company news about A truly 'adaptive, traceable, and contamination-free' coating line

Intelligent Coating Synthesis Line
Zinc-Aluminum Coating​

01 Digital Intelligent Coating Synthesis Line
 

The automotive industry is accelerating its shift toward lightweight and electrified designs, leading to an increase in the number of fasteners and higher reliability requirements. Additionally, OEMs are demanding greater traceability and consistency in coating processes, rendering traditional coating methods inadequate for future quality management systems. How to achieve more flexible production scheduling, traceable processes, and batch segregation while ensuring stable quality has become a pressing challenge for an increasing number of manufacturers.

Addressing this industry pain point, Junhe has developed a digital and intelligent coating synthesis line based on extensive experience in coating processes and equipment. By reengineering the underlying architecture and system logic, the solution has established three core capabilities: flexible design, traceability design, and anti-mixing design.

02 Three Core Competencies

Flexible design: No longer "one stoppage, entire line restricted"

Traditional coating production lines often rely on mechanical rigid connections such as incline conveyors and secondary rotations, lacking buffering and decoupling between processes. If one process is halted due to paint changes, equipment maintenance, or parameter adjustments, the entire line is forced to shut down, resulting in low capacity utilization, difficulty in inserting orders, and slow batch transitions.

Junhe's digitalized coating synthesis line structurally breaks these limitations:

• AGVs replace rigid connections, eliminating forced serialization between processes.

• Buffer zones are set up at line-side warehouses to enable batch consolidation and cycle time adjustment.

• Individual equipment can operate and be maintained independently, avoiding chain-reaction shutdowns.

Additionally, the system integrates deeply with MES to dynamically schedule production based on order deadlines, batch processes, and equipment conditions, ensuring more orderly planning, stable cycle times, and higher equipment utilization.

For workpiece handling, robotic flexible transport is introduced, reducing the risk of damage from high drop heights in traditional rigid connections and effectively ensuring stable compliance with thread gauge standards.

Traceable Design: Ensuring Every Coating Batch is Documented

In high-quality coating processes, "doing it right" is crucial, and "traceability" is equally important.

Junhe's digital coating production line, centered around MES, establishes a clear and comprehensive traceability logic:

After manual inspection and weighing of incoming materials, they are scanned into frames to create records.

Scanning information is entered into MES, where the system automatically matches the corresponding process sheet and generates a production schedule.

When workpieces reach key stations such as shot blasting, coating, and curing, scanning instantly retrieves the required process.

The industrial computer interacts with MES,

automatically issuing process parameters and task instructions,

while real-time processing data and equipment status are transmitted back.

Ultimately, each batch forms a complete data chain:

Materials → Process → Equipment → Parameters → Status → Results, truly achieving "process traceability, result verification, and accountability tracking."

Anti-mix-up design: Keeping "mixing risks" out of the system

Material mixing is one of the most unacceptable yet most common issues in fastener coating processes.

Junhe has made anti-mixing a core component of its digital-intelligent quality control system. By implementing multiple mechanisms—physical isolation, system verification, and data tracking—it has built a comprehensive anti-mixing system covering the entire process.

① Physical Isolation: Error Prevention by Design​

• Three-layer/four-layer furnace trays with step-by-step operation ensure full physical separation throughout the process.

• Dedicated processing baskets/fixtures are used—one basket per batch.

• Side-line storage is zoned to prevent cross-batch mixing or incorrect retrieval.

② System Verification: Stop on Error​

• Mandatory barcode scanning at loading and key workstations for verification.

• Equipment locks if the batch and process parameters do not match.

• AGV tasks are batch-bound, prohibiting cross-batch transfers.

• Robots perform batch recognition before handling to prevent misplacement or incorrect retrieval.

③ Data Tracking: Full-Process Monitoring​

• MES displays real-time workstation locations, quantities, and statuses for each batch.

• Automatic counting upon furnace exit and line exit, compared against expected quantities.

• Immediate alerts for quantity discrepancies or process anomalies.

• Automatic archiving of batch data across the entire line enables rapid traceability and review.

Through these layered mechanisms, Junhe minimizes human intervention risks and achieves a true "zero-mixing" operational model.

JunHe's digital coating synthesis line is not just a simple stacking of equipment, but a redefinition of the operation mode of the coating production line from the structural, systematic, and management logic levels. It provides a more stable, reliable, and long-term valuable development path for zinc-aluminum coating processing of fasteners.