Digital Intelligence Coating Integrated Production Line
JunHe Fastener’s Digitalized Coating Synthesis Line adheres to the philosophy of “Digital Intelligence empowers coating, pioneering a new chapter for the industry.” By fully integrating modular design, IoT and 5G communication, and a data cloud platform, the line achieves high levels of automation, intelligence, and flexibility.
Overall Design and Architecture
The production line utilizes assembled flexible connections and modular design. With built-in Internet of Things (IoT) modules, it realizes plug-and-play functionality and digital intelligence integration between modules.
Driven by MES + PLC + Supervisory Control Systems via 5G communication, and paired with AGV (Automated Guided Vehicle) and smart warehousing/logistics systems, the line’s main functional units include: Cleaning and Degreasing Equipment Modules, Shot Blasting and Rust Removal Modules, Dip-Spin Coating Modules, Sintering Furnace Modules, Robotics Modules, as well as AGV and Automated Storage/Retrieval Systems (AS/RS).
The system offers a rapid repair capability for modules within one hour, allows for module installation and commissioning within one day, and enables the entire line to be operational within one week. It supports unattended operation and is equipped with a cloud data interface for production data visualization.
Production Process
Incoming Material Handling and Scheduling: Materials are weighed and sorted after inspection, then loaded into baskets and scanned. The MES (Manufacturing Execution System) automatically matches the process sheet with the production schedule and communicates with the signal systems of all equipment to realize automatic scheduling. Following this, the AGV (Automated Guided Vehicle) transports the materials to the cleaning machine’s loading station.
The Cleaning Process features a modular machine design with flexible multi-tank configurations that can be dynamically switched according to process parameters, making it suitable for various workpieces. It boasts a capacity of 20 baskets per hour and a maximum load of 180 kg per basket, with a maximum power of 260 kW. Supporting flexible switching between 8, 10, or 12 tank positions, it meets the flexible production needs of both large-volume and small-batch, multi-variety orders. All cleaning data is traceable, monitored in real-time, and continuously optimized.
In the Shot Blasting Process, scanning the code automatically retrieves the shot blasting procedure for fully automated operation and management. The modular loading/unloading design is space-saving, and pulse dust removal ensures a clean, safe operating environment. Post-blasting, workpieces are free of rust, scale (oxidation), over-blasting, and floating dust. Additionally, intelligent synergy between processes significantly enhances production capacity.
Coating Stage
Planetary Dip-Spin Coater: The JUNHE®TDSP0500 Six-Basket Planetary Dip-Spin Coater is suitable for coating fasteners and hardware components. It is equipped with an intelligent material distribution system, where the workpiece baskets are arranged in a planetary fashion, combining revolution and rotation with directional reversal to ensure uniform film thickness, prevent liquid accumulation, and maintain a high yield rate. Its maximum centrifugal speed is 260 r/min, the maximum loading capacity is 60 kg × 3 per basket, with a cycle time of 180 seconds (e.g., for M10*50mm full-thread), achieving a single-coat capacity of 3,600 kg/h. The liquid accumulation rate is controlled to <5‰, and the exhaust gas collection rate is 95%.
Gantry-Type Dip-Spin Coater: The JUNHE®TDST0800R Fully Automatic Gantry-Type Dip-Spin Coater is suitable for various coatings, including zinc-aluminum micro-layer coatings, topcoats, sealants, and Teflon. It guarantees uniform coating with no dead corners and minimal liquid accumulation, resulting in a high yield rate, through methods such as low-speed leveling, high-speed centrifugation, and inclined centrifugation. Its maximum centrifugal speed is 320 r/min, maximum inclination angle is 60°, and the maximum loading capacity is 180 kg per basket. The cycle time is 180 seconds (e.g., for M10*50mm full-thread), achieving a single-coat capacity of 3,600 kg/h.
sintering process
Step-Type Box Furnace Series
JUNHE® LBGE3115 Step-Type Three-Layer Box Furnace
The LBGE3115 adopts a three-layer structure with waste heat recovery, achieving 30% energy savings and 60% floor space reduction. Equipped with an anti-collision system, it ensures a workpiece drop height of less than 250 mm. All parts pass the go/no-go gauge test, preventing material mix-ups and allowing full batch traceability.
Loading capacity: 180 kg per tray
Tray size: 1150 × 1500 mm
Heating method: optional
Total trays: 31
Maximum single-coating capacity: 3600 kg/h
JUNHE® LFEG3415 Step-Type Two-Layer Box Furnace
The LFEG3415 features tray stepping and vibration leveling, supporting batch management and high yield requirements while achieving 30% energy savings.
Loading capacity: 180 kg per tray
Tray size: 800 × 1500 mm
Furnace inlet dimensions: 1500 L × 500 H mm
Heating method: optional
Total trays: 34
Maximum single-coating capacity: 3600 kg/h
Effectively solves sintering challenges for irregular-shaped parts and large workpieces after dip or spray coating.
Logistics and Warehousing
AGVs work in coordination with the automated warehouse and scheduling system to achieve unmanned material transfer.
Coated workpieces can be delivered by AGVs to the warehouse for temporary storage and subsequent processing, while fully processed finished parts are automatically transported to the quality inspection station. The MES system autonomously identifies the process stage and synchronizes status data uploads, ensuring full-process traceability.
The JUNHE® Intelligent Coating Production Line is not only a technological breakthrough but also a practical implementation of Industry 4.0 in the coating field. We are committed to helping our customers build “Lighthouse Factories,” driving industrial transformation through digital intelligence and creating greater value for clients worldwide.
Post time: Nov-03-2025