company news about A truly "adaptive, traceable, and non-mixing" coating production line

Intelligent Digital Coating and Synthesis Line
 

Zinc-Aluminum Coating

01

Intelligent Coating Synthesis Line

With the accelerated advancement of automotive lightweighting and electrification, the number of fasteners has increased, reliability requirements have risen, and OEMs have put forward higher demands for traceability and consistency in the coating process. This has rendered traditional coating processing modes unable to meet future quality management systems. How to achieve more flexible production scheduling, process traceability, and prevent batch mixing while ensuring stable quality has become a practical challenge faced by more and more processing enterprises.

Focusing on this industry pain point, Junhe, based on long-term practice in coating processes and equipment, has built an intelligent coating synthesis line. It has reconstructed from the underlying architecture to system logic, forming three core capabilities: flexible design, traceable design, and anti-mixing design.
 

02

Three Core Capabilities

I. Flexible Design: No Longer "One Shutdown, Entire Line Restricted"

Traditional coating production lines mostly adopt mechanical hard connection methods such as climbing machines and secondary rotation, lacking buffering and decoupling between upper and lower processes. Once a certain process is paused due to paint change, equipment maintenance, or parameter adjustment, the entire line is forced to shut down, resulting in low capacity utilization, difficulty in inserting orders, and slow batch change.

Junhe's intelligent coating synthesis line breaks this limitation structurally:

AGVs replace hard connections, and processes are no longer forced to be in series

Line-side warehouses are set up for turnover buffering to realize batch order collection and rhythm adjustment

Each individual equipment can operate and be maintained independently, without连锁 shutdown

At the same time, the system is deeply linked with MES, and dynamically schedules production according to order delivery date, batch process, equipment working conditions and other information, making production plans more orderly, rhythms more stable, and equipment utilization higher.

In the workpiece transfer link, robot flexible handling is introduced to reduce the risk of collision caused by large drop height in traditional hard connections, effectively ensuring the stable qualification of thread go-no-go gauges.

Traceable Design: Make Every Batch of Coating Traceable

In coating processing with high-quality requirements, "doing it right" is important, and "being traceable" is equally critical.

Junhe's intelligent coating synthesis line takes MES as the core and builds a clear and complete traceability logic:

After incoming materials are inspected manually, weighed and divided, they are put into frames and scanned for archiving

The scanned information enters MES, and the system automatically matches the corresponding process sheet and generates a production schedule

When the workpiece reaches key stations such as shot blasting, coating, and curing, scanning the code will call up the process

Industrial computer interacts with MES,

Process parameters and task instructions are automatically issued,

Actual processing data and equipment status are transmitted back in real time

Finally, each batch forms a complete data chain:

Incoming materials → Process → Equipment → Parameters → Status → Results, truly realizing "process traceable, results traceable, and responsibility traceable".

Anti-mixing Design: Keep "Mixing Risks" Outside the System

Material mixing is one of the most unacceptable but most likely problems in fastener coating processing.

Junhe regards anti-mixing as an important part of intelligent quality control, and constructs a full-process anti-mixing system through multiple mechanisms of physical isolation + system verification + data tracking.

① Physical isolation, inherent error prevention
Three-layer furnace/double-layer furnace pallet loading, step-by-step operation, full physical isolation

Independent processing baskets/tooling, one basket for one batch

Line-side warehouses are stored in partitions, and different batches are not mixed or taken by mistake

② System verification, stop if wrong
Forced code scanning verification at frame entry and key stations

If the batch does not match the process, the equipment is prohibited from starting

AGV tasks are bound to batches, and cross-batch handling is not allowed

Robots identify batches before picking and placing to prevent wrong placement and picking

③ Data tracking, full monitoring
MES displays in real time the station, quantity and status of each batch

Automatic counting when出炉 and outgoing, compared with the expected quantity

Immediate alarm for abnormal quantity and process

The batch data of the entire line is automatically archived, supporting rapid traceability and review

Through the superposition of multiple mechanisms, the risk of material mixing caused by human intervention is minimized, and a truly "zero mixing" operation mode is realized.

Junhe's intelligent coating synthesis line is not a simple superposition of equipment, but redefines the operation mode of coating production lines from the aspects of structure, system and management logic, providing a more stable, reliable and long-term valuable development path for fastener zinc-aluminum coating processing.