Industrial Process Heating
|
Benefits to Freightliner:
Advanced Energy’s dedicated industrial process specialists have a passion for research and discovery. Our team provides direct access to in-the-field insight and innovative answers that generate practical solutions with measurable results. We have solutions for improving quality and productivity, reducing operating costs, environmental compliance, increasing capacity, and extending equipment life. Background Freightliner is a wholly-owned subsidiary of DaimlerChrysler and is the largest heavy-duty truck manufacturer in North America. It markets vehicles in more than 35 countries outside of the North American Free Trade Agreement [NAFTA]. Problem Freightliner wanted to improve the paint quality of their products to meet customer demands, which would, in turn, increase productivity and decrease overall operating costs. Previously, Freightliner did not harden or cure the liquid paint prior to going into the gas convection oven. Airborne particles and other debris would frequently stick to the paint, impacting quality issues at this stage and further into the manufacturing process. Lack of a solution for improving this process caused customer complaints to increase, and employee morale to decrease, which further decreased production. Assistance Duke Energy and Advanced Energy evaluated the existing gas-curing ovens and identified electric infrared [IR] as an acceptable solution based on quality and curing time. They recommended the installation of an electric IR pre-heater and a gas convection oven to decrease drying time. Freightliner arranged meetings with channel partners Protherm, who designed the pre-heater, and Pneu Mech, who designed the convection oven and installed all of the technology. Once the specific oven technology was determined, numerous tests were performed to verify Freightliner's requirements for the curing and for the sizing of the oven. Solution A collaborative design project yielded the decision that an electric IR pre-heater and gas convection oven would meet the customer's requests. The IR preheater allows the liquid paint to start shelling over, or hardening, which keeps airborne particles from sticking to the paint as it enters the convection oven. This increase in quality surpassed the needs of customers, and throughput reduced Freightliner's overall operating costs. Benefits Because of the success of this electric IR oven installation, other Freightliner plants are interested in converting their curing process. The benefits of Freightliner's collaboration with Duke Power and Advanced Energy includes an increase in paint quality, improved employee morale, a decrease in overall operating costs and a decrease in production time by nearly one-half. For More Information Contact Mark Gentry at 336-679-4020 or mgentry@advancedenergy.org.
|
