AETEC in-house POC

1.4 m customer samples. Reserve at least 3.6 m clear height as a study allowance; site survey required. 1,200 mm starting robot mount plus guided travel (about 851 mm sampled POC travel), adapted vertical table, removable aluminium fixture and prototype protected tool / metrology stations.

Develop scanning repeatability, coating build per pass, force / abrasive settings, cleaning release and thickness correlation. Use suitable existing plant and temporary equipment.

Final DSO cell

2.1 m workpiece study. Booth A is 4.2 W × 4.6 D × 3.3 H m (existing). Open-front connected base approximately 3.7 × 3.35 m. Robot mount starts at 1,200 mm above floor, with a guided vertical axis. Normal top scanning of the 2.1 m part exceeds the existing 3.3 m booth height; the gold 4.1 m envelope is an unapproved top-access study.

Retain common fixture, docking, tool and protection interfaces. Engineer the production frame, plant, services and control architecture using the POC evidence.

Air-clearance study

Thickness study

Select a map cell. Synthetic values, not POC measurements.

Vertical table + removable carrier

• Vertical C-axis spindle; Ø1,160 mm concept table.
• 1,100 × 1,100 mm aluminium carrier, 25 mm top plate over deep rails.
• Three datums, positive clamps, drive interface, carrier ID and bonding.
• Two 190 × 105 mm nominal fork openings, 580 mm pitch; retreat forks stay above the table.
• Fold-flat grips, removable T-handle provision and rated lifting-eye interfaces.
• Internal mast and broad contact pads; lower positive retention. No top clamp.

The elevated table supports start at 240 mm above floor; modeled stacker legs reach 130 mm. A pallet stacker makes the elevated transfer; pallet jack is for ground transport. Actual fork geometry, SWL and contact zones remain engineering inputs.

Protected tool exchange

• Six protected positions: MetraSCAN, sander, spray nozzle, cover gripper, air knife / vacuum head and blast reserve.
• Spray nozzle docks in the enclosed wet bay. Sealed automatic fluid / air couplings and head shut-off prevent open service ends during exchange.
• Scanner returns to a dry covered compartment.
• C-Track+ Elite sits above the tool cabinet on two uprights, cross-beams and diagonal braces connected to the common machine frame. A protected shutter opens only for clean scanning.
• Wet flush catchpot segregated from the optical bay.
• Filtered dry purge, pressure feedback and cleanliness release.

The spray head is absent from the wrist during scanning and sanding. The robot-side services terminate at sealed couplings. Wet receiver, cap nests and dry optics are segregated; tool payloads and service loads require verification.

Modular frame + services

• Side and rear rails with bolted splices. Front crossbar and loading-lane rails removed.
• Operating feet carry the working load; wheels are for relocation.
• Robot, table, tool cabinet and tracking datum remain connected; all operating feet sit outside the loading lane.
• Covered service trunking, keyed disconnects and hose dress pack.
• Robot shifted closer to the table: X −400 / Y −500 mm; base 1,200 mm plus up to 1,400 mm guided vertical travel.
• No building-floor anchors in this design intent.

Emergency-stop loads, stiffness, sliding/overturning, floor pressure and transport states require structural checks.

Booth + cleaning

• 4,200 × 4,600 × 3,300 mm final Booth A envelope.
• Right access door and 1,200 mm straight loading lane; no floor threshold.
• Process lighting, make-up air, filter bank, duct and exhaust fan.
• Separate sanding vacuum / dust collector.
• Paint supply and wet flush receiver inside the booth. External plant is the dedicated dust collector, explicitly labelled.
• Controller / HMI outside the process zone.

External plant, service access and stacker aisle need space beyond the stated booth footprint. POC room dimensions are a planning reservation pending site survey.

Fixture targets and robot covers

Eight spherical / 360° target-holder stations on the exposed fixture base. Permanent mechanical retention and anti-rotation seats on the aluminium carrier; no targets on the workpiece. The same lower part bolts, internal pads and fixture datum remain throughout the cycle.

Each target has a separate sealing adapter and positive-latch cap. The gripper acts on the cap handle, not the target. Clean numbered nests on the front cabinet shelf hold the caps during metrology. Verify seated / locked sensors before spraying, sanding or blow-off.

Creaform confirms 360° magnetic targets for BLACK+. The illustrated 36 mm holder is a concept envelope; OEM accessory selection, adapter retention, required target count and visibility must be qualified. Small height offsets avoid a purely coplanar reference pattern.

What cleaning accomplishes

Cleaning removes loose residue, protects optical equipment, exposes a reliable surface and prevents false pre/post surface differences. It does not cure paint, remove bonded overspray, or establish measurement accuracy by itself.

After spray: extraction plus supplier flash / cure condition; then qualified filtered, dry, oil-free low-energy air and local capture. No air blast onto wet coating. After sanding: vacuum first, then a captured air-knife pass over the rotating part; vacuum / air around still-locked cover rims. Clean tool-bay exteriors before opening.

Use a collector and conductive / bonded path suitable for the assessed residue. Rear booth suction alone is not proof that high-energy blow-off is captured. Release on airflow, residues, coating condition, temperature and tracking checks, not a fixed five-minute timer.

In-house POC funding envelope

S$441,000 excluding GST

S$386,000 defined POC scope + S$55,000 controlled provisional sums. This is a planning estimate. The user-specified ATEX package is the technical design basis; exact supplier package cost / equipment availability must be reconciled before firm issue.

Permanent final-cell equipment and production implementation are separately priced after POC and design freeze.

Commercial basis · R2 / design update · R4

Technical proposal · PDF

Detailed budgetary quotation · PDF

Current R4 design update · PDF

R2 background design sheets · superseded arrangements marked by R4 update

Original ABB PoWa model · GLB