Cybernetik’s Substrate Coating System for Catalytic Converters enables data traceability, high productivity, customized design, and safety for heavy duty trucks, passenger cars, and motorcycles.
Quality checks: Back pressure checking stations, weighing stations.
Heavy Duty Coating System
Project Video
Capacity
Customizable
Substrate size:
Diameter: 75-450 mm
Height: 100-400 mm
Industry
Automobile
Applications
DPF and SCR catalytic converters installed in heavy duty trucks.
Highlights
Automatic and semi-automatic operation.
Process:
Pre weighing the substrate on the coating station before it is coated.
Coating of one substrate at a time:
Is performed by a vacuum based substrate coating system (coater) which moves slurry from bottom to top of the substrate (converter) after dipping the latter to the prescribed depth in a recirculating slurry tank.
Vacuum turbine blower generates a vacuum.
Slurry viscosity and homogeneity maintained by agitator and continuous slurry recirculation between coating station and batch tank.
Recipe based suction time and pressure.
Accurate dip height and required isolation for vacuum suction via servo linear actuator driven top hood and bottom slurry cup.
Batch tank has high and low level sensors, and interfaces with the external slurry feeding system.
Air stripping:
Achieves required weight gain of substrate as per recipe.
Passes compressed air from compressed air buffer tank through substrate.
Post weighing checks if the substrate has gained the required weight.
Motorcycle Coating System
Project Video
Capacity
Customizable
Substrate size: 30-52 mm
Industry
Automobile
Applications
Motorcycle catalytic converters
Highlights
Integrated and flexible system for coating metallic substrates.
Intelligent mechanism with Total Recipe Management via IoT or SCADA systems.
HMI for parameter setting and alarms.
Digital bench weigh scales interfaced with PLC.
Two (2) compliant grippers on each station of the rotary indexer.
Process stations:
Loading station: Conveyor with pneumatic loader moves substrate to pneumatic gripper on the rotary indexer. Gripper holds the substrate’s external cylindrical surface.
Weighing station records uncoated weight.
Coating station vacuum raises slurry through the substrate’s honeycomb mesh after gripping it in top and bottom seal plates.
Dripping station collects excess coating in the bottom slurry tank.
Air stripping station removes excess coating using a digitally controlled air blast. Substrate is vertically inverted for a second blast.
Weighing station records coated weight.
Drying station passes substrate on a wire mesh conveyor with hot air circulation.
Reject station rejects substrates with incorrect weight gain.
Passenger Car Standalone Coating System
Project Video
Capacity
Customizable
Industry
Automobile
Applications
Passenger car catalytic converters
Highlights
Fully / semi automatic standalone set up for coating and air stripping metallic and ceramic substrates.
Recipe-based system with SCADA / IoT.
User-friendly HMI for easy operation and troubleshooting.
Flexibility:
Adjustable dipping height.
Simple and rapid fixture changing.
Material saving with slurry recirculation.
Process:
Pre weighing before coating on the pre-weighing station of the coater.
Coating of two parts simultaneously:
Is performed by a vacuum based substrate coating system (coater) which moves slurry from bottom to top of the substrate (converter) after substrate is dipped in the recirculating slurry tank to the prescribed depth.
Vacuum turbine blower generates a vacuum.
Slurry viscosity and homogeneity maintained by agitator and continuous slurry recirculation between coating station and batch tank.
Recipe based suction time and pressure.
Batch tank has high and low level sensors, and interfaces with the external slurry feeding system.
Air purging removes excess slurry from the substrate via required number of passes.
Offloading on the unload slide after purging.
Post weighing after coating on the post-weigh station of the coater.
Pre weighing before air stripping.
Air stripping:
Achieves required weight gain of substrate as per recipe.
Passes compressed air from compressed air buffer tank through substrate.
Post weighing checks if the substrate has gained the required weight.
Calciner
Capacity
Customizable
Industry
Automobile
Applications
Catalytic converters installed in:
Heavy duty Trucks
Passenger cars
Motorcycles
Highlights
Improves catalyst coating’s strength via heat treatment.
Holds coated part at pre-set temperature for pre-set duration. For e.g. at 600° C for 5 min.
Gradual heating and cooling prevents ceramic cracking.
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