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Coating Engineering Design and Project Management

Coating Engineering Design and Project Management

Coating Engineering Design and Project Management

2017-04-26

Modern automobile manufacturing typically consists of four major stages: stamping, welding, painting, and final assembly. Among these, the painting workshop is one of the most complex in terms of equipment and processes; investment in a painting workshop often accounts for more than 30% of the total investment in both processes and equipment. To build a successful painting production line, it is essential to have outstanding painting engineering design and project management capabilities. Hayden boasts an engineering team with 20 years of industry experience and, through strategic collaborations with international peers, continuously tracks and adopts new technologies and proven engineering practices. For example, our successful partnerships with overseas collaborators on two large-scale projects—Jiangling and Venucia—as well as the Russian AUTOVAZ project and the Brazilian Mercedes-Benz project—all demonstrate our ability to deliver superior technology to customers, creating high-level painting production conditions and environments at competitive costs and with exceptional efficiency. Our strategies for addressing challenges in painting engineering design and project management include: Engineering management solutions that balance efficiency and cost to ensure customers achieve a satisfactory return on investment; detailed health and safety plans; an excellent project management team; and comprehensive quality monitoring throughout the entire project lifecycle, ensuring compliance with policies and regulations both in China and globally. We also place great emphasis on fully understanding the value of operational services and taking full responsibility for the entire project lifecycle. As for technical solutions, during the design phase, our unique expertise ensures that we provide users with efficient, dynamic, and integrated systems. By combining excellent design principles with considerations for high efficiency, high reliability, high maintainability, and uncompromising quality, we comprehensively meet the specific requirements of each project. Our key advantages are as follows: Layout design philosophy—in the layout planning stage, we take into account all customer technical specifications, detailed design data and layout parameters specified in the requirements, as well as compliance with international technical standards, work practices, and methodologies. In developing the layout design, we consider the overall concept, providing numerous long-term benefits, including extended equipment maintenance and reliability, rational allocation of auxiliary production areas, centralized placement of exhaust stacks for atmospheric emissions, optimal utilization of equipment, comprehensive installation support, and consistent process alignment. Process equipment design fully considers the customer’s specific requirements regarding process timing, dimensions, and functionality, while leveraging our global capabilities and cutting-edge technologies to meet users’ needs for uniquely customized solutions.

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Innovation in Spraying Technology

Innovation in Spraying Technology

Innovation in Spraying Technology

2013-07-23

Changes in manufacturing processes call for new equipment solutions, and the right solution requires a deep understanding of the entire system. High rework rates, dirty conditions in paint shops, unstable processes, and irregularities in baking—these are common challenges faced by conventional methods: polluting materials, low-solids paints, solvent-based paints, and traditional techniques. Such methods often result in poor quality and require clean, controlled environments with properly maintained spray booths. A more engineered, systematic approach offers a "green" alternative: high-solids paints, waterborne paints, and powder coatings.

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Hayden’s Technical Comparison with Other Design Companies—Drying Oven

Hayden’s Technical Comparison with Other Design Companies—Drying Oven

Hayden’s Technical Comparison with Other Design Companies—Drying Oven

2013-07-23

Hayden air-flow mixing type—other suppliers’ conventional circulating types: circulation frequency 16 cycles/min vs. 2 cycles/min; body temperature difference no greater than 50°C vs. no greater than 110°C—especially effective in addressing insufficient heating at the bottom of the car body, where corrosion is most likely to occur. Operating costs are lower when large circulating fans are not used, resulting in lower energy consumption; using large circulating fans significantly increases energy consumption. The heating zone employs fully contoured radiant panels, ensuring uniform heating throughout the vehicle—same as the left side. Maintenance involves only a few high-temperature dampers; the piping system is complex and makes rapid heating difficult. Generally, duct lengths are very short, matching the length of the drying tunnel. Design is complex, with a short commissioning period. Separate-type exhaust gas treatment systems are available; integrated exhaust gas treatment systems are also available. Serial number Content General factory configuration Hayden configuration 1 Wall panel: foam plastic, steel plate thickness only 0.5–0.6 mm; rock wool density 140 kg/m³, steel plate thickness 1.0–1.2 mm. Insulation performance and service life differ; does not meet fire safety requirements. High-temperature sealant: during wall panel installation, either no sealant is used or domestically produced sealants containing “silicon” are used. It is crucial to use imported high-temperature sealants free of “silicon” when installing the drying oven. Sealants containing “silicon” can lead to long-term problems with coating quality. 2 Internal circulating ducts: typically made of galvanized steel sheets from general steel mills, with sheet thickness of 0.8–1.0 mm and zinc layer thickness of 50–60 mg/m². High-quality galvanized steel sheets from Baosteel have a sheet thickness of 1.2–1.5 mm and a zinc layer thickness of 80 mg/m². Differences in the thickness of galvanized steel sheets and zinc layers directly affect product appearance, service life, and oxidation resistance. Oxidation of the zinc layer will also severely impact product quality. 3 External circulating ducts: typically made of galvanized steel sheets from general steel mills, with sheet thickness of 1.0–1.2 mm and zinc layer thickness of 50–60 mg/m². High-quality galvanized steel sheets from Baosteel have a sheet thickness of 1.5–2.0 mm and a zinc layer thickness of 80 mg/m². Differences in the thickness of galvanized steel sheets and zinc layers directly affect product appearance, service life, and oxidation resistance. 4 Heating system: Italian or Taiwanese burners, self-made heat exchangers (or direct-fired type without heat exchanger), self-made hot-air filtration chambers, domestic filters. German or American burners, high-efficiency heat exchangers manufactured by professional vendors, equipped with fully imported control valve groups, professional-manufactured hot-air filtration chambers, and imported filters. The quality of burners and heat exchangers directly affects heat exchange efficiency, energy utilization rate, flue gas temperature, equipment safety during operation, equipment lifespan, maintenance rate, and overall production line efficiency, among other factors. 5 Hot-air circulating fans: generally high-temperature resistant, high-efficiency, low-noise premium fans (imported bearings); domestic and imported filters differ dramatically in filtration efficiency and precision. 6 Supply air filters: domestic filters vs. imported filters. 7 Exhaust air filters: none vs. imported filters. 8 Duct insulation: insulation thickness 50 mm, outer panel made of 0.5–0.6 mm color-coated steel; insulation thickness 100 mm, outer panel made of 1.0 mm galvanized steel. 9 Exhaust gas outlet: one set vs. two sets. Setting up two separate exhaust systems ensures that, in case of an emergency requiring furnace shutdown, hot air inside the furnace can be quickly expelled, thus avoiding unnecessary damage caused by over-drying of workpieces. 10 Control system: domestic components, domestically produced control cabinet; fully imported components, control cabinets produced by joint ventures. Control accuracy and reliability differ dramatically. 11 Material selection: general steel mills vs. high-quality steel from Baosteel. 12 Component selection: general manufacturers vs. joint ventures or well-known domestic enterprises. 13 Equipment machining accuracy: general vs. very good. 14 Overall reliability: general vs. very good.

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Hayden’s technical comparison with other design firms

Hayden’s technical comparison with other design firms

Hayden’s technical comparison with other design firms

2013-07-23

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Hayden’s Technical Comparison with Other Design Companies—Paint Booth

Hayden’s Technical Comparison with Other Design Companies—Paint Booth

Hayden’s Technical Comparison with Other Design Companies—Paint Booth

2013-07-23

HYDROSPIN High-Efficiency Paint Booth (Impact-Separation Water-Washing Type) HYDROSPIN is a paint booth developed and patented by Hayden Company in the 1970s. Over the past 30-plus years, the company has continuously refined and improved this system at its research center in Detroit, USA. The operating principle of HYDROSPIN is as follows:

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The Tasks and Development of the Technical Department

The Tasks and Development of the Technical Department

The Tasks and Development of the Technical Department

2013-07-23

Develop and adopt innovative application technologies to help our users manufacture products that represent superior coating technology—with the lowest possible investment, the highest possible quality, and the minimal environmental impact. Highly skilled R&D engineers can provide novel methods and equipment for groundbreaking innovations in both manufacturing and operation. Maintain close collaboration with chemical suppliers to adopt cutting-edge coating material technologies. Uphold a consistent design philosophy to ensure continuous improvement in stability and maintainability.

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Hayden's technology

Hayden's technology

Hayden's technology

2013-07-23

R&D of advanced application technologies and acquisition of numerous patents—Hydrospin®IIIQ spray booth, one of the industry’s technology leaders; DaimlerChrysler’s preferred spray booth system; Toyota Motor’s preferred spray booth system; J.I. Case’s preferred spray booth system; Hydrospin®LP spray booth system; AirRadiant® oven system; Hydropac® slag removal system; DryPure™II paint sludge drying system; powder coating systems.

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Can standardizing bus models and livery really prevent improper operations?

Can standardizing bus models and livery really prevent improper operations?

Can standardizing bus models and livery really prevent improper operations?

2013-03-13

Huicong Surface Treatment Network: “China’s official vehicle reform has been underway for 19 years, yet year after year, the reform seems to remain stuck in neutral. The trend of overstaffed vehicle allocations and the private use of official vehicles remains strong.” Li Weihua, a member of the National Committee of the Chinese People's Political Consultative Conference and Vice Chairman of the Anhui Provincial CPPCC, pointed out that waste and corruption on wheels cannot be delayed or postponed. He suggested institutionalizing the reform and adopting a “coordinated, holistic approach” to tackle the persistent problem of official vehicles being used for personal purposes. Once this solution—“strictly defining the scope and standards for official vehicle allocation, adopting a ‘zero-tolerance’ policy toward private use of official vehicles, dealing with each case as it arises, taking tough measures, and drawing on practices from Hong Kong and Macao by standardizing official vehicle models, uniform livery, and unified colors to facilitate public oversight”—was proposed, it immediately sparked heated debate. From a technical perspective, unifying vehicle livery is not particularly difficult to implement; the real challenge lies in whether uniform livery can truly prevent violations. At present, this remains an open question. Nevertheless, we can still explore the automotive painting processes we are already familiar with. From the standpoint of automotive painting technology, vehicle painting generally consists of two main parts: first, surface treatment of metal substrates prior to painting, also known as pretreatment techniques; second, the actual painting application process. Surface treatment primarily involves removing oil stains, dust, rust, and old paint layers during repair work from the substrate surface, thereby improving the surface condition of the workpiece. This includes mechanical and chemical treatments tailored to specific conditions, such as phosphating, oxidation, and passivation. Meanwhile, automotive painting processes vary significantly depending on the type of vehicle. For heavy-duty trucks, the primary painted components are the front cab, which has higher painting requirements; other parts, such as the cargo bed and frame, have lower painting demands than the cab. The painting of passenger buses differs considerably from that of freight trucks. The body of a passenger bus comprises the chassis, frame, interior cabin, and exterior surfaces, with the exterior surfaces having the highest requirements. Exterior surfaces must not only provide excellent protection and aesthetics but also feature large painting areas, multiple flat surfaces, and often incorporate two or more colors, sometimes even including decorative stripes. As a result, the painting cycle is longer, the construction standards are higher, and the painting process is more complex than for freight trucks. Passenger cars and small station wagons have higher requirements than large buses and freight trucks, both in terms of surface decoration and underlying protective layers. Their surface coatings must meet Class I decorative precision standards, boasting a beautiful appearance with mirror-like gloss or smooth surfaces free of fine impurities, scratches, cracks, wrinkles, blisters, or any defects visible to the naked eye, and they must also possess sufficient mechanical strength. The underlying coating must serve as an excellent protective layer, offering superior rust resistance and corrosion protection, along with strong adhesion. Local or full-area applications of putty with good adhesion and high mechanical strength should ensure that, even after several years of use, no rusting or peeling occurs.

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Dong Jie Haideng

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