Slide 1: Take full control of your paint mix room
INTRODUCING GRACO’S I N T E L L I G E N T PA I N T K I T C H E N Take full control of your paint mix room
Slide 2: Paint mix room challenges
! PAINT MIX ROOM CHALLENGES Relies too Difficult to Expensive Limited Not ready much on keep up and to control and for Industry humans running maintain monitoring 4.0
Slide 3: Introducing Graco's Intelligent Paint Kitchen
INTRODUCING GRACO’S I N T E L L I G E N T PA I N T K I T C H E N 1. What is an Intelligent Paint Kitchen? 2. What are the main benefits? 3. How does it work? 4. Which components are used?
Slide 4: 1. What is an Intelligent Paint Kitchen?
1.What is an Intelligent Paint Kitchen? ////////////////////////////////////////////////
Slide 5: Modular, easy, and cost-effective
//////////////////////////////////////////////// Modular, easy, and cost-effective system for monitoring and controlling your paint mix room
Slide 6: Monitor and control without the use of a PLC
//////////////////////////////////////////////// It allows you to monitor and control your paint mix room components without the use of a PLC
Slide 7: It's pre-programmed, so just set the parameters
//////////////////////////////////////////////// It’s pre-programmed, so just set the parameters to your preferences and you’re off
Slide 8: 2. What are the main benefits?
2. What are the main benefits? ////////////////////////////////////////////////
Slide 9: Intelligent from start to finish
I N T E L L I G E N T F R O M S TA R T T O F I N I S H Exceptional Maximum Advanced Reduced Top Results Efficiency Technology Costs Productivity
Slide 10: Exceptional Results
Exceptional Results ///////////// Optimizes the balance and performance of your paint supply and paint circulation system(s), leading to a high quality finish § Superior finish § Consistent quality § Reduced paint shear
Slide 11: Maximum Efficiency
Maximum Efficiency ///////////// Monitors and controls pressure, flow rates, tank levels, and agitator speeds to ensure your system is operating at peak efficiency § Easy start-up and operation § Modular and scalable design § Less human intervention
Slide 12: Advanced Control
Advanced Control ///////////// Real-time access to key paint circulation data from inside and outside the paint mix room enables quick diagnosis of issues § Remote monitoring § With or without PLC § Traceable and clear
Slide 13: Reduced Costs
Reduced Costs ///////////// An inexpensive way to take full control of your paint mix room. You save on installation, operating, programming, and paint costs § Cost-effective § No programming required § Increased competitiveness
Slide 14: Top Productivity
Top Productivity ///////////// Ensures your paint circulation systems are operational at all times, informing you and adjusting when necessary § Minimal downtime § Always on and connected § Ready for IoT and Industry 4.0
Slide 15: 3. How does it work?
3. How does it work? ////////////////////////////////////////////////
Slide 16: A smart set of sensors, actuators, and control modules
/////////////////////// A smart set of sensors, actuators, and control modules communicate with each other to optimize the performance of your paint supply and paint circulation system(s)
Slide 17: Tank control, pump control, overall control
/////////////////////// A smart set of sensors, actuators, and control modules communicate with each other to optimize the performance of your paint supply and paint circulation system(s) Tank control Pump control Overall control
Slide 18: Pump control
Pump control ///////////////////////
Slide 19: Pump control
Pump control /////////////////////// ü Controls fluid pressure and flow rates ü Keeps your pressure and flow stable and in balance ü Reduces paint shear
Slide 20: Pump control
Pump control /////////////////////// § Contains: § Electric/pneumatic Paint Circulation Pump § Pump Run/Stop Switch § Fluid Pressure Sensors § Back Pressure Regulator (BPR) § Electric/Pneumatic Transducer § Connected to and monitored by the Pump Control Module
Slide 21: Pump control
Pump control Pump Control Module Fluid Pressure Sensor Paint Circulation Pump Electric/Pneumatic Transducer Back Pressure Regulator (BPR) Fluid Pressure Sensor Pump Run/Stop Switch
Slide 22: Electric paint circulation pump E-Flo DC
In this presentation we use our electric paint circulation pump to visualize the system setup E-Flo DC
Slide 23: Also works with pneumatic pumps: High-Flo
But the Intelligent Paint Kitchen also works with our pneumatic paint circulation pumps High-Flo
Slide 24: Also works with pneumatic pumps: Endura-Flo
But the Intelligent Paint Kitchen also works with our pneumatic paint circulation pumps Endura-Flo
Slide 25: Controls fluid pressure and flow rates
Pump control Controls fluid pressure and flow rates The Intelligent Paint Kitchen gives /////////////////////// you the possibility to choose between pressure, flow, and hybrid mode. These modes are available for both electric and pneumatic pumps: • Pressure mode Steady fluid pressure in the paint c
Slide 26: Controls fluid pressure and flow rates: pressure mode
Pump control Controls fluid pressure PRESSURE MODE and flow rates ///////////////////////
Slide 27: Controls fluid pressure and flow rates: pressure mode
Pump control Controls fluid pressure PRESSURE MODE and flow rates 1. The target fluid pressure is set /////////////////////// in the Pump Control Module. Pump Control Module
Slide 28: Controls fluid pressure and flow rates: pressure mode
Pump control Controls fluid pressure PRESSURE MODE and flow rates 1. The target fluid pressure is set /////////////////////// in the Pump Control Module. 2. The Fluid Pressure Sensors measure the fluid pressure Fluid Pressure Sensor (BPR) inside the paint circulation line: • At the pump outlet • At
Slide 29: Controls fluid pressure and flow rates: pressure mode
Pump control Controls fluid pressure PRESSURE MODE and flow rates 1. The target fluid pressure is set /////////////////////// in the Pump Control Module. 2. The Fluid Pressure Sensors measure the fluid pressure inside the paint circulation line: • At the pump outlet • At the Back Pressure Regulator
Slide 30: Controls fluid pressure and flow rates: pressure mode
Pump control Controls fluid pressure PRESSURE MODE and flow rates 1. The target fluid pressure is set /////////////////////// in the Pump Control Module. 2. The Fluid Pressure Sensors measure the fluid pressure inside the paint circulation line: • At the pump outlet • At the Back Pressure Regulator
Slide 31: Controls fluid pressure and flow rates: pressure mode
Pump control Controls fluid pressure PRESSURE MODE and flow rates 1. The target fluid pressure is set /////////////////////// in the Pump Control Module. 2. The Fluid Pressure Sensors measure the fluid pressure inside the paint circulation line: • At the pump outlet • At the Back Pressure Regulator
Slide 32: Controls fluid pressure and flow rates: flow mode
Pump control Controls fluid pressure FLOW MODE and flow rates ///////////////////////
Slide 33: Controls fluid pressure and flow rates: flow mode
Pump control Controls fluid pressure FLOW MODE and flow rates 1. The target flow rate is set /////////////////////// in the Pump Control Module. Pump Control Module
Slide 34: Controls fluid pressure and flow rates: flow mode
Pump control Controls fluid pressure FLOW MODE and flow rates 1. The target flow rate is set /////////////////////// in the Pump Control Module. 2. The Back Pressure Regulator is set to deliver the desired fluid pressure in the system. Back Pressure Regulator (BPR)
Slide 35: Controls fluid pressure and flow rates: flow mode
Pump control Controls fluid pressure FLOW MODE and flow rates 1. The target flow rate is set /////////////////////// in the Pump Control Module. 2. The Back Pressure Regulator is set to deliver the desired fluid pressure in the system. 3. The Paint Circulation Pump circulates the paint at the desire
Slide 36: Controls fluid pressure and flow rates: flow mode
Pump control Controls fluid pressure FLOW MODE and flow rates 1. The target flow rate is set /////////////////////// in the Pump Control Module. 2. The Back Pressure Regulator is set to deliver the desired fluid pressure in the system. 3. The Paint Circulation Pump circulates the paint at the desire
Slide 37: Controls fluid pressure and flow rates: hybrid mode
Pump control Controls fluid pressure HYBRID MODE and flow rates ///////////////////////
Slide 38: Controls fluid pressure and flow rates: hybrid mode
Pump control Controls fluid pressure HYBRID MODE and flow rates 1. The minimum and maximum /////////////////////// flow rates required by the circulation conditions are set in the Pump Control Module. Pump Control Module
Slide 39: Controls fluid pressure and flow rates: hybrid mode
Pump control Controls fluid pressure HYBRID MODE and flow rates 1. The minimum and maximum /////////////////////// flow rates required by the circulation conditions are set in the Pump Control Module. 2. The minimum and maximum fluid pressure to maintain proper spray conditions are set in the Pump C
Slide 40: Controls fluid pressure and flow rates: hybrid mode
Pump control Controls fluid pressure HYBRID MODE and flow rates 1. The minimum and maximum /////////////////////// flow rates required by the circulation conditions are set in the Pump Control Module. 2. The minimum and maximum fluid pressure to maintain proper spray conditions are set in the Pump C
Slide 41: Controls fluid pressure and flow rates: hybrid mode
Pump control Controls fluid pressure HYBRID MODE and flow rates 1. The minimum and maximum /////////////////////// flow rates required by the circulation conditions are set in the Pump Control Module. 2. The minimum and maximum fluid pressure to maintain proper spray conditions are set in the Pump C
Slide 42: Controls fluid pressure and flow rates: good to know
Pump control Controls fluid pressure and flow rates /////////////////////// GOOD TO KNOW Max. 2 Fluid Pressure Sensors can Max. 1 Fluid Pressure Sensor can be connected to the Pump Control be activated for the constant Module. pressure closed loop function. Both fluid pressures can be seen The pump
Slide 43: Keeps your pressure and flow stable and in balance
Pump control Keeps your pressure and flow stable and in balance 1. A production and a non-production /////////////////////// profile are set in the Pump Control Module: • Production mode Back Pressure Regulator • Constant pressure • BPR open/closed percentage set by user • Non-production mode (sleep
Slide 44: Keeps your pressure and flow stable and in balance
Pump control Keeps your pressure and flow stable and in balance 1. A production and a non-production /////////////////////// profile are set in the Pump Control Module: • Production mode • Constant pressure • BPR open/closed percentage set by user • Non-production mode (sleep mode) • Constant flow (
Slide 45: Keeps your pressure and flow stable and in balance
Pump control Keeps your pressure and flow stable and in balance 1. A production and a non-production /////////////////////// profile are set in the Pump Control Module: Back Pressure Regulator • Production mode • Constant pressure • BPR open/closed percentage set by user • Non-production mode (sleep
Slide 46: Good to know: paint shear
Pump control Keeps your pressure and flow stable and in balance /////////////////////// GOOD TO KNOW: Paint shear Paint shear takes place mainly in It also lowers energy consumption the Back Pressure Regulator. as the pump will run more slowly (just enough to keep the paint in motion). Opening the B
Slide 47: Tank control
Tank control ///////////////////////
Slide 48: Tank control
Tank control /////////////////////// ü Controls tank levels and agitator speeds ü Keeps your fluids at level and in perfect condition
Slide 49: Tank control
Tank control /////////////////////// § Contains: § Refill Pump § Refill Pump Solenoid § Radar Level Sensors § Supply Tank § Production Tank § Electric/Pneumatic Agitators § Connected to and monitored by the Tank Control Module
Slide 50: Tank control
Tank control Tank Control Module Radar Level Sensor Refill Pump Solenoid Electric or Pneumatic Agitator Radar Level Sensor Electric or Production Tank Pneumatic Agitator Refill Pump Supply Tank
Slide 51: Controls tank levels
Tank control Controls tank levels 1. The tank target level is set in the /////////////////////// Tank Control Module. Tank Control Module
Slide 52: Controls tank levels
Tank control Controls tank levels 1. The tank target level is set in the /////////////////////// Tank Control Module. 2. The Radar Level Sensor measures the tank levels inside the Production Tank: Radar Level Sensor Production Tank
Slide 53: Controls tank levels
Tank control Controls tank levels 1. The tank target level is set in the /////////////////////// Tank Control Module. 2. The Radar Level Sensor measures the tank levels inside the Production Tank: • Tank target level • Tank fill level Tank target level Tank fill level
Slide 54: Controls tank levels
Tank control Controls tank levels 1. The tank target level is set in the /////////////////////// Tank Control Module. 2. The Radar Level Sensor measures the tank levels inside the Production Tank: • Tank target level • Tank fill level Radar Level Sensor 3. The Radar Level Sensor detects if the tank
Slide 55: Controls tank levels
Tank control Controls tank levels 1. The tank target level is set in the /////////////////////// Tank Control Module. 2. The Radar Level Sensor measures the tank levels inside the Production Tank: • Tank target level • Tank fill level Refill Pump Solenoid 3. The Radar Level Sensor detects if the tan
Slide 56: Controls tank levels
Tank control Controls tank levels 1. The tank target level is set in the /////////////////////// Tank Control Module. 2. The Radar Level Sensor measures the tank levels inside the Production Tank: • Tank target level • Tank fill level 3. The Radar Level Sensor detects if the tank fill level has been
Slide 57: Controls tank levels
Tank control Controls tank levels 1. The tank target level is set in the /////////////////////// Tank Control Module. 2. The Radar Level Sensor measures the tank levels inside the Production Tank: • Tank target level • Tank fill level 3. The Radar Level Sensor detects if the tank fill level has been
Slide 58: Controls tank levels: good to know
Tank control Controls tank levels /////////////////////// GOOD TO KNOW The actual tank level can be seen on the The Supply Tank paint level is also Tank Control Module. measured by a Radar Level Sensor. Once the tank level low deviation (TLLD) is reached, an alarm will be A tank level low and high a
Slide 59: Controls agitator speeds
Tank control Controls agitator speeds /////////////////////// 1. The Electric Agitator parameters are set: • Minimum speed (%) • Minimum tank level (%) • Maximum speed (%) • Maximum tank level (%) • On-Off time programming Electric Agitator
Slide 60: Controls agitator speeds
Tank control Controls agitator speeds /////////////////////// 1. The Electric Agitator parameters are set: • Minimum speed (%) • Minimum tank level (%) • Maximum speed (%) • Maximum tank level (%) • On-Off time programming 2. The Radar Level Sensor measures Radar Level Sensor the tank level inside t
Slide 61: Controls agitator speeds
Tank control Controls agitator speeds /////////////////////// 1. The Electric Agitator parameters are set: • Minimum speed (%) • Minimum tank level (%) • Maximum speed (%) • Maximum tank level (%) • On-Off time programming Electric Agitator 2. The Radar Level Sensor measures Variable Frequency Drive
Slide 62: Controls agitator speeds
Tank control Controls agitator speeds /////////////////////// 1. The Electric Agitator parameters are set: • Minimum speed (%) • Minimum tank level (%) • Maximum speed (%) • Maximum tank level (%) • On-Off time programming 2. The Radar Level Sensor measures the tank level inside the Production Tank
Slide 63: Controls agitator speeds: good to know
Tank control Controls agitator speeds /////////////////////// GOOD TO KNOW There are 2 different agitator profiles The Variable Frequency Drive (VFD) available. They can be linked to production can also be controlled via the HMI or non-production mode. Agitator profiles Touchscreen or via an externa
Slide 64: Overall (remote) control
Overall (remote) control ///////////////////////
Slide 65: Overall (remote) control
Overall (remote) control /////////////////////// ü Allows you to control the paint mix room from outside the hazardous area ü Gives you access to (real-time) key paint circulation data
Slide 66: Overall (remote) control
Overall (remote) control /////////////////////// § Contains: § Supervisor Box § HMI Touchscreen § Variable Frequency Drive (VFD) § Power Supply
Slide 67: Overall control
Overall control Variable Frequency Drive (VFD) HMI Touchscreen Supervisor Box Power Supply
Slide 68: Allows control from outside the hazardous area
Overall control Allows control from outside the hazardous area 1. Pump and tank control settings /////////////////////// and configurations are done via the Pump Control Module and Tank Control Module. Pump Control Module Tank Control Module
Slide 69: Allows control from outside the hazardous area
Overall control Allows control from outside the hazardous area 1. Pump and tank control settings /////////////////////// and configurations are done via the Pump Control Module and Tank Control Module. 2. All settings and configurations can also be done from outside the hazardous HMI Touchscreen are
Slide 70: Allows control from outside the hazardous area
Overall control Allows control from outside the hazardous area 1. Pump and tank control settings /////////////////////// and configurations are done via the Pump Control Module and Tank Control Module. 2. All settings and configurations can also be done from outside the hazardous area via the HMI To
Slide 71: Allows control from outside the hazardous area
Overall control Allows control from outside the hazardous area 1. Pump and tank control settings /////////////////////// and configurations are done via the Pump Control Module and Tank Control Module. 2. All settings and configurations can also be done from outside the hazardous HMI Touchscreen are
Slide 72: Allows control from outside the hazardous area: good to know
Overall control Allows control from outside the hazardous area /////////////////////// GOOD TO KNOW One Supervisor Box can control up to 20 To communicate with an external paint supply or paint circulation systems. PLC, an additional communication gateway needs to be connected to the Supervisor Box.
Slide 73: 4. Which components are used?
4. Which components are used? ////////////////////////////////////////////////
Slide 74: Pump control components
Pump control Pump Control Module Fluid Pressure Sensor Paint Circulation Pump Electric/Pneumatic Transducer Back Pressure Regulator (BPR) Fluid Pressure Sensor Pump Run/Stop Switch
Slide 75: Tank control components
Tank control Tank Control Module Radar Level Sensor Refill Pump Solenoid Electric or Pneumatic Agitator Radar Level Sensor Electric or Production Tank Pneumatic Agitator Refill Pump Supply Tank
Slide 76: Overall control components
Overall control Variable Frequency Drive (VFD) HMI Touchscreen Supervisor Box Power Supply
Slide 77: Electric Paint Circulation Pump
Pump control Electric Paint Circulation Pump ///////////// § E-Flo DC Pump: § Energy-efficient reciprocating piston pump § Electric Brushless Dual Control Motor § Continuously circulates one paint color through the paint mix room § Can operate two ways: § Constant Pressure Mode § Constant Flow Mode
Slide 78: Electric Paint Circulation Pump
Pump control Electric Paint Circulation Pump ///////////// ü Constant fluid pressure and flow rate ü Can stall under pressure (similar to pneumatic pressure) ü Optimal paint feed to the applicators ü Low pulse, low noise, no icing
Slide 79: Pneumatic Paint Circulation Pumps
Pump control Pneumatic Paint Circulation Pumps ///////////// Endura-Flo High-Flo Glutton Small to mid-sized 4-ball piston pump that 4:1 pump that is made double diaphragm delivers in mid-size to for tough applications pump that offers large circulation and has been an industry-leading applications u
Slide 80: Pump Control Module
Pump control Pump Control Module ///////////// § Pump control ‘brain’ § Connection point and power source for all pump control components § Allows advanced monitoring and controlling of the pump § Has its own software to send instructions between the non-hazardous and hazardous area § One Pump Contr
Slide 81: Pump Run/Stop Switch
Pump control Pump Run/Stop Switch ///////////// § Physical switch to start and stop the pump without switching off the AC Power to the DC Motor § Mounted close to the pump
Slide 82: Fluid Pressure Sensors
Pump control Fluid Pressure Sensors ///////////// § Measures fluid pressure inside the paint circulation line § Two pressure sensors can be installed: § One at the pump outlet § One close to the BPR § Both sensors connected to and controlled by the Pump Control Module
Slide 83: Fluid Pressure Sensors
Pump control Fluid Pressure Sensors ///////////// ü Fluid pressure can be read out on the Pump Control Module ü Pump outlet sensor can be used to reduce pulsing at the pump outlet ü Can be activated to run in closed loop function
Slide 84: Back Pressure Regulator (BPR)
Pump control Back Pressure Regulator (BPR) ///////////// § Maintains the back pressure in the paint circulation system § Based on profiles set in the Pump Control Module § Easy switching from production to non-production profiles
Slide 85: Back Pressure Regulator (BPR)
Pump control Back Pressure Regulator (BPR) ///////////// ü Stable pressure at any time ü Less paint shear and maximum material life ü Increased energy savings
Slide 86: Electric/Pneumatic Transducer
Pump control Electric/Pneumatic Transducer ///////////// § Converts a current input signal to a linearly proportional pneumatic output pressure § Based on a closed loop pressure feedback system: § Closely controls output § Compensates for supply pressure variations § Adjusts the BPR according to tar
Slide 87: Refill Pump
Tank control Refill Pump ///////////// § Air-operated double diaphragm pump § Fills the production tank from the Supply Tank, when needed § Stops automatically when fluid target level is reached § Includes a Reed Switch for cycle detection
Slide 88: Tank Control Module
Tank control Tank Control Module ///////////// § Tank control ‘brain’ § Allows advanced monitoring and controlling of tanks § Connection point and power source for all tank control components § Sends instructions between non-hazardous and hazardous area
Slide 89: Refill Pump Solenoid
Tank control Refill Pump Solenoid ///////////// § Pneumatic controlled air valve § Enables control of the pneumatic Refill Pump § Starts the Refill Pump when fluid level in the Production Tank falls below a user-specified level § Stops the pump when fluid level reaches the user-specified level
Slide 90: Radar Level Sensors
Tank control Radar Level Sensors ///////////// § Contactless fluid level sensors § Detect and communicate the fluid levels: § In the Supply Tank § In the Production Tank § When the production tank level is low, the sensor activates the Refill Pump Solenoid to start up the Refill Pump § Generates an
Slide 91: Supply Tank
Tank control Supply Tank ///////////// § Stores supply paint for the paint line
Slide 92: Production Tank
Tank control Production Tank ///////////// § Stores mixed paint for the paint line
Slide 93: Electric or Pneumatic Agitators
Tank control Electric or Pneumatic Agitators ///////////// § Keeps the paint mixed and homogeneous without incorporating air into the fluid § Speed of the Agitator depends on tank level § Mounted on each tank
Slide 94: Supervisor Box
Overall control Supervisor Box ///////////// § Communication hub for the Intelligent Paint Kitchen § Links with your Programmable Logic Controller (PLC) § Contains the software that runs the Intelligent Paint Kitchen § Can control up to 20 paint supply and paint circulation systems
Slide 95: HMI Touchscreen
Overall control HMI Touchscreen ///////////// § Remote interface between the Intelligent Paint Kitchen and operator § Displays all paint mix room conditions and settings § Allows users to change parameters and preferences or install updates § Allows users to schedule production and non-production ti
Slide 96: Variable Frequency Drive (VFD)
Overall control Variable Frequency Drive (VFD) ///////////// § Makes it possible to adjust the speed of the Electric Agitator: § Agitator slows down when the tank level is falling § Agitator speeds up when the tank level is rising § Three agitator profiles are available, depending on paint type and
Slide 97: Variable Frequency Drive (VFD)
Overall control Variable Frequency Drive (VFD) ///////////// ü Agitator speed is controlled from the non-hazardous area ü Decreases paint shear and prevents paint foaming
Slide 98: Power Supply
Overall control Power Supply ///////////// § Powers up to three Tank Control Modules (and pneumatic pump if applicable) § Includes safety barrier
Slide 99: Thank you. Questions?
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