A complete process, from start to finish.
R3: raised PoWa, open stacker lane and permanently connected spray nozzle. Run the complete 31-step process for POC or final design.
Covered during wet / dusty operations. Open only after the clean-release condition.
Motion and waiting periods are compressed for review. Robot geometry is ABB-based; part, fixtures and peripheral equipment are concept models. This display is not a measured trial result or an exact-CAD collision release.
Prove the process before building the production cell.
Understand the actual part
Measure the uncoated composite surface. Establish a stable fixture datum and identify edges, chamfers, occlusions and unsupported honeycomb regions.
Control coating build
Apply the coating, correlate pre/post geometry with a qualified direct reference, and develop the 1.0 / 1.5 mm target-zone process.
Correct and verify
Remove approved excess using compliant sanding, protect thin and invalid regions, then clean and remeasure. Record process and cycle evidence.
AETEC in-house POC
1.4 m customer samples. 1,050 mm fixed robot mount, 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. Open-front connected base approximately 3.7 × 3.35 m. Robot mount starts at 1,050 mm above floor, with a vertical lift study for upper access.
Retain common fixture, docking, tool and protection interfaces. Engineer the production frame, plant, services and control architecture using the POC evidence.
Robot selection
Option 1: ABB PoWa 20, 20 kg, with the user-specified ATEX-certified protective package. Design includes supply/purge interfaces, pressure monitoring and package-ready inhibit. The certificate number, exact covered configuration and installation conditions belong in the supplier release dossier.
Option 2: ABB IRB 5500-22 FlexPainter, 13 kg at the wrist, for the spray alternative. Its mounting and loads require a separate layout / structural review; sanding remains a separately qualified duty.
Every step stays in the same simulation.
Select a step to inspect it, or use Play complete cycle to run from preparation through unloading without changing scenes.
Air-clearance study
t = 60V / (ηQ) × ln(C₀/C), V = 63.756 m³, illustrative residual 1%. Five minutes is an example minimum. Measured atmosphere, residues, temperature and coating cure are separate release conditions.Thickness study
Select a map cell. Synthetic values, not POC measurements.
Blue: thin · green: study band · coral: excess · grey: invalid. Target changes from 1.0 to 1.5 mm at the axial mid-point.Open access. Raised cobot. Permanently connected spray.
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
- Scanner, sander and blast-ready exchange bays; no detachable spray bay.
- Spray nozzle, material hose and air line permanently connected to the wrist; adjacent tools exchange through the covered changer.
- Scanner returns to a dry covered compartment.
- C-Track+ Elite remains fixed while its full-width shutter retracts.
- Wet flush catchpot segregated from the optical bay.
- Filtered dry purge, pressure feedback and cleanliness release.
The permanent spray assembly remains during every scan / sand operation. Its shield closes during inactive use. Combined payload, moment and hose loads need the tooling review. Blasting trials and recovery plant remain a separate scope.
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 mount raised to 1,050 mm; final lift concept up to 900 mm 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.
- Extracted cleaning trolley and controlled waste / flush containment.
- 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.
Manufacturer reference geometry
MetraSCAN BLACK+ Elite: 289 × 235 × 296 mm nominal scanner envelope. C-Track: 1,031 × 181 × 148 mm nominal envelope. The R3 models reproduce the black marker cage, twin scanner cameras and long stereo tracking bar from official reference imagery. Mounts, shrouds and interfaces are concept designs, not OEM CAD.
Updated layout and full-cycle simulation preview.
R3 preview with on-screen captions: raised cobot, clear stacker access, detailed optics and permanent spray connection, followed by every process step. Demonstration time is accelerated; no narration.
Download the MP4 and open it in your device video player.
Previous R2 narrated walkthrough · archived design
The 9:48 R2 film explains the POC purpose and earlier design. Its frame, robot elevation and detachable spray-head arrangement are superseded by R3. Use the current simulation for the revised mechanism.
Proposal and quotation
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 · R3
Detailed budgetary quotation · PDF
Current R3 design update · PDF
R2 background design sheets · superseded arrangements marked by R3 update
Web app: R3-20260921. R2 proposal and quotation remain the commercial baseline; R3 supersedes the frame, elevation, optics and spray-connection arrangement. This design update is not a new firm quotation.