A complete process, from start to finish.
One continuous 31-step demonstration. Both layouts use the specified PoWa 20 with ATEX-certified protection package.
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. Fixed raised robot pedestal, 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. Connected base approximately 3.7 × 3.35 m, with a vertical robot 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.One connected base. Exchangeable interfaces.
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 concept fork openings, 580 mm pitch.
- Fold-flat grips, removable T-handle provision and rated lifting-eye interfaces.
- Internal mast and broad contact pads; lower positive retention. No top clamp.
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
- Separate scanner, sander, spray and blast-ready positions.
- Tool ID, lock feedback, capped services and master shroud.
- Scanner returns to a dry covered compartment.
- C-Track remains fixed while its shutter retracts.
- Wet flush catchpot segregated from the optical bay.
- Filtered dry purge, pressure feedback and cleanliness release.
Actual abrasive-blasting trials and recovery plant are a separate scope; the future interface is reserved.
Modular frame + services
- Bolted machined splices, locating features and bonded common rails.
- Operating feet carry the working load; wheels are for relocation.
- Robot, table, tool cabinet and tracking datum share the same structure.
- Covered service trunking, keyed disconnects and hose dress pack.
- Final robot 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 straight loading lane.
- 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.
Purpose, design and the full operating sequence.
The 9:48 film explains the POC and final cell, shows the layout dimensions and continues through every process step.
Use the direct MP4 download above, then open it in your device's video player.
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.