From insolvency to technology leader: in times of economic uncertainty, innovation, expertise and a clear vision are crucial. Eisenmann has not only mastered these challenges, but has also established itself as a pioneer in paint shop technology. The company is setting new standards with its revolutionary collaboration with Wiferion.
Good Lack: Autonomous AGVs ensure energy savings in the automotive industry
Body shell cleaning, seam sealing, dip and top coating – to prevent the paint from peeling off, a car body has to go through a number of steps in the painting process. As they only receive their tires at the end, the metal bodies are usually placed on carriages that are transported from station to station using skid conveyor technology. A well-known problem in the painting industry is the extreme heating and cooling of the car body and the skid during the process, which leads to considerable energy consumption. Thanks to the innovative AGVs from Eisenmann, which are supported by the robust and efficient etaLINK systems from Wiferion, these challenges are a thing of the past.
From sledges to autonomous vehicles: increasing efficiency in the paint shop
In addition to conveyor technology for pre-treatment and cathodic dip painting, Eisenmann’s portfolio includes versatile systems for paint drying and deposition as well as application technology for automated handling. The paint shop specialist, which was already one of the technology leaders in its sector in the 1990s and primarily supplies the automotive industry, can look back on a long tradition of automated guided vehicle systems. In 2020, Eisenmann began planning and designing a new AGV specifically for the varnishing process. The VarioMover not only moves the car bodies from station to station, but also travels with them through all the painting process steps – without being exposed to the paints and temperature fluctuations itself.
Temperatures of up to 200 degrees prevail at the various stages of the painting process. Added to this is the spray mist that gives the bodywork a new shine. Both are a challenge for the conveyor technology. The solution: a sophisticated cooling system, good insulation for the AGV and protected driving areas.
Eisenmann brings the wheel to the body with the VarioMover
In addition to the special requirements of the paint shop, the AGV needed to fulfill other characteristics. “We wanted to develop a system that was as compact as possible and could maneuver in the smallest and tightest of spaces,” says Axel Eipper, Product Management at Eisenmann. The VarioMover has eight driven wheels that are omnidirectional, i.e. they can turn on the spot. This enables it to realize even compact travel paths. The wheels can be used for both driving and steering. This means that even heavy loads of up to 3.5 tons can be moved with maximum acceleration and precision. At the same time, the wheel system protects the floor from high loads and the associated wear.
Eisenmann also attached great importance to industry-standard control technology during the planning stage. This is because technology that the customer’s maintenance team is familiar with, makes it easier for them to ensure the smooth operation of the AGV. As the vehicle’s control system comes entirely from Siemens, the customer also benefits from good, long-term availability of spare parts. With a basic height of 250 mm, which can be extended with additional components depending on the functionality of the AGV, the VarioMover is optimally designed for the standard transport height of 500 mm in the automotive industry.
Tailor-made technology for maximum scalability in painting
The VarioMover has a patented technology for use in automotive painting. It is equipped with various interfaces and can be adapted to the customer-specific application according to the modular principle. Possible applications include the maximally scalable StoreMover area storage system, the process-integrated PaintMover AGV, which is used specifically in the painting area, or the AssemblyMover for final assembly. The StoreMover in particular takes an innovative approach. Usually, sorting and buffer storage in the form of high-bay warehouses are located between the individual production steps in automotive production. However, these require a lot of space and are expensive to maintain. With the StoreMover, the high-bay warehouse is replaced by an area storage system. The AGV is only designed to distribute the car bodies in this passive storage system and pick them up again at the right time to return them to production.
All solutions can be fully integrated into existing production processes and can also be subsequently adapted to changing capacity and production requirements. The technology therefore offers maximum flexibility and scalability in the modern paint shop.
A particular challenge for Eisenmann, however, was the search for a suitable charging structure.
Targeted charging without flying sparks
One of the most common energy transfer methods, contact charging, was out of the question for use in the paint shop. In addition to the high cost of installing the charging contacts in easily accessible places and ensuring the required contact pressure, the risk of flying sparks in such a sensitive area is unacceptable. “That’s why it was clear from the beginning that the system we wanted to use had to be inductive,” says Axel Eipper. “As we also wanted to retrofit the existing systems without a great deal of effort, we were looking for a minimally invasive solution. We wanted to avoid costly interventions in the floor structure, such as milling grooves or channels. That’s why we opted for the solution from Wiferion.”
As well as being easy to integrate into existing infrastructures, the etaLink system from “Wiferion – a PULS brand” is characterized by its high level of efficiency. “A major concern of our customers is that the strong electromagnetic fields could have a negative impact on the health of their employees or on the steel structure of their production facilities,” reports Axel Eipper. “With Wiferion’s charging system, however, the energy is transmitted in a particularly targeted manner, as a highly directional charging lobe is created at the interface between the active and passive pads. This means that significantly less energy is released into the environment than with other charging systems.”
The high flexibility of the Wiferion solution also speaks for itself. etaLINK is designed for different battery formats and technologies. Whether LiFePo, lithium or titanate – the inductive charging system is highly compatible. This clear advantage also played important role in Eisenmann’s decision to opt for Wiferion.
The perfect complement: Eisenmann’s AGV and Wiferion’s charging technology
The etaLINK system is now an integral part of Eisenmann’s AGV modular system. As a rule, the loading plates are used in external areas outside the painting stations. As it is important in the automotive industry to intercept peaks , not all vehicles are usually in use at the same time. “If three car bodies are completed at the same time, three AGVs must be available for onward transportation, even if one would be enough for us in terms of capacity,” says Axel Eipper. “As a result, we usually have too many AGVs that we can easily charge during the waiting time.” At the customer’s request, Eisenmann also integrates the Wiferion charging stations at strategically useful hubs along the process stations to enable charging during operation. This can be done at points where the AGVs stop for a load change.
“We have already been able to convince our customers of this innovative technology,” says Axel Eipper. “The first projects are therefore currently in the implementation phase. Further promising projects are already being planned. All of this shows that etaLINK is the perfect addition to our AGV range. Together with Wiferion, we not only offer the automotive industry current added value, but also pave the way for future innovations. The further development of our technologies will continuously optimize production processes and make them more sustainable.”
