Wheel Rim Repair and Finishing Conveyor System
Pacline Conveyors partnered with an integrator to help a wheel rim repair shop automate their finishing process. By integrating the high-capacity floor-mounted slot sideways Pac-Max™ conveyor with other finishing equipment, the facility transitioned from a manual powder coating system to a fully automated solution.
This case study highlights the successful deployment of Pacline’s conveyor technology, enabling precise, high-quality finishes for various wheel rims.
The Challenge
The end-user wanted to automate their wheel rim finishing process. Previously, they manually placed rims on racks and then moved them throughout the facility to be hand-painted, which was labor-intensive and prone to inconsistencies.
Therefore, they sought to fully automate the process to improve production efficiency and reduce labor costs. One of the major requirements of the system was to have the rim spin at high speeds yet still be able to attain a precise and even finish on the rims. The automobile wheel rims were of various sizes, reaching a maximum of 26” diameters and 12” height, which the system had to be able to handle.
The Solution
Pacline, working with an integrator, developed and installed a customized conveyor solution using a slot slideways Pac-Max™ conveyor system. The system totaled 112 feet and was installed 20″ off the ground, all floor-supported.
Pacline designed a sprocket rotator and spindle to accommodate various sizes of rims. The first part of the finishing process required the rims to travel through a pre-heat convection oven that required no part rotation and had the conveyor travel at 2 feet per minute speeds.
Then, the rims travel through a powder-coating spray booth. When they reach the spray booth, the sprocket rotator engages with a powered rotator to allow the operator to customize the speed at which the rims rotate, ensuring that multiple coats can be applied evenly and quickly depending on the size of the rim. Since the powered rotator is driven by a separate motor and controls, the conveyor speed is not affected by any changes to increase or decrease rotation speed.
The powered rotator is covered by galvanized sheet metal to prevent paint and debris from contaminating the chain. Since a precise and quality finish was part of the requirement of the system, Pacline provided sections of PAC-MAX™ Tite Track which allows for more stability through the spray booth.
The rims then travel through a 450 F degree IR Oven and engage with a gear rack to allow slow part rotation. Pacline also provided guide rails within the oven to keep the rims centered and in place to ensure consistent curing. After curing, the rims travel to an unloading area where they are taken off the system and prepared for pick up or shipment.
The Result
Pacline completed the conveyor installation in five days, as our integrator was responsible for all controls and electrical work for the entire system, including our conveyor.
The automated system significantly improved the efficiency of the facility’s rim-finishing process. With the powered rotators, the operator could now customize the rotating speed through powder coating, thus shortening the spray time drastically compared to manual spraying. The production rate accelerated by averaging 5-8 full rim revolutions per minute utilizing the powered rotator, and the new system ensured a more consistent, high-quality finish. Ultimately, the facility reduced labor costs and improved rim finishing quality.
Overall, the slot-sideways Pac-Max™ conveyor integrated seamlessly into the automated finishing system the integrator had designed to minimize manual handling and maximize production throughput.
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