Dr. Jochen Weyrauch, CEO of Dürr AG, said: “With CATL we have gained another customer in the up-and-coming market of battery production technology. Our technology will make a major contribution in helping CATL produce its electrodes in a way that is both sustainable and economical.” He also emphasized the importance of the battery sector for electromobility: “More battery cells are required for electromobility to prevail. This is leading to the construction of new battery factories, especially in Europe. The production processes these use ultimately play a critical role in determining the size of an electric vehicle’s environmental footprint.”

Cooperation for further growth in battery production

The Dürr Group is planning further growth in the business field of battery production. In September, the company therefore announced its alliance in the battery sector with the German mechanical engineering firms Grob and Manz. The three partners want to combine their technologies and expertise to establish themselves as an end-to-end supplier for the equipment of entire battery factories. This market is currently dominated mainly by Asian mechanical engineering firms. However, many battery manufacturers building factories in Europe would like partners from the European mechanical engineering market, so they can source their production systems locally. Dürr, Grob, and Manz are addressing this need through their cooperation. In this, Dürr is responsible for electrode manufacture, while Manz covers battery cell assembly and Grob delivers technology for the assembly of the battery packs. Dr. Jochen Weyrauch stated: “The combined technology offering of Dürr, Grob, and Manz makes for highly efficient manufacturing processes with maximum digitalization, a high level of availability, and excellent product quality. This enables both mass and premium manufacturers to produce exactly the right battery types for their requirements.”

Electrodes are an integral part of every lithium-ion cell. Dürr’s process, which is established in the battery industry, uses the solvent N-Methyl-2-pyrrolidone (NMP) to dissolve the active materials employed in electrode coating. Classed as a hazardous substance, NMP must be used with utmost care. However, due to its excellent properties as a solvent, it is indispensable in series production. Furthermore, at around € 3,100 per ton, NMP is an expensive operating material. These reasons have led Dürr to develop an innovative, closed-loop solution. Dürr’s Sorpt.X LC solvent recovery system removes solvents from the exhaust air of electrode coating systems, while recovering the heat and 99.9 percent of the NMP contained therein. Thanks to Dürr’s technology, the solvent concentration in the air emitted to the atmosphere is only 1 mg/m3.

Ken Zak, CEO of Dürr’s Clean Technology Systems division, declared: “Thanks to its high level of efficiency, the patented Dürr solution enables the recovery of 99.9 percent of NMP, of which over 95 percent can be reused in the coating process after distillation. Plus, the new solvent recovery system enables us to achieve excellent emission levels, which meet the most stringent local and global requirements.”

Images for this press release can be found here.

With five different versions of the EcoPump2 VP covering a pressure range from 22 to 306 bar, the pump is suitable for applying paints, high-viscosity materials, and adhesives to furniture, steel constructions, and many more materials. It can also handle acidic hardeners commonly used in the 2K process in the North American market without any difficulty.

The first feedback from customers has been consistently positive. The pump is quieter, it pulsates less, and takes less time to clean than the predecessor model. Dürr will be presenting the new pump generation at its stand at this year’s PaintExpo in Karlsruhe, the world’s leading trade fair for industrial painting technology.

Dr. Jochen Weyrauch, CEO of Dürr AG, accepted the award in Munich: “Every good innovation needs good partners on the customer side who can see the potential. The BMW Group is such a partner. With the overspray-free process we have revolutionized series painting together.”

This is the second time Dürr has been presented with the BMW Group Supplier Innovation Award. The mechanical and plant engineering firm first received the award in 2011 for its energy-efficient EcoDryScrubber technology for the dry separation of overspray. “Now, with the EcoPaintJet Pro, we have achieved another giant leap in innovation: The first award was about better overspray separation, whereas this time we have eliminated the overspray altogether,” says Dr. Jochen Weyrauch.

“The system takes the 60% methane, 40% carbon dioxide (CO₂) gas mixture produced by anaerobic digestion of manure and upgrades it to 98% pure methane for injection into the Guardian pipeline, which is a small natural gas pipeline that brings gas from northern Illinois into Wisconsin,” said Tim Golden, Director of Alternative Fuels at Dürr’s Clean Technology Systems division. “There it will be used to create compressed natural gas for vehicles, replacing more than 11,000 gallons of diesel fuel each day and decreasing dependency on fossil fuels.”

Eleven local dairy and beef farms will provide more than 900,000 gallons of manure to the anaerobic digester facility each day using a hub and spoke system. In addition to creating renewable natural gas, the project aims to protect natural resources by reducing potential greenhouse gas emissions and decreasing the amount of manure applied to the land.

After the manure has been digested, the solids will be dried and separated to create more than 135 tons of fiber bedding for cows each day. The remainder will be sold to the horticultural market for use in boxing mixes and as a replacement for peat moss. This process will significantly reduce the amount of phosphorus released into the Lower Fox River watershed in Wisconsin as well.

BC Organics will also produce more than 400,000 gallons of clean, dischargeable water per day using ultrafiltration and a forward/reverse osmosis system. Each participating farm will receive clean water in exchange for its manure, resulting in a reduced need for local ground water. As an added benefit to the local communities, the anaerobic digestion process will also reduce odor by more than 90%.

“BC Organics is providing a more sustainable manure management option for the farms it will serve,” said Golden. “When coupled with the ability to make renewable energy and recycle resources, it’s a clear win for the community and environment.”

For more information about Dürr’s Sorpt.X SB biogas purification technology, visit our website. For additional details about Dynamic renewables visit www.dynamic-renewables.com.

To present this variety of products to a diverse audience, Dürr launched the NEXT.assembly Innovation Summit. “Today and in the future, we want to help our customers build their vehicles in the most efficient way possible. With our first innovation summit for final assembly solutions, we demonstrate our expertise and share our ideas with the world. Our new concept for the final assembly of the future opens a new chapter in greater manufacturing flexibility,” said Bruno Welsch, CEO Paint and Final Assembly Systems of Dürr Systems AG, at the event opening. The event was broadcasted virtually from a studio near Dürr’s headquarters in Bietigheim-Bissingen.

Exemplary solutions in contemporary final assembly

The event opened with insights into completed customer projects to illustrate Dürr’s complete range of products and services for final assembly – from AGVs (automated guided vehicles) to test stands in both greenfield and brownfield settings. “Our successes reflect the current evolution in the automotive market. Custom solutions ensure greater agility in plant design, make it easier to integrate battery-powered vehicles into existing plants, and support greenfield start-ups of electric vehicle manufacturing,” said Dirk Gorges, Executive Vice President Sales Paint and Final Assembly Systems at Dürr Systems AG.

A vision for the future

Using the motto “NEXT.assembly of the future,” Dürr came up with a concrete picture for the final assembly of the future: An integrated concept that rethinks final assembly and makes the previously unachievable possible, such as the variable adjustment of manufacturing volumes or the redeployment of equipment to other factories. “An essential key to this flexibility is complete independence from the building itself,” said Dirk Gorges, explaining the innovative concept. Pits and suspended ceilings are no longer required in any process step thanks to new solutions like AGC ProLiner and x-combined.

Automated guided carrier for flexible chassis lines

In the NEXT.assembly concept, traverses are no longer used in final assembly. AGVs perform the work in the trim and final line and connect all areas with several vehicles in transit as a small buffer to compensate for interruptions on the line. “Since AGVs in the chassis line are not enough to meet the special requirements of this important manufacturing step, our engineers developed something completely new with the automated guided carrier. AGCs are autonomous, battery-powered structural steel modules with integrated hangers,” explained Denny Monti, Business Development Director of CPM S.p.A., an Italian subsidiary of Dürr Systems AG. The pre-assembled AGCs, equipped with off-the-shelf profiles, are not connected to each other and therefore are easy to redeploy to adapt the lines to corresponding manufacturing levels.

Compact, fully automatic and without pits

In a change that seemed impossible until now, the final assembly of the future no longer requires pits at the end of the conveyor belt. “This is the main pillar of our concept, made possible by our new development x-combined: the world’s first combined test stand for inspecting both wheel alignment and brakes and sensors. Depending on the respective cycle time, the headlight settings can optionally be additionally measured and adjusted with the new measurement and adjustment system x-light,” reported Jörg Neumann, Director Product Line EoL at Dürr Assembly Products GmbH.

Flexible scalability

Overall, the new design concept from Dürr represents a final assembly solution that is completely flexible, modular, and scalable. Customers now have the option to adapt their manufacturing to market conditions. Furthermore, individual modules or the entire manufacturing system can be moved to another location if needed. “Massive and difficult-to-alter final assembly systems are a thing of the past. That is our central message,” summed up Dirk Gorges.

More than 400 participants from all over the world watched the event and took part in the Q&A sessions after two and a half content-packed hours. The first iteration of the NEXT.assembly Innovation Summit was geared towards interested parties in Europe and the Americas. On November 17, Dürr will host a Chinese-language event for its customers in China.

Extensive ensemble of robots

Dürr is equipping the new paint shop with an extensive ensemble of robots. The 92 painting robots will include 16 EcoRP E043i and four EcoRPL043i. These robots, which are very mobile because of their seventh axis, can easily reach even difficult-to-access places in the body interior. EcoBellCleaner D2 devices clean the high-speed rotary atomizers from the outside within the cycle time. Color changes and color channel cleaning inside the atomizer occur in parallel, so the system is ready for the next paint job after 15 seconds. In addition, there are 38 EcoR30L 16i and EcoRS 16i sealing robots responsible for all bonding and sealing processes and four compatible cleaning robots.

Many modules from the DXQ software family

The “highly intelligent paint shop” Chery desires will become a reality in combination with DXQ software products. Dürr will use DXQcontrol for higher-level control of the plant. The software seamlessly tracks the life cycle of each body. The DXQequipment.operation human-machine interface visualizes and monitors individual processes from any device. DXQquality.management connects process monitoring with vehicle details, creating a seamless data record for each vehicle. And DXQequipment.maintenance logs when individual components like pumps, valves, or filters need to be maintained. In addition, numerous other DXQ portfolio modules will guarantee data-based and fully automated paint shop operation.

Energy efficiency through intelligent air management

In addition to plant flexibility and the networking of all components, energy efficiency is important to Chery. EcoSmart VEC regulates the ovens’ fresh and exhaust air control, which are the biggest energy consumers in the coating process alongside the painting booths. Intelligent air management adjusts the energy supply to the actual need and reduces it in partial-load operation, saving not only energy but reducing CO₂ emissions.

Chery is China’s top car exporter

Car manufacturer Chery was established in 1997 and is China’s top car exporter. According to their figures, Chery has already sold over nine million vehicles in more than 80 countries and regions. In 2019, the company opened a development and design center in Raunheim near Frankfurt, Germany, to gain a foothold in the European market.

EcoPaintJet Pro improves sustainability

The EcoPaintJet Pro’s innovative process shows its strengths not only in terms of possible design diversity and lower production costs but in sustainability improvements to individual paint shops. Among other things, the DXQ3D.onsite software provides support here: an initial measurement detects and compensates for any inaccuracies in the conveyor system or the body shop. A second sensor mounted on the robot measures the deviation of the car body to be painted from the reference pattern. The robot controller adjusts the painting paths in real-time. The speed and tilt angle of the applicator is controlled so that the paint is always applied evenly, and there is no overspray or need for masking. This saves more than 1.5 million square meters of film and 2.2 million meters of masking tape in a standard production line that paints 110,000 car bodies per year, plus a lot of manual work. Another advantage is that the new process requires up to 30% less energy than the conventional method. These benefits are attracting a great deal of attention from car manufacturers. As a result, Dürr has already won its first order for the EcoPaintJet Pro from a major American OEM.

The 28th annual PACE Awards were presented by Automotive News. The competition was open to suppliers that contribute products, processes, materials, or services directly to car or truck manufacturing. The Automotive News PACE Award is the global industry benchmark for innovation.

A global high-tech mechanical engineering company, Manz AG brings its development skills to the partnership. In addition, it provides extensive experience in key production stages for both the manufacture of different lithium-ion cell types and their assembly into a battery module. They range from wound button cells and prismatic cells through to stacked pouch cells.

For more than 95 years, GROB has been a trendsetting pioneer in the construction of production and automation systems. It boasts strength of implementation in the conception, planning, and commissioning of highly complex and customer-specific plants for large-scale production, especially for the automotive industry, with a strong emphasis on e-mobility, focusing on e-drives and battery technology.

Dürr AG, one of the world’s leading mechanical and plant engineering firms, completes the alliance. Dürr has expertise in the field of electrode manufacturing and further production stages in cell and module assembly. Among other things, Dürr provides coating systems for electrodes to Cellforce, the Porsche joint venture. Dürr also brings to the partnership its skills in large project execution as well as in automation and digitalization.

Dr. Jochen Weyrauch, CEO of Dürr AG, says: “Battery production is one of the fastest-growing sectors in the European industry landscape. The rapid building of production capacity is a prerequisite for European automotive manufacturers to maintain their leading market positions in the age of electromobility. Our customers want reliable, local partners to implement their battery factories. We are taking on this challenge and are joining forces. The combined technology offering of Dürr, GROB, and Manz, stands for highly efficient manufacturing processes with maximum digitalization, a high level of availability, and excellent product quality. This enables both mass and premium manufacturers to produce exactly the right battery types for their requirements.”

Martin Drasch, CEO of Manz AG, comments: “Manz has carved out an excellent position for itself in the battery market. We see fantastic opportunities to benefit from the dynamic development of electromobility, so we have focused our business model accordingly. We firmly believe that, based on the trendsetting alliance with GROB and DÜRR — an alliance that is unique in Europe — we have reached another important milestone toward fully harnessing the huge market potential. The cooperation agreement enables us, together with our partners, to cover the entire value chain in battery production and to considerably speed up the development of system technology for manufacturing the next generation of batteries. We are thus also helping to make Europe independent in this strategically important market of the future.”

German Wankmiller, Chairman of the Board and CEO of the GROB Group, adds: “We are delighted to be cooperating with Manz and Dürr, two such well-respected partners. GROB is a family-owned company that has gained comprehensive knowledge of machines, system technology, and process flows for the entire e-mobility portfolio in a very short space of time. It has now become world market leader in the manufacture of production systems for electric drives. Furthermore, in the field of battery storage technology with a focus on systems engineering, we have developed process knowledge for battery module and pack systems with pouch and hard-case cells, and we have already delivered several large-scale plants. In a further consistent move, GROB has also started developing system technology for the production of battery cells. Through our cooperation with Manz and Dürr, we see ourselves in an even better position and can quickly implement large-scale plants for the international automotive industry and its suppliers. This enables us to offer solutions from a single source along the entire value chain, from coating through to pack assembly. Customers thus enjoy advantages such as high throughput, low production costs, and maximum innovative strength.”

Company profiles

Manz AG — engineering tomorrow’s production

Manz AG is a global high-tech engineering company.

Focusing on the automotive industry and electromobility, battery manufacturing, electronics, energy as well as medical technology, Manz develops and builds innovative and efficient production solutions: From customized single machines for laboratory production or pilot and small series production, to standardized modules and systems, to turnkey lines for mass production.

Technologically, Manz's production equipment is based on many years of experience in the fields of automation, laser processing, inspection systems, and wet chemistry.

With currently around 1,400 employees, the Manz Group develops and produces in Germany, Slovakia, Hungary, Italy, China and Taiwan. Sales and service subsidiaries also exist in the USA and India.

Manz AG was founded in 1987 and has been listed on the Frankfurt Stock Exchange since 2006. In fiscal year 2021, the group generated revenues of around 227 million euros.

GROB-WERKE GmbH & Co. KG — Shaping the future of manufacturing

For more than 95 years, our company has been one of the global players in the development and manufacturing of machines and production lines. Our customers include the world`s most prestigious car manufacturers, their suppliers and many other renowned companies from various industries. With five production plants in Germany (headquarter), USA, Brazil, China and Italy, and 15 worldwide service and sales subsidiaries, GROB is represented around the globe. The GROB Group generates a worldwide output of 1.2 billion euros (fiscal year 21/22) with a workforce of about 7,500 employees.

The portfolio ranges from 4- and 5-axis universal machining centers to highly complex manufacturing systems with own automation solutions to production plants for electric motors and assembly systems for battery and fuel cell technology. The GROB-NET4Industry software developed in-house for the digitalization and networking of production processes rounds off the GROB product portfolio.

Dürr AG — Leading in Production Efficiency

The Dürr Group is one of the world's leading mechanical and plant engineering firms with extensive expertise in automation and digitalization/Industry 4.0. Its products, systems and services enable highly efficient and resource-saving manufacturing processes in different industries. The Dürr Group supplies sectors like the automotive industry, mechanical engineering, chemical, pharmaceutical, medical technology, and woodworking industries. It generated sales of €3.54 billion in 2021. The company has around 18,000 employees and 120 business locations in 33 countries. The Dürr 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, assembly and test systems for medical devices
• Application Technology: robot technologies for the automated application of paint, sealants, and adhesives
• Clean Technology Systems: air pollution control, noise abatement systems and coating systems for battery electrodes
• Measuring and Process Systems: balancing equipment and diagnostic technology
• Woodworking Machinery and Systems: machinery and equipment for the woodworking industry

Rapid assistance in the event of plant downtimes

Schur Star Systems, an international manufacturer of packaging solutions, availed of Dürr’s digital service offering after its industrial air pollution control system went down. Dürr’s regenerative thermal oxidation (RTO) system is a key component of production at Schur Star Systems. It purifies exhaust air streams from several upstream production systems before the exhaust air is released into the environment. The failure of the air pollution control system resulted in the production lines having to be shut down, which is why a solution that could be implemented at short notice was needed. Schur Star Systems opted for the digital service package. Once the customer had installed the security-certified IoT Edge gateway in the control cabinet of the RTO, Dürr technicians were able to immediately access operating states, valve positions, and alarm codes and then identify the problem and upload a modified control program via remote access. This meant the system could be returned to operation quickly and cost-effectively – compared to an on-site visit – and the upstream production was able to start again. Pascal Englert, Vice Operation Manager, Schur Star Systems, explains: “Dürr’s digital solutions impressed us. Since then we have also been using the other modules to prevent future failures as well as to increase the process efficiency of our air pollution control.”

Modular structure with three expansion stages

The digital service packages for environmental systems are available in three different expansion stages, depending on the desired functionality and the available budget. The basis of the IoT-ready package is the IoT Edge gateway, which enables both industrial remote access as well as the continuous collection of process data. The IoT Edge gateway can optionally be connected to the Internet via mobile radio or the operator network. In case of malfunctions or system downtimes, Dürr technicians can analyze possible causes quickly and effectively using state-of-the-art software solutions. This can be done from the office, without the need for an on-site visit. The IoT Edge gateway is ready for operation immediately after installation in the control cabinet, as the Schur Star Systems example shows.

IoT applications

The second expansion stage includes access to an IoT application consisting among other things of dashboards for visualizing operating information, a data explorer for quick viewing of process data, a virtual image of the system as well as the Smart Rules module for a continuous comparison of the nominal and actual process values. As part of this, process data is visualized in real time and analyzed by algorithms. In case of deviations from the defined normal condition, the software automatically sends messages (via e-mail or SMS) to a predefined group of recipients.

Monthly reports and intelligent models

A comprehensive monthly report containing an analysis of the most important process data by Dürr experts gives system operators a quick overview. The monthly report provides insights into complex issues, among other things by evaluating the operating states and alarm messages, calculating key performance indicators, and making recommendations for improving the process sequences. The third expansion stage additionally uses intelligent models, which analyze deviations and trends on the basis of statistics and machine learning and forecast when maintenance will be required.

Detecting potential for optimization with data analytics

The continuous analysis of process data makes it possible to leverage previously unused optimization potential to improve resource efficiency. By modifying the control program and optimizing process parameters, it is possible, for example, to increasingly operate exhaust air pollution control systems autothermally, which significantly reduces gas consumption. The need for mechanical modifications can be identified by analyzing the process data. In addition, the intelligent models enable predictive maintenance, which not only increases the availability but also avoids over-maintenance of individual components.

All Dürr ovens – from the traditional oven to the EcoSmartCure compact to the innovative EcoInCure with body drying from the inside – can operate with the energy sources of the future. In addition to favored green electricity, conversion to hydrogen and biogas is also possible. As a pioneer in electric ovens, Dürr demonstrates its expertise not only in the electrification of new ovens but also in brownfield retrofits. The machinery and plant engineering company offers individual assessments for existing plants to develop an optimal conversion concept so manufacturers can achieve short conversion times, and outstanding cost efficiency. 

Reducing costs through energy efficiency
Further increases in fossil fuel prices are expected in the medium term, while the costs for regenerative plants are falling as the number of installed plants grows. 

"We have developed a complete concept with several energy efficiency modules so that car manufacturers can already leverage environmentally friendly green electricity for cost-effective production," explains Heiko Dieter, Product Manager at Dürr Systems AG. "With a state-of-the-art insulation concept, skidless conveyor technology, and our EcoSmart VEC oven control system, we are coming at this from many directions". 

Lowest exhaust air temperatures
The Oxi.X.RV air pollution control system works electrically according to the principle of regenerative thermal oxidation (RTO). Dürr is the only supplier able to offer a complete concept consisting of electrically heated ovens and electric exhaust air after treatment. Electric heating uses the RTO method, which decouples heating and air pollution control. Decentralized, compact individual units provide heat. The units have the additional benefit of streamlining the layout since large duct systems for supplying heat are no longer required. Highly efficient heat recovery means that manufacturers can use the energy in the exhaust airflow almost completely for heating fresh air. This reduces energy losses via the exhaust air to an unprecedentedly low level. 

Needs-based control of the electrical supply
Another energy-efficient tool is the predictive EcoSmart VEC fresh and exhaust air control system. The intelligent software regulates the oven's electricity consumption by tailoring the energy demand to the exact number of bodies in the oven and reducing consumption during operation at partial load. Switching to skidless conveyor technology like Dürr's traverse technology also saves energy since the oven heats less material which needs to cool down later.

No change to the painting process with electric body drying
Dürr notes a sharp increase in the demand for electric ovens. “Currently, we have several projects in the pipeline. As the only paint shop supplier, we can offer a complete package for the electrification of dryers and air pollution control, combined with energy efficiency technologies for reducing operating costs”, says Heiko Dieter. “We are putting all this into practice with products from our portfolio. For our customers, switching to electric body drying is completely risk-free. With no change in the usual Dürr quality and no change in the drying conditions, the only change is in the energy source".

Precise application guarantees results with millimetric accuracy

The clearance and work angle of the robot-guided applicator can be variably adjusted to easily access difficult body parts. Its needles are activated individually so that the applicator can apply sealant to the body with consistent precision and quality. Each needle can apply the material in jets or individual drops through the application nozzles – the robot speed and the amount of material determine the variable, high-frequency needle activation making the applicator extremely flexible. It can be used for seam geometries of different densities and widths that – without exception – exhibit a border with high edge definition and no overspray. Precise application and the ability to adjust material thickness as required ensure no sealant waste. Individual needle activation also prevents material doubling where the seams join. The resulting reduction in material use is an advantage that should not be underestimated, and not only for cost reasons: reduced material thickness leads to lower overall vehicle weight. Since the new applicator can work around add-on parts, studs, and holes, masking and cleaning become obsolete, saving you both time and material. These downstream processes can therefore be reduced or eliminated entirely.

Learning algorithms for overall equipment effectiveness (OEE)

An increased level of automation in sealing is a real benefit, not only for workstation ergonomics but for cost efficiency and environmental protection. Process optimization also plays an important role here. On the one hand, permanent monitoring of individual components such as pumps, temperature controls, dosing units, or valves support optimization. On the other hand, Dürr relies on AI to improve manufacturing processes. The DXQequipment.analytics software package analyzes machine data, detects quality problems in real-time, and optimizes maintenance requirements. This means that future predictions, for example, about a product fault or a plant component needing maintenance, will become more and more precise over time. Intelligent machine learning algorithms support maintenance, resulting in the highest possible plant availability.

Digital file for each body

The basis of DXQplant.analytics is quality information recorded digitally for each workpiece during the surface inspection. In addition, process parameters, alarms, and anomalies from the individual processing steps supplement the workpiece-related data records. This creates a digital file for each body that models the entire production and life cycle, including any faults found. Machine learning can help identify patterns and correlations in data records. If there are frequent contaminants in the paint, the software will detect this and immediately assign information about the underlying cause to the fault pattern.

Easier fault analysis

Detecting recurring paint defects is very laborious, and locating faults is time-consuming and expensive. DXQplant.analytics flags problematic fault sources to the quality manager and provides targeted help with analyzing the cause. Correlating graphics and automatically generated reports easily document insights to share with colleagues, workers, and management. Integrated documentation functions allow the DXQplant.analytics user to save and manage defined optimization measures and track their impact on quality. Therefore, DXQplant.analytics helps the paint shop operator increase the first-run rate in a targeted way, thus boosting overall equipment effectiveness.

Comprehensive service along the life cycle

Software solutions must always be kept up to date for users to leverage their full potential. With DXQsupport, Dürr offers its customers a comprehensive service package for use and maintenance of its digital solutions. Providing support for the entire software life cycle increases availability, performance and quality and maintains them at this level. In addition to regular updates, Dürr offers a team of experts who constantly monitor live production activity to react quickly in the event of failures or irregularities. These services are complemented by a comprehensive modular training catalog, allowing operators to leverage the full potential of their digital portfolio.

Improving sustainability

The innovative process shows its strengths not only in terms of possible design diversity and lower production costs. The invention can also improve the sustainability of individual paintshops. Among other things, the DXQ3D.onsite software provides support here: an initial measurement detects and compensates for any inaccuracies in the conveyor system or the body shop. A second sensor mounted on the robot measures the deviation of the car body to be painted from the reference pattern. The robot controller adjusts the painting paths in real time. The speed and tilt angle of the applicator are controlled so that the paint is always applied evenly and there is no overspray and no need for masking. In a standard production line that paints 110,000 car bodies per year, this saves more than 1.5 million square meters of film and 2.2 million meters of masking tape every year plus a lot of manual work. Another advantage is that the new process requires up to 30% less energy than the conventional method.

The Surface Technology Award has been run by the Fraunhofer Institute for Manufacturing Engineering and Automation since 2012. For the top position, technologies must convince in the criteria innovation leap, sustainability, enabler technology and industrial feasibility.

Permanent guest at awards ceremonies

Thanks to its innovative strength, the EcoPaintJet Pro has already won several prizes in Germany and abroad - including the German Innovation Award. It was also recently a finalist for the prestigious European Inventor Award, which is organized by the European Patent Office.

Dürr Assembly Products demonstrated what this looks like in practice to KOTSA officials on its test stand in Püttlingen. For the first time, the experts used a random vehicle off the street for this. They simulated two scenarios: The vehicle is in danger of leaving its lane, therefore a steering intervention is needed. The vehicle has to perform an emergency stop in response to the vehicle in front braking. Appropriate realistic traffic situations were depicted on a monitor. Radar signals simulated other traffic users to match the display on the monitor.

For Timo Wallscheid, x-road Product Line Manager at Dürr Assembly Products, the successful commissioning of the x-road curve is a major step in the testing of partially and fully autonomous vehicles: “For the first time, the actual reaction of safety-related systems on a vehicle that had not been prepared in any way was tested in a simulated traffic situation. The steerable x-road curve test stand from Dürr and the simulation environment from dSPACE complemented each other perfectly.”

Dirk Berneck, Senior Manager Engineering Services at dSPACE, views the new complete validation system from Dürr and dSPACE as decisive for the testing and homologation of highly automated vehicles by testing organizations, and explains: “Imaging sensors like radars and cameras are playing an ever-greater role here. dSPACE’s highly precise traffic and environment simulation with a comprehensive library of flexibly executable driving situations is an efficient way of validating vehicle and sensors on compact test stands.”

The public authority KOTSA is responsible for the PTI (Periodical Technical Inspection) in Korea. The x-road curve was installed and commissioned at its headquarters in Gimcheon, and officially presented to the public in mid-March. The event was attended by representatives from the Korean Ministry for Land, Infrastructure and Transport. The guests also included the Hyundai Motor Company and Mercedes-Benz Korea as well as reporters and representatives from other testing organizations like the German KÜS (an automotive monitoring organization made up of independent professional automotive experts).

Sensors and actuators in autonomous and semi-autonomous vehicles are extremely complex. On top of this, different software versions have to be compatible. Dürr Assembly Products, a subsidiary of the Dürr Group, therefore expects that test stands like the x-road curve will be indispensable in the future, especially as legislation will require such tests as proof of operational safety.

Use cases for digital expertise

Dürr is presenting its expertise in digitalization at the Hanover Fair using various use cases:

Flexible Manufacturing

The growing variety of products and increasing individualization are pushing conventional line layouts for painting to their limits. That is why the Paint shop of the future needs flexible and scalable production layouts. The use case "Flexible Manufacturing" shows the possibilities of flexible production, based on Dürr's box concept and integrating automated guided vehicles (AGVs). Dürr's control software guides the AGVs to the next process step in each case and ensures efficient utilization of all paint booths.

Holistic Production Control

More transparency and control along the entire value chain: the second use case is aimed at optimizing all manufacturing processes. Dürr's DXQenergy.management will also be presented for the first time in this context. The new product from the DXQ family offers the possibility of central monitoring of energy consumption in a production plant all the way to detailed analysis of individual consumption. The intelligent energy monitoring solution can also be used to display energy flows in production and respective energy costs.

Manufacturing Analytics and Intelligence

"From prevention to prediction" is the motto of the third use case. It showcases the extensive documentation of all available process data in the interaction of products of the DXQanalyze product family. With the help of artificial intelligence (AI) and machine learning, the products analyze collected data and thus detect potential errors or quality defects in real time. This helps prevent machine downtime and determine the most optimal maintenance times possible. The DXQanalyze product family recently won the Industry 4.0 Innovation Award and the Microsoft Intelligent Manufacturing Award.

VOCs escape along the entire line

The challenges involved in air pollution control for the innovative manufacturing process for monoblock aerosol steel cans are significant: Polluted exhaust air is emitted from almost 30 sources at temperatures that vary widely. In a three-stage process, the aerosol cans are painted or printed from the inside and outside. Unlike paper or plastic packaging, metal does not provide an absorbent substrate. The paint colors therefore contain up to 70 percent solvent. During the burning-in and drying process at temperatures of up to 300 degrees Celsius, the volatile organic compounds (VOCs) contained in the paints and varnishes are released. In addition to the three ovens, the three coating stations, tower storage, and various transport routes are relevant emission sources in aerosol can manufacturing.

Bake-out for reliable removal of deposits (self-cleaning)

As part of the manufacturing process, there is also a risk of the condensation of critical pollutants, giving rise to solids that can severely clog pipes and the air pollution control system. To purify the exhaust air effectively and, above all, economically, powerful regenerative thermal oxidation (RTO) with a thermal efficiency of up to 97 percent and purification rates approaching 100 percent is used. With an oxidation temperature of up to 850 degrees Celsius, this process even eliminates odor emissions. The Oxi.X RA system type, with over 100 references in this industry segment, also has a fully ceramic internal structure and a special bake-out process.

Heat exchanger as heat accumulator

The Oxi.X RA RTO from Mall + Herlan is rated for a maximum treatment capacity of 11,000 m³/h and pollution loads of 1 to 2 g/m3. In normal operation, which is equivalent to the range from 1.3 to 1.6 g/m3, the highly efficient heat exchanger reduces the operating costs to the absolute minimum through largely autothermal operation. What does this mean? The burner can be switched off completely, and no additional primary energy is needed to operate the air pollution control system. This is possible because the heat exchanger simultaneously acts as a heat accumulator by storing the excess energy in phases with high solvent concentrations. In subsequent phases with low pollutant concentrations, the excessive temperature level – i.e. the stored excess energy – is slowly lowered again and made available. This also saves natural gas. Dürr is increasingly employing this special principle of “thermal buffering” with fluctuating solvent concentrations to “smooth” the resulting fluctuating energy entries.

Environmental protection meets economy

For Mall + Herlan, the Oxi.X RA RTO proved to be the best solution both economically and ecologically. Regenerative thermal oxidation is not only a pioneering and reliable way of ensuring that no official limit values are exceeded, but the high oxidation temperatures and the extremely high degrees of purification achieved as a result mean there is no need for the determination or complex verification of odor emissions in accordance with the new "Technical Instructions on Air Quality Control 2021".

Multi-stage test setup

Originally founded for the aerospace industry, the private research institute Rescoll, has increasingly opened up to other industries. In addition to the EcoBell2 equippped ready2spray robot, which has already been in use, Dürr's EcoPaintJet is now being added to the test portfolio at then Pessac laboratories. The test process takes place in several stages: First, the customer sends the relevant paint or substrate to Rescoll, where it is checked whether the material is suitable for carrying out the test at all, which is then performed. Once the test has been successfully completed, the results are sent to the manufacturer, who is then able to adjust the paints and substrates to ultimately adapt Dürr's technology. Dürr already refers to the possibility of testing inks as well as the substrates first at Rescoll in use with the EcoPaintJet in consultation meetings with its customers. If the results are satisfactory to the customer, a suitable integrator is then found in the integrator network who will bring the Dürr equipment to the customer's premises ready for operation.

Best practice from the automotive industry

As early as 2019, Dürr's overspray-free technology called EcoPaintJet was introduced in the automotive industry, where it is already being used in series production. The process is characterized by its high efficiency, as masking is completely eliminated. This is ensured by a completely new type of applicator that applies the paint with absolutely sharp separation. This means that the coating lands exactly on the intended surfaces, but not off them - even in very small quantities. What has already proven itself in the automotive industry is now to be used in other industries as well. All applications in which paint is applied in lanes are possible.

No more overspray

The EcoPaintJet achieves its high precision because the applicator works completely without overspray. This describes the paint mist consisting of tiny droplets that is produced by other atomizers and ends up outside the target area. In the case of the EcoPaintJet, a filigree nozzle plate measuring just a few square centimeters prevents overspray from occurring. The nozzle plate forms the underside of the rectangular applicator and is provided with around 50 barely visible holes, which have a diameter of around 1 tenth of a millimeter. The paint is applied in parallel jets from a distance of 30 millimeters through them.

EcoPaintJet paints live at PaintExpo 2022

PaintExpo is the world's leading trade show for industrial painting technology and gathers the who's who of the industry every two years. This year, the trade show will be held in Karlsruhe from April 26 to 29, where Dürr will not only be represented with an impressive booth but will even demonstrate the overspray-free technology live to visitors with its EcoPaintJet.

For the challenging task of applying all paint types completely automatically in two-tone lines without any overspray, Dürr enhanced its EcoPaintJet system and came up with the EcoPaintJet Pro. This unique robot system with an overspray-free applicator and modified paint supply process includes all the components needed to meet these exacting requirements. In addition to an innovative cleaning process, it automatically checks the spray pattern, uses camera-based sensors for measuring the body as well as various software tools for robot control, generates the robot program, and adapts the painting program to the actual vehicle with accuracy down to tenths of a millimeter.

Innovative technology for more design variety

At the heart of the system is the EcoPaintJet Pro applicator, which, unlike a rotary atomizer, applies the color with the help of an intricate nozzle plate. Several dozen barely visible individual nozzles with a diameter of around one-tenth of a millimeter apply the color to the body in parallel streams from up to 25 millimeters. Since one hundred percent of the paint lands on the surface without any loss, two-tone paint jobs can be completed with more speed and less waste – even without masking.

Nozzles opening and closing independently in fractions of a second offer completely new design possibilities for carmakers. Based on the new application principle, design elements like decorative stripes or contrasting colors are applied to the body automatically. The EcoPaintJet Pro can paint large areas, apply patterns and directly transition between the two functions.

Fast color changes without any waste

From the beginning, Dürr designed the EcoPaintJet Pro to make color changes easy. Its design prevents paint accumulation which is crucial for fast switching between two paint shades with minimal losses.

This feature is also critical when working with 2C paints because they cure quickly. The fine nozzles can become clogged by even minimal residue left after rinsing. With the EcoPaintJet Cleaner, no waste is released into the booth environment because all cleaning and rinsing processes occur in a closed system. And no overspray means no need for an overspray separation system!

Fully automated individualization

The complex geometries of the body parts to be painted pose substantial challenges to the 3D measurement and programming of robot paths. The DXQ3D.onsite software helps operators configure the process parameters by automatically calculating the painting paths where the applicator hovers over the surface. An initial measurement registers and compensates for any inaccuracies in the conveyor technology or the body-in-white. A second sensor mounted on the robot measures the variation between the painted body and the reference model. The robot controller adapts the painting paths in real-time. The applicator’s speed and incline angle are controlled, so the color is always evenly applied without overspray. The development of the software tools is an ongoing process, with additions and improvements regularly incorporated.

Complete process layout flexibility

With EcoPaintJet Pro, car manufacturers can integrate overspray-free application not only into new plants, but also existing ones. Various processes that integrate at different points in the paint shop make this possible. For example, the contrast color can be applied to the base coat following intermediate drying or as a single-layer clear coat on the cured clear coat. Masking-free two-tone painting with EcoPaintJet Pro requires much less space and energy than a comparable, conventional line. Calculations show energy savings of up to 32 percent (based on the entire painting line), equating to a CO₂ emissions reduction of up to 33 kg per car body.

Dürr’s new process offers substantial benefits when it comes to manufacturing costs and environmental compatibility, too. No overspray means no need for overspray separation, and the fact that the rest of the body no longer needs film masking eliminates large amounts of waste. Another benefit is a better utilization of paint shops. Dr. Lars Friedrich, President & CEO Application Technology Dürr Systems AG, is confident that “printing instead of spraying is the future of automotive painting.” “Our process involves no overspray and no masking, even for vertical surfaces. In terms of cost efficiency and sustainability, Dürr has taken another step in the right direction with the EcoPaintJet.” A car manufacturer is currently integrating the new process in its manufacturing facilities and expects it to be up and running in the second half of 2022.

Gather, evaluate, predict

The products from the DXQanalyze family gather available machine and plant data, like process and workpiece information, and evaluates it. Possible quality defects in workpieces as well as imminent wear on plant components can be identified at the point of origin, and appropriate actions can be defined. The data is visualized and can be historically evaluated over long periods of time, in some cases in real time. In combination with machine learning, large amounts of data including historical data can be used to continuously make accurate forecasts for the future. This is where the application DXQequipment.analytics comes in. DXQplant.analytics analyzes the data and the documented workpiece quality on a superordinate level, and in this way can draw conclusions about the operation of individual systems along the value chain. Historical data on workpiece quality is used as a basis for defining patterns and establishing correlations to machine and system states. In this way it is possible to adjust the plant operation at an early stage in order to increase the painting quality in production.

Machine learning ensures greater transparency

Using machine learning methods, the software products can identify and predict wear on components and anomalies in production systems on the basis of rules and data. This takes transparency about the operating behavior of machines and systems to a whole new level. DXQanalyze provides information based on specific systems and uses, enabling it, for example, to forecast the remaining service life of system components or establish links between quality results and machining processes.

Contribution to digitization impresses jury across all categories

The award focuses on products that offer pioneering solutions for industrial production. In a selection process consisting of several stages, DXQanalyze impressed the jury across all categories: “What is impressive about the Dürr solution is the level of maturity already demonstrated by the AI and the forecasting of anomalies. This technological development will permit enormous cost savings. Production plant failures will be reduced as well as material rejects,” says jury member Prof. Dr. Oliver Niggemann of the Institute of Automation Technology at the Helmut Schmidt University / University of the German Federal Armed Forces Hamburg, in praising the smart software.

The software can be used in new and existing systems, depending on the application. Installation on individual systems (on edge), in a company’s internal network (on premise), or in a cloud environment is supported. The software can be integrated in different IT systems and adapted to customers’ different architectural requirements.

Universal use for all painting tasks

The EcoBell4 Pro can be used for interior and exterior painting in addition to all paint materials. The portfolio includes atomizers for both water-based and solvent-based paints in. The EcoBell4 Pro can serve both existing and new painting needs, from 4x1C painting for the base coat to 3x2C solutions for clear coat and all combinations in between.

The perfect combination: EcoBell4 and EcoProBooth

The flexibility and universality of the EcoBell4 Pro are best demonstrated in combination with the new EcoProBooth. With its smart painting booth design, the EcoProBooth combines all painting tasks in just one box, including the new, innovative EcoBell4 Pro Ux atomizer. The same bell disk/shaping air ring and external charge system handle all interior, exterior, and metallic painting (bell-bell process). The atomizer equally applies narrow spray jets inside the body and wide spray jets on the outer skin with Dürr’s usual high efficiency. Another innovation is the patented exchangeable external charge systems, which individually combine within the Pro series. Dirty electrode rings are simply discarded and replaced with clean ones in one of the four service cubicles of the EcoProBooth – without stopping the system for cleaning to take place.

Fault prevention with RFID technology

Whether in the bell disk, the shaping air ring, the turbine or the atomizer: Dürr adds RFID technology to improve processes directly in the paint booth and maintenance. RFID (radio frequency identification) is a wireless data exchange between a transponder and a writing or reading device. Since Dürr’s transponders can read and write operating data, components can store data directly and track wear.This technology provides operators with reliable information about the current condition, enabling them to make optimum use of the service life of components and plan maintenance times in advance. However, it is not just the parts needed for the maintenance work displayed. Visualization of required work steps occurs at a maintenance station with an RFID connection in assembly videos using defined sequences. Typical sources of error, such as the incorrect assignment of bell disks or air shaping rings after a break for cleaning, can also be eliminated thanks to RFID. The system detects the incompatible component when it reads out the data and warns the operator via a pop-up window even before the painting process starts. This feedback increases system availability and positively affects the first-run rate

All EcoBell4 atomizers are equipped with RFID technology. In addition, Dürr has enhanced the external charge system to make it even more efficient. Other new features include a robust rotation speed acquisition system designed for easier maintenance, a vibration sensor integrated into the robot that detects imbalances in the bell disk and turbine before they cause damage, and a protective stocking with a patented attachment concept. It reduces soiling so that at least four hours of painting are possible without cleaning the atomizer in between.