his career life developed lots of technologies and patents in plast ic industr y, the most important patents are Cirqual® burner and ATmaP™.

Registered Trademarks

ATmaP and Cirqual Are Registered Trademarks Of FTS Systems LLC

ATmaP®USPTO # 6,582,773 B2

USPTO # 6,716,484 B2Cirqual® BurnerUSPTO # 6,796,793 B2USPTO # 6,946,165 B2Fiber Glass Chop ProcessUSPTO # 6,582,773 B2USPTO # 6,716,484 B2

PANWEN Automation is the exclusive authorized dealer in China of the FTS Technologies Inc, USA for its flaming equipment, sales and service.

FTS TECHNOLOGIES: THE GLOBAL LEADER IN SURFACE TREATMENTS：

Technical Advantage of Cirqual® Burner Over the Traditional Linear Burner

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Cirqual burner Traditional Linear Burner Dimenson Φ75mm 8"/203mmFlame Width 75-200mm 15mmFlame Velocity 900 - 1100 ft/min / 275-335 meter/min 225 - 275 ft/min / 70-83 meter/minSpeed of Robots with Flame 800-900 mm/s, up to 1200mm/s 200-300 mm/sOutput 80000 BTU/h 5000 BTU/h/InchType of Gas LPG/Natural Gas/PropaneNormal Inlet pressure gas 0.3 Bar 0.3 BarGas consumption(Maxium) 2. 3Nm3/h 1.3Nm3/hNominal Volumetric Burner Output 400 L/min 200 L/minSummary Synchronizing with 6th axis of the robot, easy to program, better flaming velocity with stiff flame profile, the flame shape remains when the robot is moving fast, cycle time and gas consumption per part are reduced significantly


PANWEN Automation

ATmaP™ is an innovative patented one step process for treating a range of materials (e.g., Plastics, Glass,and Metals) prior to painting or bonding without the need to use Adhesion Promoting Primers. ATmaP™ isan acronym for; Accelerated Thermo-molecular adhesion Process.ATmaP™ is the process of grafting a nitrogen-based coupling agent to the surface of a material being treatedvia atomization and vaporization through the center of a Cirqual® gas burner. When the Cirqual® flame (withthe atomized and vaporized coupling agent) contacts a component being treated, it chemically bonds oxidesof Nitrogen into its surface. ATmaP™ is an environmentally friendly process, with no discharge of VOC’s orabatement. Current technologies, such as adhesion promoters, conventional flame treatment, corona discharge and plasma chambers are unable to match the levels of adhesion achieved by ATmaP™. ATmaP™ exceeds current OEM requirements for industry standard adhesion tests such as; Stone-chip Resistance, GasolineSoak, Mandrel Bend, Water Jet, Thermal Shock, Humidity, Chemical Resistance, Lap Shear, and Cross Hatch etc.

ATmaP™ Performance Standards:DaimlerChrysler in July 2003 issued a Global Process Specification (PS-10789) for use of the ATmaP™technology on painted exterior TPO/PP.General Motors Holden has also tested the ATmaP™ process on interior and exterior painted TPO/PP, withATmaP™ exceeding current GMH per formance specifications.

The ATmaP® Process Offers The Following Benefits:

• Increased Adhesion without the use of Adhesion Promoters• Cost Reductions:• Reductions in Energy Consumed in Production Process• Faster Process Time• Allows for Material Substitution (recyclable and lower cost materials)• Oppor tunity to sa lvage scrap products / components• Reduced Maintenance Costs• No Required Abatement• Possible Weight Reductions (material substitution)• Reduced use of Solvents• Recyclability (by material substitution)• Improved 'First Time Quality' • Reduced Warranty Claims• Environmental Improvements

ATmaP™ (Accelerated Thermo-Molecular Adhesion Process) Executive Overview

Performance Of The ATmaP™ An Elcometer, vertical pull strength test wasperformed on an ATmaP treated TPO bumperfascia that was painted without the use of AdhesionPromoting Primers. The resulting basecoat-tomaterialbond was so strong that a 100% cohesive failure of the substrate occurred at 1750 psi.

A Cross Hatch Test performed on an ATmaP treated TPO body molding that was treated then stored for 5 months before being painted without the use of Adhesion Promoting Primers. The ATmaP treatment durability has been tested to 12 months with perfect results.ATmaP™ treated materials that have been paintedwithout Adhesion Promoters can withstand a GasSoak in excess of 24 hrs without any loss ofadhesion.

When an Elcometer Test was performed on a regular production part (Adpro, Base, Clear System), the resulting facture point occurred between the ADPRO and material with zero cohesive failure of substrate.This fracture point occurred at 250 psi.

Adhesion Promoter, because of its reactivity toGasoline, cannot match the same standards as itsATmaP™ counterpart. Failure occurred after onlythree hours.

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PANWEN Automation

ATmaP™ is a patented, one-step process that uses a Cirqual® gas burner attached to a robot arm in order to surface treat both, flat and three dimensional surfaces alike. However it is not the same as traditional flame treatment. A technical description of ATmaP™ is detailed below:• A highly controlled flame delivered by the Cirqual® burner, using either natural gas or propane, is generated with control of oxygen content in the range of 0.2% - 1.2% depending on thematerial being processed. • A dimine compound is solubilized in water at less than 10.0% mix ratio. This “water-borne”solution is

The ATmaP™ Surface Treatment Te c h n o l o g y p r o v i d e s m a n y additional benefits beyond the most prevalent; the elimination of Adhesion Promoting Primers. These added benefits could represent significant savings and/or improved ef f i c ienc ies in manufactur ing environments.L e s s E n v i r o n m e n t a l Wa s t e GeneratedThe el imination of ADPRO wil l significantly decrease the amount of Sludge / Contaminated Water produced as a result of paintingapplications.Less Solvents RequiredSolvents will no longer be required for ADPRO thinning / mixing. Also, there will be the elimination of flushing operations for ADPRO fluid lines & spray guns. This also reduces amount the environmental waste caused by recaptured / contaminated solvents.L e s s E n e r g y R e q u i r e d F o r

injected into the flame via an internal mix spray gun, located in the center of theCirqual® burner. The spray gun is highly modified to generate low velocities yet high atomization. The highly atomized liquid is vaporized within the flame and generates an active ‘chemistry’ which in turn is carried to the surface of the material / molding, by the flame itself. The total volume of liquid sprayed is no more than 25ccm.•The a tomiz ing med ia u sed i s Nitrogen (oxygen free) at volumes of no more than 12 - 15 l/min.Nitrogen is used because it is an inert gas and therefore does not affect the O2 content of the flame itself.

Abatement SystemReductions in VOC concentrations enable air volumes to be reduced in an abatement system, which results in the requirement forless energy inputs to achieve 100% VOC destruction.Environmental CreditsOverall reduction in environmentally damaging discharges into the air and landReduced VOC DischargesLess VOC emissions due to ADPRO can enhance p roduc t vo lume throughput due to freed-up capacity within VOC permits.Reductions In Product ScrapImproved FTQ due to the elimination of one coating and possible dirt contaminates that occur with an ADPRO system.Reductions In Floor SpaceElimination of ADPRO ovens (If currently required), which can occupy as much as 30% of total floor space.Reduced Maintenance Time &

Nitrogen is also capable of, and reacts to, changes of polarity. One of the effects of combustion is to generate a small electric current. This ‘charge’ becomes an integral part of the overallchemistry generated which is transferred to / integrated with, the surface of the substrate. The net effect is to increase the polarity of the substrate.• Hydroxyl, Carboxyl, and diimine-derived functionality’s (oxides of Nitrogen) are chemically bonded into the surface of the substrate being treated.• These functional groups cause variations in electro negativity across the surface of the part,which enhances adhesion (for painting/bonding & laminating etc.)• More than 65 indiv idual chemical reactions take place within the flame and on the surface of the substrate.• The chemical bond is permanent and treated parts can be stored and painting/bonding & laminating etc. delayed for up to 12 months.• The application traverse speed can be up to 2000 mm/second with treatment coverage being approximately 200 mm wide per pass.• There are no EPA issues (no VOC’s are used or produced by the ATmaP™ process .and no abatement required).

US EPA Clean Air Excellance Award

Year 2006

GM Environmental Sustainablity Award

Year 2012

Daimler Chrysler Environmental Award

Year 2005

CostsATmaP™ equipment comprises of modular constructed units with wide process windows and operational tolerances. These components require less maintenance than current ADPRO equipment.Reduced Warranty ClaimsATmaP™ provides improved adhesion when compared to current ADPRO systems.RoboticsATmaP™ does not require the use of intrinsically save and costly Paint Spray robots, which can be substituted with less expensive Industrial robots.ADPRO Oven Costs (If Applicable)No requirement for an ADPRO oven means significantly reduced energy consumption.

Technical Overview Of The ATmaP™

Added Benefits Of The ATmaP™

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PANWEN Automation

The patented Cirqual® burner is a very important part of the ATmaP™ process. It allows the ATmaP™process to generate the required flame-chemistry and induce the necessary chemical modifications on thematerials surface.

The Cirqual® Burner, with its lightweight aluminum construction, provides One Step processing of materials and has proven to reduce cycle times and produce a consistent, quality, surface treatment.

The Cirqual® burners radical three-dimensional‘mushroom’ flame shape, three inches in diameter,allows for successful treatment to span eight inchesin a single pass.

Intricate surface geometry is also overcome viathe unique flame shape and its ability to spreadupon contact, conforming to contours and wrapping around edges/parting lines.

Feature Benefit

Improved First Time Quality, Improved ‘Wettability’ Promotes Even Paint Flow, forming a Consistent Layer with Better Wrap on Edges, Particularly on Designs with Sharp Edges Lower Warranty Claims, Cheaper Substrates May Be Used

Treated Parts Have Been Successfully Painted12 Months After Being ATmaP™ Treated

Less Floor Space Required than Conventional, Methods or Surface Pre-treatment, Fast Processing Speeds (Example: Bumper Fascia = 35-45 Seconds)

No Abatement RequiredEnvironmental Credits Maybe Available

No Abatement RequiredEnvironmental Credits Maybe Available

Able To Treat a Range Three-DimensionalSurfaces, Including Deeply Recessed lightsockets and grills etc

Offers Opportunities for Treatment to OccurEither Online or Off-lineTreated parts can be stored up to 12 Months

Increased Levels of Adhesion

Large Open Process Window From Time Of Treatment till Coating

F l e x i b l e M a n u f a c t u r i n g Opportunities

Fast, One-Step Processing

No VOCs

Very Low Energy Consumption

Highly Controllable and Flexible Flame Dynamics

Cirqual® Burner Description

Features And Benefits Of The ATmaP™

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PANWEN Automation

1. For products: Bumper, IP, Door Panel, etc.;2. With Flaming System from FTS Technologies, USA;3. UL/CE certified flaming cabinet;4. Three products ranges for Flaming System：

a Fully automatived close loop controled flaming equipment(with oxygen analyzer, hose and plumbing kits for the robots）、

b Laborator y F lame Treatment（(with oxygen analyzer，manually adjustable, with swivel, hose and plumbing kits for the robots）、

c Deflashing system（manually adjustable, no oxygen

analyzer, with swivel and hose and plumbing kits for the robots）、

5. Option for the burner : linear（4/6/8/12 inch）or（Cirqual® burner）；

6. Type of the robots: FANUC/ABB/MOTOMAN;7. Type of the working table: stationary/

rotating；8. Standard control for the cell: SIEMENS PLC,

with touch screen in Chinese/English；9. POKA YOKA as option；10. Laser printer for bar-code as option；11. Exhaust vacuum as option（above the home

position of the robot）；12. Option for the Gas: LPG/Natual Gas/ Propane；13. Production process menu will be trialed and

ready before the shipment from PANWEN's workshop, the machine is ready to produce upon arrival at the customer's site.

General Introduction of Robotic FlamingCell By PANWEN Automation:

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PANWEN Automation

Flame Treatment Of Plastics

In industr y today the usage of plastics is becoming more widespread due to their increased p r o c e s s a b i l i t y , m e c h a n i c a l s t rength , and res i s tance to chemica l at tack . Due to the resistance of plastics to chemical attack, their use in painting or bonding applications is somewhat restricted.It has been known that the surface properties of plastics can be changed by Flame Treating the surface prior to any painting or bonding application as means to increase the plastics characteristics of adhesion and help overcome any level of chemical resistance.

Treatment of the surface with the plasma of a flame imparts oxygen into the surface molecular layers of the substrate in order to increase the surface energy of the treated material. Increasing the surface energy (measured by dynes or contact angle), improves the wettability and provides an

improved and consistent surface for further processing to occur, such a painting, printing, bonding, or laminating.

Approximate Surface Energy/D y n e L e v e l s O f C o m m o n Untreated Plastics

Polypropylene 29Polyethylene 31Polystyrene 32Ionomer (Low) 33Ionomer (High) 37Vinyl Acrylic 39Saran 40Cellulose 42Polyester (Mylar) 43Nylon 46

Oxygen Content Of A Flame (Air/Gas Ratio)

All Flame Treatment Systems manufactured by FTS Technologies contain Oxygen Analyzers to monitor the air/gas combustion mixture for excess oxygen within the flame. The signal from the analyzer is processed and a tightly

controlled predetermined level is maintained via an automatic gas trim proportioning solenoid.This propor t ioning solenoid cont ro l s the vo lume of gas entering the mixture line and maintains a constant and stable amount of excess oxygen within the flame.

The correct level of excess oxygen within the flame depends on the type of material being treated. Optimum ranges for today’s modern substrates are between 0.2% and 1.0% excess oxygen within the flame with an accuracy level of +/- 10%. Processability studies will be conduced by FTS Technologies during the normalinstallation of the equipment and the appropriate oxygen set point will be determined.

The Burner-To-Target DistanceThe optimum burner to target distance to ensure a high level of flame surface treatment is approximately three (3) inches.

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PANWEN Automation

F l a m e C o n t a c t T i m e W i t h Product (Dwell Time)The dwel l t ime of the f lame is critical as some 90% of the a c h i e va b l e t re a t m e n t l e ve l (depending on the substrate) is obtained during the first pass of the flame over the substrate. Additional passes only serve tomarginally improve the treatment level, and most systems utilizing t r a d i t i o n a l l i n e a r b u r n e r technology use a secondary pass to provide comfort when treating complex shapes.

Use of FTS Technologies Cirqual® Burner technology allows for complex three-dimensional shapes to betreated more consistently with faster robot traverse speeds than conventional linear burner technology due to the flames unique circular/mushroom flame shape, its ability to maximize dwell time, and wrap around edges and parting lines.

The traverse speed of the burner/flame across the surface of the substrate depends on the type of substrate being treated. FTS Technologies will determine the appropriate robot traverse speed during the normal optimization of the flame treatment process at time of installation.

The Size Of The Flame (Energy Output)The size of the flame and its output of energy is a major consideration when optimizing the flame treating process. The generation of heat during the process is an unwanted by-product that has no bearing on the quality of surface treatment.However, the velocity of the flame impacts the total energy outputfrom the burner, meaning that the higher the velocity the greater theamount of heat that is generated. FTS Technologies will balance theburners velocity in relation to energy output at the time of installation, taking into account that velocity is

key in overcoming any boundary layers of air moving with the part and to ensure that the flame reaches into all intricate geometries.

Flame Deflashing TechnologyExecutive OverviewFTS Technologies have developed a complete line of flame deflashing equipment intended to facilitate high volume injection molding facilities eliminate manual Deflashing operations and produce a more consistent part of higher quality.FTS Technologies flame deflashing units use the patented Cirqual® Burner that produces a highly consistent circular flame of sufficient size and energy to produce an exceptionally large processing window. The use ofthe Cirqual® Burner places less emphasis on maintaining a perfect burner to- target distance, with the dynamic of the burner easi ly accommodating for fluctuations in distance and part geometry. These unique benefits allow robot programs to be written faster with the utilization of faster traverse speeds, the ability to deflash a greater surface area of the part, improveoverall part consistency and quality, and do it all without compromising theoverall molding cycle time.Flame deflashing has historically been the bottleneck in the injection molding process, with manufacturersconstantly balancing part quality against faster cycle times to meet volume demands. The use of FTS Technologies flame deflashing system and Cirqual® Burner technology has el iminated the bottleneck, allowing for the most complex of parts be 100% deflashed well within current molding press cycle times.Current Product Offering:• A flame deflashing unit that houses electrical and mechanical controls to operate a single Cirqual® Burner.• A flame deflashing unit that houses electrical and mechanical controls to operate two Cirqual® Burners either independently or in unison.

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PANWEN AutomationPANWEN Automation Systems Eng. (Shanghai) Co., Ltd盘玟自动化系统工程（上海）有限公司Address: No. 140 Hangtou Rd, Damaiwan Industrial Zone, Hangtou Town, Pudong District Shanghai, 201317 P.R.China.中国上海浦东新区大麦湾工业区航头路 140 号(邮编：201317)Tel : +86-21 61559671 Fax +86-21 33250539 Email: [email protected] www.panwen.com.cn

fts Technologies 11084 Hi Tech Drive • Whitmore Lake, MI, 48189 USA Tel +1 734.449.5100 • Fax +1 734.449-5101 E-mail [email protected] www.ftstechnologies.com

All Rights Reserved.PANWEN Automation 2012

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