| Precision
spray control allows
manufacturer to improve product quality
Problem:
A building materials manufacturer needed to prevent small particles
of fiberglass from becoming airborne and causing irritation to the
installer of the fiberglass mat. To achieve this goal, they needed
to spray varying amounts of a proprietary product on the top and
bottom of batt insulation, which varied in thickness. This process
modification was due to their customers complaining about end-product
quality.
 Solution:
AutoJet® Technologies engineers designed a control system to
provide precise spray control for two banks of spray guns each comprised
of five Spraying Systems Co. 10535 automatic air atomizing spray
guns. Both banks of spray guns continuously apply the proprietary
coating to the top and bottom of fiberglass batt insulation. The
control panel allows for various flow rates based on varying production
rates.
The
Model 2250 AutoJet Spray Controller, powered by SprayLogicTM
software, uses a turbine flowmeter in a closed loop flow system
to control the flow rate for each bank of guns. Production line
speed is represented by a remote analog input signal to the controller.
As the line speed varies from a specified maximum value, the flow
rate to each bank of spray guns is adjusted accordingly to maintain
a consistent application rate. The controller's PID control feature
allows the manufacturer to spray the top and bottom of the insulation
at one time, eliminating the need for multiple controls.
The
AutoJet 10535 air atomizing spray guns are equipped with clean-out
needles to keep the system operating at peak efficiency. Automatic
gun clean-out cycles are programmed via an external timer. This
feature eliminates downtime caused by clogged spray nozzles and
also minimizes time spent manually cleaning the spray guns.
The spray system supplied by AutoJet Technologies improved the company's
product quality by eliminating the loose fiberglass particles. The
company has also maximized their production rates while minimizing
overspray, which is key to sustaining profitability. System installation
was supervised by AutoJet Technologies Engineering, which also provided
one day on-site training for production personnel.
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