The Smartcoater Laser Roller is a roller coater machine designed for finishing flat boards and surfaces with various types of coating products, including polyurethane, polyester, acrylic, and water-based finishes. Its modular mechanical design allows for a wide range of applications, catering to modern coating techniques.
Technical Specifications:
- Operating Speed: 5 to 20 meters per minute.
- Motor Output:
- Conveyor: 1.5 kW
- Doctor roller: 0.75 kW
- Applicator roller: 0.75 kW
- "LASER" applicator roller: 1.5 kW
- Roller Diameter:
- Doctor roller: 173 mm
- Applicator roller: 248 mm
- Workpiece Thickness Range: 0 to 100 mm
- Worktable Height Range: 880 to 940 mm
- Compressed Air Requirements: 54 Nl/min at 6 bar
- Air Pump Pressure: 2 to 10 bar
- Total Weight: 3036 kg (standard version), 3086 kg (explosion-proof version)
- Maximum Working Width: 1350 mm
- Maximum Allowable Workpiece Thickness: 100 mm
- Maximum Air Pump Capacity: 30 l/min at 10 bar
Installation and Safety:
The machine is shipped in suitably sized wooden cases. If the machine is too large for a single container, it will be disassembled and packed in several cases for reassembly, installation, and testing by service personnel on-site. Careful handling during transport and movement is crucial to prevent the cases from falling or overturning.
The machine must be placed on a stable, level floor capable of supporting its weight. Any level variations should comply with building codes. For optimal performance, the machine must be perfectly level, which is achieved by adjusting the base feet and tightening screws using a precision spirit level.
Electrical connections must be performed by qualified industrial electricians in compliance with EN60204-1 standards. The machine typically requires a 3-phase, 50 Hz, 380 Vac supply. The main power supply must be turned off before any electrical work. Air connections are made using a quick coupling with a 1/4" GAS internal diameter, requiring a minimum compressed air pressure of 6 bar.
Safety Devices:
The Smartcoater Laser Roller is equipped with four "positive-action" and two "passive" safety devices:
- Positive-action devices:
- Conveyor stop band: Prevents oversized or stacked workpieces from reaching the applicator rollers and stops the conveyor motor if activated.
- Doctor roller interlock switch: Activated when the doctor roller is moved 100 mm away from the applicator roller, allowing safe manual cleaning of the rollers.
- Applicator/doctor roller guard interlock: Activated when the protective cover for the application heads is opened, stopping the rollers.
- Red emergency stop button: Located on the control panel, it is self-latching and stops the machine instantly in emergencies.
- Passive safety devices:
- Removable scrapers: Allow manual cleaning of the rollers without risk to the operator.
- Two-sided roller covers: Facilitate access to the rollers for manual cleaning in a safe position.
To enhance safety, a suitably sized ventilation system should be installed in the work area to prevent the concentration of acetone vapors.
Operating Instructions:
Before operation, the user should be familiar with the machine's functions and maintenance procedures. The machine applies various chemical-based coating products to flat panels. The rubber-coated applicator roller (B) coats the workpieces, while the chrome-plated doctor roller (C) works in contact with it, holding the paint film. Workpieces are transported by the conveyor belt (A). The pump (E) draws coating product from the container (D) and delivers it to the machine's center via hose (F). Excess product flows from the sides of the rollers to drain channels, collected in the trough (G), and returned to the container (D).
Preliminary Operations:
- Conveyor speed adjustment: Synchronize the conveyor speed with the finishing line speed by activating the "in-line work" option on the PLC control panel. Improper synchronization can lead to workpiece displacement.
- Doctor roller speed adjustment: Adjust via the PLC menu.
- Applicator roller speed adjustment: Adjust via the PLC menu.
- Roller lift adjustment: Adjust the working thickness from the control panel. This must be done with the machine stopped.
- Doctor roller pressure adjustment: Adjust the pressure of the doctor roller (B) on the applicator roller (C) by turning the handwheel (A) clockwise, referencing the indicator (D). This must be done with the machine stopped.
- Scraper positioning: Adjust scrapers (A and E) to be in contact with the applicator (B) and doctor (C) rollers for even coating. Do not leave scrapers resting on stationary rollers to prevent damage.
- Paralleling the scrapers: Ensure rollers and scrapers are perfectly parallel for even coating. This adjustment must be done with the machine stopped.
- Air pump adjustment: Ensure the pressure regulator knob is fully anticlockwise (0 bar pressure) before opening cutoff valves and turning the knob clockwise to start the pump.
- Machine position adjustment in the coating line: If the machine needs to be removed from the line, release the brake (A) and push up the knob (B). Slide the machine out along the tracks.
Control Panel (PLC Version):
The control panel (1) includes pushbuttons for starting/stopping machine groups and an emergency stop. The display shows various work pages, including:
- Start page: Appears after startup, prompting for "RESET PROTECTIONS."
- Work page: Allows all working adjustments, including starting individual motors (conveyor, doctor roller, applicator roller) and setting working speeds.
- Main menu: Accessed via the "HOME" button, leading to parameter settings, recipes, and services.
- Parameter page: Allows setting applicator roller diameter, head limit switches, clearance recovery, prestop, slow speed start, emergency offset, and disabling value.
- Calibration page: Accessed with a password, allowing calibration of speed and thickness settings.
- Info page: Provides statistical and diagnostic data, including motor work hours.
- Recipes page: Manages recipes, allowing loading, saving, and creating new ones.
Maintenance:
- Periodic cleaning: Thorough cleaning of the coating system is essential for long-term efficiency. The manual provides a table with cleaning frequencies for various components (pump, scrapers, troughs, rollers) using pure acetone.
- Material compatibility: The conveyor belt is PVC and is NOT compatible with acetone or its derivatives. The rubber-covered rollers have varying resistance to chemicals; a table indicates compatibility. Corrosive acetone should not be used on rubber components.
- Removing and cleaning scrapers: Loosen knobs, pull up the scraper body, and clean with pure acetone. This should be done with caution to avoid cuts.
- Removing and cleaning side troughs: Raise the applicator assembly, lift out the trough, and clean with pure acetone.
- Cleaning applicator and doctor rollers: Stop the pump, run the doctor roller motor clockwise, raise scrapers, drain product, replace the can with pure acetone, and run the pump to dilute residual paint. This must be done by trained personnel with the machine stopped.
- Lubrication: A table specifies lubrication points (tie bolt, pillow block, conveyor belt, lower roller, gearbox, lead screw, guiderail, scraper blade, grease fittings) with recommended lubricants and frequencies.
- Diathermic oil insertion: For first use, fill the tank (A) and heating system with approximately 20 kg of ROLOIL AERTERM/320 diathermic oil (or equivalent) with the heater off and cold. Check the oil level with the gauge (D). Failure to follow precautions can result in burns or hot oil spurting out.
Troubleshooting:
The machine may stop automatically due to:
- Breakdown or malfunctioning of overload cutouts.
- Incorrect installation of control system actuators.
- Malfunctioning of the control system.
The manual provides tables for common mechanical and electrical faults, their causes, and remedies. For complex issues, contact SORBINI's After-Sales Department.
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