Rippert's wheel coating plants
Wheel coating plants of the highest calibre
Aluminium wheels can make or break a car’s image with their individual design. Many car owners see them as a sign of prestige, a further feather in their cap. Car manufacturers expect the quality to match this. They expect aluminium wheels which are flawlessly painted in precisely defined colours and which meet all quality standards, all while complying with every rule, regulation and environmental consideration including during the production process. In order to live up to these standards, coating companies are forced to adopt the most cutting-edge machinery and systems – irrespective of the size of their operation and the quantities they produce.
Rippert wheel coating plants have all options on offer. Technically innovative, modular design, individual customisation, high-precision surface coating, environmentally friendly and sustainable, energy and cost effective – these are product features which have been continuously perfected over 50 years of design and production success.
Innovative solutions ranging from process engineering and material-handling technology to automation and environmental protection can be selected according to the customer. The focus is always on the quality of the coating, the availability of the plant and the flexibility to cater for new processes and improvements. Both in a small and a big way.
The controlled downward air velocity in the coating chambers as well as the use of electronic gripper systems can serve as examples here.
The division of the plants into warm areas, “dirty areas” and clean areas already predetermines a clear quality structure in the planning stage.
SIMPLE CONTINUOUS FEED PLANT OR HIGHLY FLEXIBLE COATING PLANT
The processes used depend on the desired surface quality. We distinguish between a three-layer paint system for standard wheels and up to six layers for machine-polished wheels.
The most important procedural steps are:
- Chromium-free pretreatment including cleaning and anti-corrosion baths (12 to 14 zones)
- Priming with light-grey, black or coloured powder
- Base coat predominantly in silver colours
- Application of a transparent layer with paint or polyester powder, or alternatively acrylic powder
For machine-polished wheels there may be an additional coating of anti-corrosion paint, clear powder and/or clear paint (also as an ABD coating). Normally, the different procedural steps are separated by conveyor equipment and linked by the automatic transfer of workpieces by articulated robots. The way the workpieces are transported has a very significant impact on product quality.
Nowadays, overhead circular conveyors are only still in use in the pretreatment area; in the coating areas, the transportation of workpieces lying down is regarded as state of the art.
As far as control systems are concerned, it goes without saying that all Rippert plants ensure seamless product tracking. The data entered for each wheel as it enters the facility accompanies it through the entire plant – the data sets are passed on from one piece of material-handling equipment to the next. This information is then available anywhere in the plant where it is needed. Furthermore, all quality assurance regulations can in this way be fulfilled and documented.
Using standardised modules as a basis, the plant is individually tailored to the requirements of the customer in terms of capacity, spatial considerations and coating requirements. This must not, however, stifle the flexibility required for future improvements. Optimisations as well as the implementation of specific customer wishes will always dictate operations. Continuous improvement is an absolute must for all new plants.
Rippert wheel coating plants stand for cost efficiency.
The implementation of environmentally friendly technology yields considerable energy savings. The cornerstone of cost efficiency is the high manufacturing quality of the basic systems. Robust facilities can achieve less downtime over a long lifetime. How well the plant can be cleaned and maintained is another important consideration for coating plants. Painstakingly economising on the consumption rates of electricity, gas, water, compressed air as well as the required chemicals minimises ongoing costs. Short, effective pathways and transparent processing chambers facilitate the quality checks of operators.
These are the most important factors to consider for a consistently high coating quality and extremely low reject rates.
Energy-efficient technology plays an increasingly important role in production. Laws are becoming more stringent and complex. Customers themselves usually expect an even higher standard than this, which is also stipulated in supply contracts.
Rippert wheel coating plants – a big advantage for suppliers
FROM THE BASIC VERSION TO ALL THE TRIMMINGS
Even in the basic version, Rippert wheel coating plants meet all current requirements in terms of quality, throughput speed, environmental compatibility and the standards of the automotive industry. Through a diverse range of performance packages, modules and technical features, the plants can also undergo further optimisation in terms of control systems, quality, energy conservation and unit costs.
MOSTLY PREFABRICATED – LOW SETUP TIME
Various units of the wheel coating plant are assembled, wired up and outfitted with tubes in our factory in Clarholz, where they are tested as complete systems before being delivered to the customer. This high degree of prefabrication reduces setup times enormously and ensures that all tested systems are in working order.
SYSTEMATIC CONTROL SYSTEMS
Programmable logic controllers with an integrated visualisation module are a matter of course at Rippert. Alongside a detailed software application which is continually being optimised in this field, we also aid energy conservation with integrated energy management in the machine controllers to gather data on and record total energy consumption.
CARRIED OUT WITH COMPETENCE, PURPOSE AND EXPERIENCE
All Rippert plants contain the technical know-how of 50 years’ experience in plant design, production and assembly in the surface coating and dedusting industries. That also applies for the growing field of aluminium wheel coating.
Through the acquisition of experienced employees in this business segment, Rippert is entering the field of aluminium wheel coating plants with a wealth of established experience.
This endeavour is being carried out in numerous existing wheel coating plants – of course Made in Germany.