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Monday, December 11, 2006

Mercedes paints their cars virtually first
The DaimlerChrysler researchers are developing special calculation methods to optimize painting processes. Even prior to production start-up, they can thus determine how a vehicle body can be painted as efficiently as possible or how an existing painting process can be improved. This early planning helps cut costs and enhances planning reliability.

The path of thousands of paint particles is traced by computer in the spray painting process - from the time they leave the spray nozzle until they make contact with the component. The experts must take into account that not all particles actually reach their destination; the proportion of impacting particles is a measure of process efficiency.

The DaimlerChrysler researchers calculate the dynamics of the paint particles under the influence of the diverting air stream and the electric field applied, whereby the particles are subjected to a large number of physical forces. With the help of this simulation, the expected thickness of the paint layer can be forecast. The calculations also allow predictions as to the best procedure for applying the paint - especially for problem areas such as cavities and protrusions on the body. The researchers can thus determine the ideal conditions for the most diverse vehicle geometries.

For the first coat of paint the body-in-white is not sprayed, but immersed in a bath. This method is known as cathodic dip painting. A wide range of effects must be taken into account for this process, such as air pockets during immersion or excess paint fluid removed with the body from the bath.
posted by Muamer Hodzic @ 12/11/2006 09:41:00 AM    
 
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