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Catalytic Convertor

Catalytic converters largely neutralize carbon monoxide, nitrous oxides, hydrocarbon, and particulate matter from automobile exhaust.


Substrate Coating, Drying, & Calcining System

Project Videos

Capacity

Customizable

Market

Automobile

Applications

Catalytic converters installed in:

  • Heavy duty trucks
  • Passenger cars
  • Motorcycles

Highlights

  • Total traceability i.e. every operation on each part is inspected and the data noted down for real time supervision and control.
  • Online tracking & traceability via SCADA systems, inkjet printers, and barcode readers.
  • Recipe based management.
  • Calciner treatment at 6500C.
  • Tray dryer with upto 1200C temperature. 
  • Fast and accurate solution with robotic pick & place based on 2D vision.
  • Error-proofing through inline poka yoke complete with weighing conveyors, colour sensors, and dimension measurement mechanisms.
  • Sub systems:
    • Washcoat automation:
      • Premix tank
      • Brewing tank
      • Activation tank
    • Coating automation:
      • Passenger car standalone coating system
      • Motorcycle coating System
      • Heavy duty coating system 
    • Substrate handling & thermal processing automation: 
      • Dryer
      • Calciner
      • Robotic pick & place 
    • Quality Checks Automation:
      • Track & trace: Height sensor, pad printer, laser printer, barcode scanner.
      • 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.
  • Mesh belt conveyor moves parts continuously.
  • RTDs monitor temperature.
  • Pressure sensor checks air flow continuity.

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