Automated Metallizing Booth: Greater Safety and Efficiency in Arc Spray Processes

Industry: Metalworking

Summary

The customer was using conventional lathes and metallizing booths to process small parts, which reduced the available capacity for large parts and created operational limitations. CIP and in collaboration with CA6s We developed a specialized booth for small parts, designed to optimize capacity, safety and production flow.

Using an overhead crane and a motorized system that automatically feeds the workpiece into the booth, the operator remains in a safe zone without direct contact with the arc spray process.
The result is a more efficient, controlled, and significantly safer process, freeing up production capacity and increasing operational efficiency.

Initial Situation

The client was performing metallizing processes using lathes and booths designed for large parts, even when they needed to work on small parts.
This resulted in inefficient use of capacity, delays, and saturation of equipment intended for larger parts.
The handling of the parts and their placement inside the booth was manual, which exposed the operator to risks inherent in the arc spray process.
The increase in demand made it necessary to have a safer, faster system better adapted to small parts.

Challenge

Lack of specialized equipment for small parts, causing bottlenecks in the main cabins.
Exposure of the operator to hazardous conditions due to proximity to the metallizing process.
Slow and non-standardized operations when manually loading and positioning parts.
Need to improve production flow without affecting the operation of large parts.
Total customization was required, as there were no commercial solutions that perfectly matched their needs.

Solution

Design and manufacture of a specialized cabin for small parts, with optimized dimensions and protections.
Integration of an overhead crane to load the parts safely and without operator effort.
Implementation of an automated system that introduces the part using a motor, ensuring a safe distance between the operator and the process.
Configuration of insulation, visibility and ventilation systems suitable for the arc spray process.
Complete customization of the equipment:
- Optimal robot cable routing,
- Custom-designed clamps and interfaces,
- Unified control for simple and safe operation.

Results

Greater operational safety, by eliminating direct operator exposure to the metallizing process.
Increased efficiency, by freeing up large booths for larger parts and allowing parallel production flow.
Automated loading and positioning, reducing preparation times and eliminating manual effort.
Greater installed capacity, allowing the reconstruction of small parts without affecting other areas.
Repeatable, controlled and personalized process, 100% adapted to the client’s needs.
Reduction of downtime, by standardizing the handling and insertion of parts.

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