Cylindrical steel parts on a rotating hanging line — seven GR6150-1500 robots, GOST paint system
Seven floor-mounted CMA GR6150-1500 robots coat cylindrical steel parts (Ø152 × 810 mm, 60 kg) on an existing overhead line running at 1.0 m/min, 300 parts per hour, hangers rotating at 120 rpm. GOST single-colour system, SAMES guns and pumps, pressurised Ex ib mb pxb IIC T4 Gb protection for a ПУЭ class В-Iа area.
The problem the customer brought
Not enough skilled operators, a manual process that was hard to manage, and finish quality that was hard to control.
Workpiece
Cylindrical parts Ø152 × 810 mm, 60 kg, on an existing continuous overhead line at 1.0 m/min with 200 mm hook pitch, 300 parts/h, hangers rotating at 120 rpm, 3.5 h cure. Single external coat including the bottom face, with no misses and no runs permitted.
Robots
7 × CMA GR6150-1500, floor-mounted, with online tracking modules.
Process and equipment
GOST single-colour system (primer ВЛ-02 / АК-070, topcoat ХВ-124). Seven SAMES A25 automatic air guns and seven SAMES 01D100 paint pumps with regulators, filters, back-pressure valves, pneumatic agitation and 80 L float-level day tanks; DeVilbiss R4 remote proportional regulators. Explosion protection to ПУЭ class В-Iа using a combined pressurised scheme, Ex ib mb pxb IIC T4 Gb and IIIC T135 °C Db. Seven process control cabinets, two cell control cabinets, seven operator consoles and seven safety sets. Pre-assembled and pre-commissioned in China; on site, four fitters and three commissioning engineers for 35 days each.
Pre-integration and factory acceptance test
Equipment counted against the packing list; safety logic proven, robot paths run, electrical circuits and connections checked, inspection point by point before crating.
Commercial terms
Lead time 2–3 months after deposit, EXW; equipment 40/30/30 with the balance after installation acceptance.
Shipping terms on current projects: EXW, FOB, CIF or DAP. Customer names, plant locations and prices are not published.
Result
Concluded and executed. The customer, working from a flameproof tradition, challenged the protection concept and expected 1ExdIIC. We answered with a standards comparison table explaining that the combined ib + mb + pxb type suits complex electrical equipment with several ignition sources, that IIC is downward-compatible with IIB, and that flameproof d suits simple single devices such as motors, lamps and valves.
What we do differently because of this project
The quotation showed a quantity of seven but the subtotal was calculated for two — five sets short. Quantity × unit price is now checked line by line before any offer leaves. Pressurised (px) protection also needs a continuous protective-gas supply and a start-up purge, so the standards comparison table and the air calculation go into the first version of the proposal.