Paint Booth for Alternators
An alternator, as an integral part of every combustion engine vehicle, its main responsibility is to convert chemical energy to electrical energy so that you can charge and replenish the battery in your engine and other electrical components in a car. Also an Alternator is an electrical generator that converts mechanical energy to electrical energy in the form of alternating current.
Spray booth for Alternator generators – Autocoat Engineering has a vast experience in the field of pretreatment of parts of electric motors & induction motor before painting . Most important is the process flow which would divide the pretreatment process as per material of construction . Alternator /Generator casting are pretreated separately while some parts are precleaned in the paint booth before final painting .Painting line for the alternators should not only take care of the asthetics but also internal parts like stator & rotor.
Spray Painting process in alternator paint booth – Alternators like motors are divided into 3 major parts Casing , Stator & Rotor. All these bodies require painting . The stator and rotor are only primer painted wherevernecesary , whereas the casing is primer painted plus one more coat of final colour.
Process 1 - Pre-treatment of alternator casting body .Casting after manufactured take lot of time to reach the final customer before sending to paint booth for alternator painting. Therefore Autocoat recommends to shot blast such alternator castings at the vendors point itself & a coat of primer paint or red oxide should be applied in the alternator spray booth at the vendors premises .
Other ways to pretreat the alternator castings or fabricated items is by having a dedicated pretreatment 9 tank process with water drying tank equipment . This process will also help in giving phosphating coating to the various parts ,increasing the paint adhesion properties. Pretreatment for alternator castings and body removes the rust and oil contamination on the parts used during the previous processes. Pretreatment plat is also widely know as phosphating plant.
Process 2 – Painting in gel coat on stator in alternator paint booth , once the stator is been assembled with internal copper windings and other accessories , it is now to be sprayed with gel coat insulation. This gel coat is also know as epoxy resin or varnish. Normally such resins are applied with either brush or dip /rolling process , but now with the use of special spray guns ,the gel coat can be sprayed in the alternator spray booth . The special spay guns are able to handle the viscosity of the thick gel resin. Autocoat has deviced many such spray booth for alternators where such gel coats are been sprayed and all left over sprays are captured on continuous basis As per latest. Spraying the gel coat gives a n even coverage on the required insulated parts of the stator. Note – These processes can differ from company to company.
Process 3 – Painting of gel coat varnish on rotor in rotor painting spray paint booth.Here the above process is similarly repeated . Rotor gel spraying is more faster than the previous process as the component size is 50% of the stator. With better jigging , 2 rotors at a time can be painted for better economics.
Autocoat has supplied many such gel coat booths for alternator internal parts painting . Please see some photos for ready reff.
Process 4 – Final finish coat of paint to be applied on the external surface of the assembled alternator in Alternator paint booth . After a series of testing’s ,assembled alternators or generators are lifted with handling cranes or other mechanisms and loaded in the paint booth or on conveyor . Assembled alternator generators are heavy and larger in size , Autocoat has devised mechanisms that can handle assembled alternators , with special jigs which can accommodate weight wise heavy alternators , generators with minimized efforts. Material movement of the semi large heavy alternators is done by roller conveyors & then handling by hoist facility . Autocoat paint booth for alternators has very good suction to take of any paint dust floating in the air and trapping them inside the extraction chamber.
Process 4 – Final finish coat of paint to be applied on the external surface of the assembled alternator in Alternator paint booth . After a series of testing’s ,assembled alternators or generators are lifted with handling cranes or other mechanisms and loaded in the paint booth or on conveyor . Assembled alternator generators are heavy and larger in size , Autocoat has devised mechanisms that can handle assembled alternators , with special jigs which can accommodate weight wise heavy alternators , generators with minimized efforts. Material movement of the semi large heavy alternators is done by roller conveyors & then handling by hoist facility . Autocoat paint booth for alternators has very good suction to take of any paint dust floating in the air and trapping them inside the extraction chamber.>
Other Process for handling Very large Alternators generators in paint booth for alternators – Special heavy generator alternators used in windmill generators and other engines or power plants , tend to have complex size a, shape and can weigh more than 4/5 tons . Such alternators are to be handled with factory EOT hoist only . Due to such kind of handling ,Autocoat gives large top slot on the alternator spray booth, this helps for easy movement of generators inside the paint booth for shifting , lifting , lowering activities.
Autocoat has supplied many alternator paint booths & conveyorised motor painting lines, which are running almost in 3 shift basis trouble free. We have designed, developed & manufactured Conveyored alternator painting lines are similar to motor painting lines .For small size alternator painting it is better to go for conveyorised setup is very fast & economical.With addition of online convection oven the drying process of the paint film can be accelerated & dust settling on the painted alternators can be reduced greatly.
All above photos of alternator paint booths have dedicated material method that enhances the capability of the painter to lift & lower the heavy & also to rotate . Our spray booths are very efficient & match the pollution board norms. Training sessions are been conducted to educate the painters & subordinates to get maximum productivity & effective maintenance.