Paint Shop Automation – Automotive Industry
In one of our key automotive projects, we automated a pre-treatment station in the paint shop where a Kawasaki industrial robot was used for air blasting to remove dust, residue, or solid impurities from components before firing and painting. The system was coordinated through a Delta PLC, ensuring tight synchronization, process readiness, and operator-friendly control.
System Overview
PLC–Robot Communication
We established a reliable digital handshake and I/O mapping between the Delta PLC and the Kawasaki robot. The Delta PLC functioned as the process controller, managing:
- Part presence detection and positioning
- Paint booth readiness and interlocking logic
- Triggering air blast cycles via robot program calls
- Zone-specific enable/disable logic based on part type
- Flush/clean interlocks and safety verifications
The Kawasaki robot was programmed to perform targeted air blasting, ensuring all surfaces were clean and free of particles before subsequent firing or painting steps.
Air Blast Cleaning Process
- High-pressure air nozzles mounted on the robot end-effector
- Custom path execution for full coverage of part geometry
- Blasting sequence adapted per part via PLC-selected recipes
- Dust evacuation and airflow control managed via booth logic
- PLC logic ensured robot operation only under safe and ready conditions
Periodic Jig Cleaning Alert
In addition to pre-paint cleaning, we also implemented a cycle-based cleaning alert system for the fixtures and jigs used:
- Tracks the number of cycles each jig undergoes
- Alerts operator when cleaning is due
- Maintains fixture surface cleanliness and product quality
✅ Key Outcomes
Reliable coordination between Delta PLC and Kawasaki robot
Effective removal of surface impurities before painting or heat treatment
Consistent pre-treatment quality across batches
️ Operator-friendly Delta HMI for manual override and alarm handling
Quick reset and restart after part or recipe change
This project showcases our capability to integrate robotic systems for utility functions like air blasting with custom PLC control, enhancing cleanliness, safety, and downstream process reliability in automotive paint shop environments.