ABB and ESS partner to enhance automotive paint shop efficiency

In a significant development within the automotive industry, ABB, an industrial automation specialist, has joined forces with Engineering Software Steyr GmbH (ESS) to enhance the energy efficiency and environmental performance of automotive paint shops. This collaboration aims to revolutionise the painting process, traditionally known for its high energy demands and material intensity, which contribute significantly to the overall emissions in vehicle manufacturing.

According to a research paper titled “Life Cycle Environmental Assessment of Paint Processes” authored by Stella Papasavva, Sheila Kia, Joseph Claya, and Raymond Gunther from General Motors Co., automotive painting is the most emissions-heavy manufacturing operation. This partnership is set to mitigate these impacts while driving down costs by as much as 30 percent.

As part of their collaboration, ABB will incorporate ESS’s advanced simulation technology into its RobotStudio platform, recognised globally as a leading offline programming and simulation tool for robotic applications. This platform is available across various technologies, including desktop, cloud, and augmented reality, making it a versatile solution for manufacturers.

The focus of this initiative will be on optimising the complex series of processes that characterise automotive paint facilities. The painting operations involve over 20 intricate steps, which range from degreasing, electrocoating, sealing, and spraying to the final baking process. Each of these steps comes with a set of varying parameters, including material viscosity, adhesion, and drying time, which need thorough testing and optimisation before a new vehicle model can go into mass production. This meticulous procedure is not only time-consuming but also costly.

In speaking to Design News, Marc Segura, president of ABB’s Robotics division, noted, “Delivering faster and more energy-efficient solutions for the paint process is the final piece of the puzzle in digitalizing the manufacturing transition in the automotive industry.” He highlighted that the collaborative innovations are expected to reduce vehicle development time by up to a month and generate substantial cost savings, thereby enhancing manufacturers’ competitiveness and resilience. He further elaborated that a manufacturer producing 300,000 vehicles could potentially decrease CO2 emissions by nearly 17,000 tons annually, a figure equated to the emissions generated from flying an airliner around the Earth 19 times.

The partnership will also leverage ABB Robotics’ expertise in smart automation solutions, which includes innovations like PixelPaint, an inkjet-style paint head that ensures precise detailing, and the RB1000i-S digitally-enabled atomiser, achieving an impressive 99 percent transfer efficiency. This efficiency allows for reduced paint consumption and material waste.

Dr. Martin Schifko, CEO of ESS, emphasized the importance of providing all manufacturers, regardless of size, with access to modern digital tools that facilitate innovation. He remarked, “We recognise how crucial it is for all players — large, medium, and small companies — to have access to the right digital tools for innovation.” He pointed out the existing challenges faced by smaller enterprises in adopting complex digital solutions, expressing a commitment to making their simulation technology more accessible in an increasingly competitive landscape. Schifko’s vision is to empower manufacturers to innovate with greater speed and reduced environmental footprints, aligning with the industry’s demands for sustainability and efficiency.

Source: Noah Wire Services