Solutions

Robotic painting automation solutions

Engineered systems for every stage of painting automation — from complete turnkey cells to targeted robot integration and booth upgrades.

Robotic Painting System Integration

We provide system-level integration rather than standalone equipment. Our solutions combine robot selection, spray process configuration, booth design, control integration, and commissioning support. Applications primarily serve automotive component production and industrial finishing environments targeting global markets including Europe and North America.

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Paint Booth Automation for Robotic Spray Painting

Engineering and integration of paint booth automation for robotic spray painting. New booth build or retrofit into existing booths, airflow/ventilation design support, controls integration, and ATEX-ready configurations for automotive and industrial finishing.

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Paint Robot Integration

Expert selection, programming, and production-line integration of industrial painting robots.

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Automated Coating and Finishing Systems for Panels

Panel coating projects need more than a spray device. They require a line concept that aligns part presentation, conveyor flow, finish target, changeover logic, and the right automation level for flat or semi-profiled products.

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Technology Advantages

Engineering Excellence

15+ years of industrial painting automation expertise distilled into proven technology platforms.

Multi-Brand Robot Integration

Seamless integration of ABB, Yaskawa, Kawasaki, FANUC robots with Sames, Ransburg, Binks, Graco spray equipment on unified Siemens S7-1500 PLC platform.

Break vendor lock-in, flexible equipment selection

Robot Collision Detection

Proprietary torque-sensor-based collision detection compares real-time position data against taught paths. Automatic alarm and emergency stop upon deviation, protecting both robots and workpieces.

Patent-pending safety technology, zero collision damage

Vision-Based Part Recognition

Multi-point visual inspection system identifies product model, position, and orientation before spraying. Automatic fixture alignment detection prevents mispositioned parts from entering the spray zone.

Eliminate missprays, support mixed-model production

Missed-Spray & Skip Detection

Automated missed-spray detection with alarm logging. Hanging fixture wire-break detection using micro-current sensing prevents product drops during conveyor transport.

IATF 16949 compliant, batch traceability

20+ Color Fast Change System

Sames PPH707 rotary bells with automatic purge sequence. Color change in under 3 minutes with minimal waste. Integrated Lactec and Timmer bead-dispensing systems for sealing applications.

High-mix low-volume production ready

Transparent Paint Level Monitoring

Real-time paint liquid level monitoring with radar-based level control and dual-threshold alarms. HMI graphical display shows all tank levels with automated refill triggers.

Zero-downtime paint supply, visual management

Water-Based Paint Temperature Control

Pipe-in-pipe thermal management maintaining ±1°C precision for water-based coatings, ensuring consistent atomization and film formation across all spray stations.

Industry-leading stability for water-borne systems

Remote Diagnostics & Programming

RobotStudio and ShopFloor Editor remote access enables off-site troubleshooting, program optimization, and software updates. PROFINET/Ethernet dual-redundant network ensures reliable connectivity.

50%+ faster fault response, minimize site visits

MES/SCADA Integration

Full manufacturing execution system connectivity for equipment interconnection, runtime statistics, fault logging, and production data exchange with factory-level MES/ERP platforms.

Complete production traceability, data-driven decisions

Industry 4.0 & AI Intelligence

Data acquisition and intelligent analysis platform for predictive maintenance, spray parameter optimization, and production efficiency tracking. Digital twin capability for virtual commissioning.

Predictive maintenance, continuous process improvement
Equipment Integration

Robot + Atomizer Integration

Precision integration of painting robots with high-speed rotary bell atomizers — hollow-wrist routing, electrostatic cascade, and CAN-bus process control.

ABB painting robot with hollow-wrist internal routing for paint lines, air supply, and electrostatic cables

Hollow-Wrist Internal Routing

Paint supply lines, shaping air hoses, electrostatic HV cables, and PROFINET communication routed through the robot arm — eliminating external cable interference and enabling full 6-axis freedom of motion.

ABB painting robot with Sames rotary bell atomizer and protective capot installed

Sames Rotary Bell Integration

High-speed electrostatic rotary bell (up to 60,000 RPM) with 100kV cascade, dual shaping air control, and CAN-bus communication — achieving 65-85% transfer efficiency on automotive-grade finishes.

60K RPM
Bell Speed
100 kV
Electrostatic Cascade
15–50 mm
Bell Cup Range
65–85%
Transfer Efficiency
Technology in Action

See Our Technology at Work

Advanced painting automation technologies demonstrated through real equipment and 3D simulation.

ABB PixelPaint Dual-Color Technology

Precision dual-color robotic spraying using ABB PixelPaint technology. Multiple robots coordinate wall-mounted, floor-mounted, and inverted configurations to achieve sharp two-tone finishes with 20–50 micron droplet control.

SAMES PPH707 & EVO Robotic Painting

Automotive body painting with SAMES PPH707 and EVO rotary bell applicators. Multi-robot booth configuration with electrostatic coating for high transfer efficiency and OEM-grade surface finish.

Timmer Bead Dispensing System

3D animation walkthrough of the Timmer bead dispensing system used in automotive sealing applications. Precision material delivery through automated track-guided bead application for consistent seal quality.

System Configurations

Proven Configuration Examples

Real-world system architectures delivered for automotive plastic component painting applications.

Compact Cell

2-3-2 Configuration

  • 1 robot pre-treatment (flame/plasma)
  • 2 robots primer spray
  • 3 robots topcoat spray
  • 2 robots clearcoat spray
Typical capacity: 65–90 parts/hour
Mid-Scale Line

4-6-4 Dual-Color Configuration

  • 4 robots pre-treatment station
  • 6 robots basecoat with dual-color capability
  • 4 robots clearcoat station
  • Quick color change system integrated
Typical capacity: 96+ parts/hour
Large-Scale

4-6-6 Full Water-Based Line

  • 4 robots water-wash pre-treatment
  • 6 robots basecoat with RB1000i-WSC color changers
  • 6 robots clearcoat with CBS cleaning stations
  • Full water-based paint temperature control
Typical capacity: 120+ parts/hour
Market Experience

Proven Across Scale and Industry

Track record spanning 30+ cities, from single-robot cells to 100+ robot complete paint shops, across automotive OEM and industrial sectors.

30+
Cities Covered
Nationwide deployment experience across major industrial regions
1–169
Robots per Project
From single-cell stations to 100+ robot mega-lines
60%+
Automotive OEM
Primary focus on vehicle body & component painting
40%
Industrial & Parts
Heavy equipment, parts suppliers, and general industrial

Project Type Distribution

Based on cumulative project portfolio

New Line Builds60%
Line Modifications33%
Capacity Expansions7%

Majority new-build projects, with significant retrofit and expansion capability.

System Scale Distribution

Robots per project across portfolio

1–10 robots
38%
11–40 robots
45%
40+ robots
17%

Flexible integration capability from compact cells to complete paint shop turnkey delivery.