berita perusahaan tentang Full-process digital management and control: a coating production line that can adapt to changes, be traceable, and prevent material mixing

Digital intelligence

Coated synthetic thread

Modularization, flexibility, unmanned operation

With the accelerated advancement of automotive lightweighting and electrification, the number of fasteners has increased, reliability requirements have risen, and automakers have put forward higher demands for traceability and consistency in the coating process. This has rendered traditional coating processing modes unable to meet the future quality management system. How to achieve more flexible production scheduling, traceable processes, and no mixing of batches while ensuring stable quality has become a practical challenge faced by more and more processing enterprises.

Focusing on this industry pain point, Junhe, based on long-term practice in coating processes and equipment, has built an intelligent digital coating synthesis line, reconstructed from the underlying architecture to system logic, and formed three core capabilities: flexible design, traceable design, and unmanned design.

Intelligent and Digital Coating Synthesis Line

I. Flexible design: No longer “a shutdown in one place, the entire line is restricted”

Traditional coating production lines mostly adopt mechanical hard connection methods such as climbing machines and secondary rotation, lacking buffering and decoupling between upstream and downstream processes. Once a certain process is suspended due to paint replacement, equipment maintenance, or parameter adjustment, the entire line is forced to shut down, resulting in low capacity utilization, difficulty in inserting orders, and slow batch change.Junhe’s intelligent coating synthesis line breaks this limitation structurally:AGV replaces hard connections, and processes are no longer forced to be in series.A turnover buffer is set up in the line-side warehouse to realize batch order collection and rhythm adjustment.Each individual equipment can operate and be maintained independently, without shutdown.At the same time, the system is deeply linked with MES, and dynamically schedules production based on information such as order delivery date, batch process, and equipment working conditions, making production plans more orderly, rhythms more stable, and equipment utilization higher.In the workpiece transfer link, robot flexible handling is introduced to reduce the risk of collision caused by large drop height in traditional hard connections, effectively ensuring that the thread go-no-go gauge is stably qualified.

II. Traceable Design: Making Every Batch of Coating Traceable

In high-quality coating processing, “doing it right” is important, and “being traceable” is equally crucial.Junhe’s intelligent coating synthesis line, with MES at its core, has built a clear and complete traceability logic:After incoming materials undergo manual incoming inspection, weighing, and distribution, they are put into frames, scanned, and filed.The scanned information enters the MES, and the system automatically matches the corresponding process sheet and generates a production scheduling plan.When workpieces reach key stations such as shot blasting, coating, and curing, scanning the code will call up the process.The industrial computer interacts with the MES,Process parameters and task instructions are automatically issued,Actual processing data and equipment status are transmitted back in real-time.Finally, each batch forms a complete data chain:Incoming materials → Process → Equipment → Parameters → Status → Results, truly achieving “processes can be checked, results can be traced, and responsibilities can be pursued”.

III. Anti-mixing Design: Keep “mixing risks” outside the system

Material mixing is one of the most unacceptable yet most prone problems in the coating process of fasteners.Junhe regards anti-mixing as an important part of digital and intelligent quality control. It has built a full-process anti-mixing system through multiple mechanisms including physical isolation, system verification, and data tracking.

① Physical isolation for inherent error prevention
Three-layer furnace/double-layer furnace pallet loading and step-by-step operation with physical separation throughout the process.Independent processing baskets/tooling, one basket for one batch.Offline warehouses are stored in zones, with different batches not mixed or taken by mistake.

② System verification, stopping when errors occur
Mandatory code scanning verification at the time of entering the frame and key workstations.If the batch does not match the process, the equipment is prohibited from starting.AGV tasks are bound to batches, and cross-batch handling is not allowed.Robots perform batch identification before picking and placing to prevent wrong placement and picking.

③ Data tracking for full-process monitoring
MES displays in real-time the workstation, quantity, and status of each batch.Automatic counting when (coming out of the furnace) and (leaving the line), compared with the expected quantity.Immediate alarm for abnormal quantity and process.Batch data of the entire line is automatically archived, supporting quick traceability and review.Through the superposition of multiple mechanisms, the risk of material mixing caused by human intervention is minimized, realizing a true “zero mixing” operation mode.

Junhe’s intelligent coating synthesis line is not a simple superposition of equipment, but redefines the operation mode of coating production lines from the aspects of structure, system and management logic, providing a more stable, more reliable and more long-term valuable development path for fastener zinc-aluminum coating processing.