The plant design of the moulded part flocking offers the ideal conditions for the large-scale production of elaborately designed, three-dimensional objects, using the automated and innovative flocking technology. The moulded part flocking has already proven itself over decades in the automotive industry, for the flocking of glove boxes up to the centre console as well as other industrial branches, such as in the furniture industry for aesthetic features. In this case, the plant design covers the large-scale production of several hundred thousand pieces, complicated three-dimensional objects, requiring a minimum of manpower. The technique of electrostatic and pneumatic flocking is used for the ideal flocking of concave as well as convex geometries.
Moulding flocking process:
1. Withdrawal from material
Three-dimensional moulding flocking is possible as an inline process, whereby the product is removed directly from the production machine by hand and then passes through the flocking process automatically.
Furthermore, there is the possibility of offline flocking, in which case the object is transported to the material storage and automatically or alternatively manually inserted from there into the flocking machine.
The adhesive coating is applied in an air-conditioned robot booth. A handling robot loads the conveyor belt of the automatic adhesive coating line and removes the coated objects. They are then transported to the conveyor belt of the automatic flocking line. The flocking is carried out in several flocking zones by means of robots or linear systems. All individual process steps can be automated by robots or carried out by manual distraction.
After the three-dimensional objects have passed through the pre-cleaning unit, they are removed by robot or manually and, where necessary, manually cleaned by an operator, resulting in a final optical quality control. The products are then palletized or conveyed onto a conveyor belt.
In order to achieve a uniformly dense flocking, an optimal adhesive coating is of utmost importance. The adhesive can be applied manually in spray booths or automatically by robots.
In order to be able to flock at a high quality level, the use of robots is often indispensable. The three-dimensional object is detected by sensors when it is conveyed into the flocking booth, the robot is coded with the required program or is detected by means of camera technology, which provides an optimal flocking result.
After completion of the flocking process, the program-controlled flocking robot cleans the three-dimensional object by means of additional blowing nozzles, which are installed separately on the robot arm.
For high-quality flocking of three-dimensional objects, it is imperative to work with support in addition to the purely electrostatic application process. Only a suitable air flow enables the interior of deeper three-dimensional objects to be flocked correctly. We carry out electrostatic-pneumatic flocking in various degrees of automation, depending on individual requirements and wishes.
In the throughput process, the process steps are divided into clocked work steps to achieve a high throughput. The plant offers continuous production and a solid and durable machine frame for large series production.
The integrated blowers allow ideal climatic conditions to ensure a constant machining process and to maintain the necessary climate in the flocking booth. Using the robots, the individual work steps can be carried out automatically or, depending on the complexity, can be effected by lift-swivel units.
With a central flock storage container, the entire system can be supplied with new flock and the electro-pneumatic units can be individually adjusted. By adjusting the speed of the fan, the air flow and the delivery rate of the flock of the electro-pneumatic units is regulated and thus enables precise dosing.
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