Case Studies

Challenge

A major Chinese automotive OEM required a complete vehicle body painting system for their new manufacturing facility. The project demanded high-volume production capacity of 200,000 vehicles annually while meeting stringent Class A finish requirements for both interior and exterior surfaces. The multi-coat process (mid-coat, topcoat, clearcoat) required precise coordination across multiple painting stations with integrated door/lid opening systems.

Solution

TD delivered a turnkey robotic painting line featuring 32 Yaskawa painting robots with Ransburg Robobell electrostatic rotary atomizers. The system includes: mid-coat external spray (3 robots), topcoat internal spray (4 robots + 2 lid-opening + 4 door-opening), topcoat external spray (6 robots), clearcoat internal spray (4 robots + 1 lid-opening + 4 door-opening), clearcoat external spray (4 robots), plus UBS and UBC sealing stations (4 robots total). Full process coordination ensures consistent finish across all vehicle surfaces.

Outcomes

• 200,000 vehicles/year production capacity achieved
• 32 integrated robot systems operational
• Class A finish quality on all surfaces
• Full interior/exterior automation with door/lid handling

Challenge

A leading Chinese EV manufacturer needed high-quality painting systems for plastic exterior components including bumpers, mirrors, and trim parts at their Wuhan facility. The challenge involved achieving consistent finish on complex plastic geometries while maintaining fast cycle times (65-96 seconds per fixture) to meet aggressive production schedules. Flame treatment was required for plastic adhesion.

Solution

TD engineered two specialized robotic cells using ABB robots with ABB electrostatic rotary atomizers. The bumper line features: flame treatment station (1 robot), primer spray (1 robot), topcoat spray (2 robots), and clearcoat spray (1 robot), achieving 96-second cycle time. The component line includes primer, topcoat, and clearcoat stations with 5 ABB robots total, achieving 65-90 second cycle times. Both systems feature automated recipe management for multiple part variants.

Outcomes

• 65-96 second cycle times per fixture
• Integrated flame treatment for plastic adhesion
• Multi-variant recipe management system
• Consistent Class A finish on complex geometries

Challenge

A construction equipment manufacturer in Zhuhai required automated painting for large structural components including excavator booms, arms, and frames. Manual spraying of these oversized parts (up to 4+ meters) resulted in inconsistent film build and poor transfer efficiency. The high-build 2K coating system demanded precise application parameters for corrosion protection in harsh outdoor environments.

Solution

TD designed a specialized paint cell featuring 4 Kawasaki painting robots mounted on 7th-axis linear tracks for extended reach. The system uses Graco high-pressure electrostatic spray equipment optimized for heavy-build protective coatings. Configuration includes 2 primer robots and 2 topcoat robots, all with 7-axis capability for complete coverage of large complex geometries. Recipe-based control automatically adjusts parameters based on part type.

Outcomes

• 12-minute cycle time per fixture
• 7-axis robot systems for extended reach
• High-pressure electrostatic for thick film builds
• Consistent corrosion protection on large parts