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The European OEM automotive industry has been investing heavily in new and expanded automatic painting workshops.
Due to the automotive industry’s leading position in product and process technology development, the progress in coating applications led by many such investments is likely to have a long-term impact on most areas of the European coatings industry.
Innovations in automotive coatings, especially in their application areas, will sooner or later be introduced to other coatings markets.
The European automotive industry is the largest R&D investor in the region, and its R&D expenditure accounts for 28% of the total R&D expenditure, second only to the pharmaceutical industry.
In 2018, the EU's automotive research and development investment increased by 6.
7% annually to reach 57.
4 billion euros (63 billion U.
S.
dollars).
The growth of paint shop projects stems from the demand for more efficient coating processes to reduce costs, eliminate waste, reduce energy consumption, and reduce carbon dioxide and air pollution volatile organic compound (VOC) emissions.
The growth of paint shop projects stems from the demand for more efficient coating processes to reduce costs, eliminate waste, reduce energy consumption, and reduce carbon dioxide and air pollution volatile organic compound (VOC) emissions.
Another major factor is the need to keep pace with digitization and automation in order to maintain the international competitiveness of the European automotive industry.
Among European paint shops and other car manufacturing capabilities, the most active investors are Chinese car manufacturers, who have adopted highly automated technologies in their Chinese car factories.
In addition, in the face of the likely growth in demand for electric vehicles (EV) and their hybrids, European OEMs must reorganize their coatings and other production processes.
In the long run, automakers must also prepare for self-driving cars with new exterior and interior designs.
According to data from the Brussels Transport and Environment Agency, sales of electric vehicles in the European Union increased by 38% in 2018.
Electric vehicles still account for 2% of the entire European car market.
However, the status of electric vehicles and hybrid vehicles will change in 2020.
By 2030, the output of light vehicles powered by internal combustion engines will be almost zero.
Analysts said that by then about three-quarters of the new cars will be various types of hybrid cars, and the rest of the electric cars will be powered entirely by EV batteries or fuel cells.
Volkswagen, Europe's largest car manufacturer, is revamping its entire plant in Zwickau, Germany, including the paint shop, to produce about 300,000 electric cars per year.
At the same time, the European Commission (European Commission), the European Commissioner, predicts that by the 2020s, European highways and cities will allow partially autonomous cars and trucks to travel at low speeds.
They will start to be fully autonomous in 2030.
Due to the increase in digitization and automation, especially through the use of robots, new or expanded paint shops in Europe will have unprecedented versatility.
In a new paint shop recently opened by Skoda, a subsidiary of the German Volkswagen Group, in Mlada Boleslav, Czech Republic, 66 robots are assisting the painting process.
The company’s board member Michael Oeljeklaus described it as "one of the most advanced factories of its kind in Europe.
" These include a new generation of 7-axis paint shop robots developed by Durr Systems AG in Germany, which can easily reach parts of the car body that are usually inaccessible.
According to Skoda, the new robot can cover 108 square meters of coating on the car body, while the current average surface area of passenger cars is 88 square meters.
The digital system of the new paint shop (such as Mlada Boleslav) allows the process parameters of each car to be individually selected, allowing a range of customization, especially in color applications.
The identification of each car can be digitally transmitted to each workstation in the paint shop, so that a specific color or effect can be applied to the applied vehicle.
This ability increases the production of two-tone cars, which usually have a different roof color from the rest of the body.
Japan’s Nissan has invested 100 million pounds ($135 million) in its plant in Sunderland, northeast England, to launch the new Juke compact car mainly for the European market.
This includes four new spray booths in its paint shop, which can apply 15 different two-tone body color combinations.
For ordinary paint systems, the use of two-tone colors requires extra time and effort, especially because masking tape must be used to prevent the second color from overlapping the basic color.
Due to the precision of the manipulator, automation eliminates the need for masking tape to spray cars.
Durr claims that using one of its next-generation robots, contrasting colors can be applied to a car in a cycle time of 120 seconds, compared to about 50 minutes in the case of masking tape.
The advanced painting workshop robot has the precision and adaptability of a digital printer because it has multiple digital control holes in the nozzle.
As a result, in the paint shop production line, each car can be given a different color design.
Maserati, the luxury car subsidiary of Fiat Chrysler Automobiles (FCA), has opened a paint shop at its headquarters in Modena, Italy, to produce a variety of electric models.
Customers will be able to visit the paint shop and watch their new Maserati cars painted in their favorite color designs.
Not all major innovations in the new paint shop are entirely dependent on automation.
At the Skoda Mlada Boleslav plant, the car is moved into the oven from the side instead of being placed in the front.
Hot air from the oven flows through the window openings and the engine compartment, speeding up the drying process with the length of the drying line halved.
The plant also has an innovative air purification system that uses ground limestone to absorb paint residue contaminated by VOCs.
Limestone and waste paint are thermally recycled and used for desulfurization of flue gas emitted by nearby heating plants.
Reducing VOC emissions is an important priority for the European automotive industry in its efforts to make its production processes cleaner, of which paint shops are a major source.
Between 2005 and 2018, VOC emissions per unit of production dropped by nearly 44%, but the downward trend has stabilized in recent years.
Due to the automotive industry’s leading position in product and process technology development, the progress in coating applications led by many such investments is likely to have a long-term impact on most areas of the European coatings industry.
Innovations in automotive coatings, especially in their application areas, will sooner or later be introduced to other coatings markets.
The European automotive industry is the largest R&D investor in the region, and its R&D expenditure accounts for 28% of the total R&D expenditure, second only to the pharmaceutical industry.
In 2018, the EU's automotive research and development investment increased by 6.
7% annually to reach 57.
4 billion euros (63 billion U.
S.
dollars).
The growth of paint shop projects stems from the demand for more efficient coating processes to reduce costs, eliminate waste, reduce energy consumption, and reduce carbon dioxide and air pollution volatile organic compound (VOC) emissions.
The growth of paint shop projects stems from the demand for more efficient coating processes to reduce costs, eliminate waste, reduce energy consumption, and reduce carbon dioxide and air pollution volatile organic compound (VOC) emissions.
Another major factor is the need to keep pace with digitization and automation in order to maintain the international competitiveness of the European automotive industry.
Among European paint shops and other car manufacturing capabilities, the most active investors are Chinese car manufacturers, who have adopted highly automated technologies in their Chinese car factories.
In addition, in the face of the likely growth in demand for electric vehicles (EV) and their hybrids, European OEMs must reorganize their coatings and other production processes.
In the long run, automakers must also prepare for self-driving cars with new exterior and interior designs.
According to data from the Brussels Transport and Environment Agency, sales of electric vehicles in the European Union increased by 38% in 2018.
Electric vehicles still account for 2% of the entire European car market.
However, the status of electric vehicles and hybrid vehicles will change in 2020.
By 2030, the output of light vehicles powered by internal combustion engines will be almost zero.
Analysts said that by then about three-quarters of the new cars will be various types of hybrid cars, and the rest of the electric cars will be powered entirely by EV batteries or fuel cells.
Volkswagen, Europe's largest car manufacturer, is revamping its entire plant in Zwickau, Germany, including the paint shop, to produce about 300,000 electric cars per year.
At the same time, the European Commission (European Commission), the European Commissioner, predicts that by the 2020s, European highways and cities will allow partially autonomous cars and trucks to travel at low speeds.
They will start to be fully autonomous in 2030.
Due to the increase in digitization and automation, especially through the use of robots, new or expanded paint shops in Europe will have unprecedented versatility.
In a new paint shop recently opened by Skoda, a subsidiary of the German Volkswagen Group, in Mlada Boleslav, Czech Republic, 66 robots are assisting the painting process.
The company’s board member Michael Oeljeklaus described it as "one of the most advanced factories of its kind in Europe.
" These include a new generation of 7-axis paint shop robots developed by Durr Systems AG in Germany, which can easily reach parts of the car body that are usually inaccessible.
According to Skoda, the new robot can cover 108 square meters of coating on the car body, while the current average surface area of passenger cars is 88 square meters.
The digital system of the new paint shop (such as Mlada Boleslav) allows the process parameters of each car to be individually selected, allowing a range of customization, especially in color applications.
The identification of each car can be digitally transmitted to each workstation in the paint shop, so that a specific color or effect can be applied to the applied vehicle.
This ability increases the production of two-tone cars, which usually have a different roof color from the rest of the body.
Japan’s Nissan has invested 100 million pounds ($135 million) in its plant in Sunderland, northeast England, to launch the new Juke compact car mainly for the European market.
This includes four new spray booths in its paint shop, which can apply 15 different two-tone body color combinations.
For ordinary paint systems, the use of two-tone colors requires extra time and effort, especially because masking tape must be used to prevent the second color from overlapping the basic color.
Due to the precision of the manipulator, automation eliminates the need for masking tape to spray cars.
Durr claims that using one of its next-generation robots, contrasting colors can be applied to a car in a cycle time of 120 seconds, compared to about 50 minutes in the case of masking tape.
The advanced painting workshop robot has the precision and adaptability of a digital printer because it has multiple digital control holes in the nozzle.
As a result, in the paint shop production line, each car can be given a different color design.
Maserati, the luxury car subsidiary of Fiat Chrysler Automobiles (FCA), has opened a paint shop at its headquarters in Modena, Italy, to produce a variety of electric models.
Customers will be able to visit the paint shop and watch their new Maserati cars painted in their favorite color designs.
Not all major innovations in the new paint shop are entirely dependent on automation.
At the Skoda Mlada Boleslav plant, the car is moved into the oven from the side instead of being placed in the front.
Hot air from the oven flows through the window openings and the engine compartment, speeding up the drying process with the length of the drying line halved.
The plant also has an innovative air purification system that uses ground limestone to absorb paint residue contaminated by VOCs.
Limestone and waste paint are thermally recycled and used for desulfurization of flue gas emitted by nearby heating plants.
Reducing VOC emissions is an important priority for the European automotive industry in its efforts to make its production processes cleaner, of which paint shops are a major source.
Between 2005 and 2018, VOC emissions per unit of production dropped by nearly 44%, but the downward trend has stabilized in recent years.
