Digital and Intelligent Coating Synthesis Line
Junhe’s digital and intelligent coating synthesis line for fasteners upholds the philosophy of “Empowering Coating with Digital Intelligence, Leading a New Chapter of the Industry.” It fully integrates modular design, the Internet of Things, and 5G communication to achieve a high level of automation, intelligence, and flexibility.
Overall Design and Architecture
The production line adopts an assembly-style flexible connection and modular design, with built-in IoT modules enabling plug-and-play functionality and digital-intelligent integration between modules. Through 5G communication, it is jointly driven by MES, PLC, and upper-level control systems, coordinating with AGVs and intelligent warehousing and logistics systems. Its core components include equipment modules for cleaning and degreasing, shot blasting and rust removal, dip-spin coating, sintering furnaces, and robots, as well as AGVs and automated storage systems. The line offers rapid module maintenance, unmanned operation capability, and visualized production data via cloud-based data interfaces.
Production Process
Incoming Material Handling and Scheduling
After inspection, incoming materials are weighed and sorted, placed into baskets and scanned. The MES system automatically matches process sheets with production schedules and communicates with each piece of equipment to enable automated scheduling. AGVs then transport the materials to the loading area of the cleaning machine.
Cleaning Stage
The cleaning machine adopts a modular design with multiple flexible tank configurations, allowing process parameters to be switched as needed for different types of workpieces. It offers a capacity of 20 baskets per hour, a maximum load of 180 kg per basket, and a maximum power of 250 kW. Supporting flexible switching between 8/10/12 tanks, it accommodates both high-volume and small-batch, multi-variety production needs. All cleaning data are traceable, enabling real-time monitoring and continuous process optimization.
Shot Blasting Stage
By scanning, the shot blasting process parameters are automatically retrieved for fully automated operation and management. The modular loading and unloading design saves space, while pulse dust collection ensures a clean and safe working environment. After shot blasting, workpieces achieve a rust-free, scale-free, over-blast-free, and dust-free finish. Intelligent coordination between processes further improves production efficiency.
Coating Stage
Planetary Coating Machine
The JUNHE® TDSP0500 six-basket planetary coating machine is designed for coating fasteners and hardware parts. Equipped with an intelligent feeding system, it arranges workpiece baskets in a planetary layout, combining revolution and rotation with directional switching to ensure uniform film thickness, prevent liquid pooling, and achieve a high yield rate. It offers a maximum centrifugal speed of 260 r/min, a maximum load of 60 kg × 3 per basket, a minimum cycle time of 180 s, a maximum throughput of 3,600 kg/h, a liquid accumulation rate below 5‰, and a 95% exhaust collection rate.
Gantry Coating Machine
The JUNHE® TDST0800J fully automatic gantry coating machine is suitable for zinc-aluminum micro-coatings, topcoats, sealers, and PTFE coatings. Using low-speed spreading, high-speed centrifuging, and inclined centrifuging, it ensures uniform coverage with minimal dead zones and liquid accumulation, achieving high yield rates. It features a maximum centrifugal speed of 350 r/min, a maximum tilt angle of 75°, a load capacity of 180 kg per basket, a minimum cycle time of 150 s, and a maximum throughput of 4,320 kg/h.
Sintering Stage
Stepping Box-Type Vertical Furnace
The JUNHE® LBGE3115 stepping box-type vertical furnace features a multi-layer structure with waste heat recovery, achieving 30% energy savings and 60% space reduction. It includes an anti-collision system with a workpiece drop height of less than 250 mm, ensuring gauge compliance, preventing material mixing, and enabling batch traceability. It supports a load of 200 kg per tray, tray dimensions of 1150 × 1500 mm, optional heating methods, a total of 31 trays across the line, and a maximum single-coating throughput of 6,000 kg/h.
Stepping Box-Type Double-Layer Furnace
The JUNHE® LFEG3415 stepping box-type double-layer furnace utilizes tray stepping and vibration leveling to meet batch control and high-yield requirements, also achieving 30% energy savings. It supports a load of 180 kg per tray, tray dimensions of 800 × 1500 mm, optional heating methods, a total of 34 trays across the line, and a maximum single-coating throughput of 3,600 kg/h. It is particularly suitable for sintering after coating of irregular or large parts.
Logistics and Warehousing
AGVs work in conjunction with the automated storage system and scheduling platform to realize unmanned material transfer. Coated workpieces can be sent by AGV to the automated warehouse for further processing, while finished products after all processes are sent to the quality inspection station. The MES autonomously identifies process locations and synchronizes status data, ensuring full-process traceability.
Conclusion
The Junhe Digital and Intelligent Coating Synthesis Line is not only a technological breakthrough but also a practical implementation of Industry 4.0 in the coating field. We are committed to supporting customers in building “lighthouse factories,” driving industry upgrades through digital intelligence, and creating greater value for customers worldwide.
Post time: Sep-16-2025