Mastic and Adhesive Application with Electric Pumps

As the automotive industry transitions toward electric vehicles, manufacturing facilities are also shifting their production techniques to electrical systems. In factories and production facilities, traditional pneumatic-hydraulic systems in paint, sealant, and adhesive lines are being replaced by next-generation electric units. Automotive facilities' body shop sections are working with stronger and lighter material combinations. Composites, ultra-high-strength steel and various aluminum alloys, for example. When different materials need to be joined, adhesive chemicals rather than welding become the priority. In the electric vehicle production process, which is also on Turkey's agenda, there is greater demand for adhesives and sealants compared to standard vehicle manufacturing processes. However, joining techniques that use less welding technology and more chemicals carry certain application challenges.

To perform correct dosing, various system components are needed: external dosing systems, counters (shot-meter), valves, sealant regulators and the like.

In Graco's EFlo IQ series, many components that are mandatory for use on robot arms in traditional pneumatic systems are not needed. Dosing is performed via a servo-controlled electric pump at a different point from the robot arm. The absence of the need for these counters in the electric pump series provides flexibility in robot selection. Since the weight carried by the robot arm will be reduced, smaller robots can be preferred, providing savings both in cost and in the production area covered by the robotic system. Robot arms contain control panels, various fluid line connections and cables in addition to counters, and the high number of parts increases maintenance and spare parts costs; maintenance not performed in time leads to system performance degradation and defective part production. In the electric Eflo system, the quantity and flow of the chemical is dosed by the system at the barrel pump outlet, with speed and motion controlled via servo-based control systems. Sensors at different positions on the electric pump line monitor the pressure of the chemical and indirectly its flow from the barrel containing the chemical to the application point at the robot tip. When continuous low-volume application is involved, electric systems are much more efficient than pneumatic/hydraulic systems. Eflo IQ, which provides system integration with PLC through Ethernet/IP, Profinet, Devicenet, Profibus and Discrete I/O communication interfaces, also offers the advantage of quieter operation (<70 dba) thanks to its electric motor compared to its pneumatic-hydraulic counterparts. With the 3 different options it offers in dispensing valves mounted at the robot arm tip, it meets application needs in the automotive sector and among Tier 1 suppliers. With this unit, discharge can be performed from standard barrels of 20, 60 and 220 liters. Heating, which is required for some chemicals, is available as an option. Application of sealants and adhesives up to 70°C is possible. With electric pumps capable of reaching pressures up to 207 bar, application rates between 10 cc and 3200 cc per minute are achievable. Different valve and programming options allow for various application profiles. Genmar, which has been operating as a "solution partner" for industrial facilities and especially the automotive and supplier industry since 1986, is at your side with its experience in the installation of these new products to our country's automotive facilities as well as the global market. You can contact us for presentation and demonstration.