Challenges in the Paint Shop
Up to 80 atomizers operate simultaneously in one paint line. All components – bell cups, turbines, valves, and air ring nozzles – require regular maintenance and replacement when necessary. Until now, it was difficult to reliably document the lifecycle of each part. Production and maintenance areas are often located separately, and shift changes further complicated traceability.
As a result, mix-ups often led to errors that only became visible after several car bodies had already been coated incorrectly.
RFID as a Key Technology
To increase transparency, Dürr equips the current EcoBell4 atomizer generation with RFID transponders from Kathrein Solutions. Each component carries its own dataset:
- Valves record switching cycles,
- Bell cups track rotation speeds and paint volumes,
- Service life is calculated and adjusted individually.
A total of 28 painting robots in Ingolstadt are already equipped with this technology. The data is stored both on the RFID chips and in a central database – ensuring a seamless system for production and maintenance.
Customized Transponders for Metallic Environments
Paint booths are often made of metal, which shields radio signals. Standard RFID solutions cannot function reliably in such conditions. That’s why engineers from Dürr and Kathrein Solutions developed custom transponders with individual antenna geometries.
- Low Range antennas operate with minimal interference inside the booths.
- Wide Range antennas power the passive transponders outside the booths.
This ensures reliable data exchange despite the challenging environment.
Preventing Errors with Automatic Identification
RFID readers identify each component via a unique ID. If a wrong part is installed or a component is missing, the system automatically alerts the operator – before the painting process starts. This prevents typical errors that previously led to costly rework.
Demand-Driven Maintenance and Training
The digital maintenance station provides technicians with a full overview of specifications, operating data, and service history. Components are no longer replaced at fixed intervals, but only when required. This extends service life, reduces costs, and enables precise planning of downtimes.
Additional tutorials and videos support staff during maintenance – from required tools and consumables to detailed step-by-step instructions. Labels with operating data ensure clear identification within the production line.
Contribution to Sustainability and Efficiency
Audi places great importance on sustainable production. The new system not only increases line availability but also reduces paint consumption. The EcoBell4 technology saves so much paint that up to 12,500 additional car bodies could be coated annually – without extra resource usage.
Read the full story at Kathrein Solutions.
The RFID system from Kathrein Solutions and Dürr demonstrates how digital technologies can optimize traditional manufacturing processes. Transparent component histories, condition-based maintenance, and error-free workflows make Audi’s paint line more efficient, sustainable, and cost-effective.
