Arc Spray Metallizing Booth: Customized Solution with Rotary Table and 6-Axis Robot

Industry: Metalworking

Summary

The client was facing a growing demand for rebuilding parts whose size and weight exceeded the capacity of their existing cabinets. This limited their response times and operational capacity.
CIP designed and manufactured a fully customized arc spray metallizing cabinet, equipped with a heavy-duty rotary table capable of handling parts weighing up to 5 tons, ensuring a uniform and safe application.
In addition, several challenges present in their previous processes were resolved, such as optimal cable routing for the robot, the design of special clamps to secure the parts, and the complete integration of the control system.

With this solution, the customer now has a robust, safe cabin adapted to their real needs, significantly expanding their capacity to rebuild critical parts and improve the efficiency of their operation.

Initial Situation

The client needed to rebuild large industrial parts using arc spray metallizing processes.
The parts exceeded the capacity of their current equipment, seriously limiting their productivity and response times.
The existing process lacked automation, which resulted in variability, long times, and greater operator exposure.
There were no standard equipment on the market capable of meeting their specific needs for size, movement, and control.

Challenge

Inability to process heavy and large volume parts due to lack of a suitable cabin.
Need for a system that combined precise movement, load capacity, and flexibility for different geometries.
High operational risks due to manual handling and proximity to the arc spray process.
Lack of automated control to guarantee repeatability and uniform quality.
Requirement for a fully customized system, including rotary table, fixtures and proper robot routing.

Solution

Design and manufacture of a fully customized metallizing booth for large parts.
Integration of a high-capacity rotary table, with reinforced jaws and controlled movement.
Implementation of a 6-axis robot to ensure a precise, repeatable trajectory adaptable to multiple parts.
Development of an optimized cable routing system for the robot, avoiding interference and risks during the process.
Implementation of safety controls, lighting, extraction and easy access for maintenance.
Turnkey solution, designed specifically for the client’s workflow.

Results

Immediate increase in production capacity, allowing the reconstruction of parts that previously could not be processed internally.
Higher quality and repeatability, thanks to the 6-axis robot and the synchronized rotary table.
Significant reduction of operational risk by automating movements and removing the operator from the arc spray process.
Workflow optimization, with a booth designed exactly to meet the client’s needs.
Flexibility to process diverse parts, from simple geometries to complex structures.
100% customized solution, resolving limitations that commercial teams could not cover.

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