International Journal of Recent Technology and Engineering (IJRTE)

ISSN: 2277-3878, Volume-X, Issue-X, July 2019

Automation of Masking and De-masking in

Powder Coating Process
Ajay Kurhade1, Ajinkya Potbhare2, Praveen Wakchaure3, Sundaram Singh 4 ,
Prof.K.B.Kshirasagar5


Abstract: The main objective of today's manufacturing

industries is to produce low cost, high quality products in short
time. However, the key element for achieving high quality at
low cost is Design of Experiments. The present work analyses 3.Demasking: De-masking is the process of removing the masks
different parameters of manufacturing processes to minimize of the component. This process needs skilled worker to remove
the defects. Good surface finish with required tolerances and the mask from the component. Main problem arrived in this
dimensional accuracy can be achieved by automation of process is
controllable process parameters. Moreover, by selection of chances of damaging the powder coating. If mask does not
automatic process parameters defects are minimized. The remove properly, then there is a chance of damaging the powder
present technique of masking is manually operated which is coating, which further results in rejection of the component.
more time consuming, it requires more labours and also there
are chances of damaging the powder coating during de- II. LITERATURE REVIEW
masking of the component. The objective of this project is to
reduce the process time and to design the automatic technique 1.Masaru Oda et al. studied the “masking system using masking
for the same. piece.” In a masking system a robot performs first conveyance
work
Keywords: Automatic technique, Design of experiments, of making an object gripping unit grip an object and set the
High Quality, Tolerances and Dimensional Accuracy. object at a predetermined position based on positional
information of the object which was detected by a first detection
I.INTRODUCTION unit, coating work of making a coating unit coat an adhesive on a
masking location of the object which is set at the predetermined
position, and second conveyance work of making a masking
Automation is the technology by which a process or procedure
piece gripping unit adhere a masking piece to the masking
is performed with minimal human assistance.  Automation or
location of the object based on positional information of the
automatic control is the use of various control systems for
masking piece which was detected
operating equipment such with minimal or reduced human
by a second detection unit.
intervention. Automation has been achieved by various means
including mechanical, hydraulic, pneumatic, electrical, electronic
2.Iqbal et al. studied the “facility and method for applying
devices and computers, usually in combination. The benefit of
coatings to elongated automotive parts.” An installation and a
automation includes labour savings, savings in electricity costs,
method for applying coatings to automotive enlarged pieces are
savings in material costs, and improvements to quality, accuracy,
disclosed. The installation comprises an elevated conveyor,
and precision.
wherein the enlarged pieces are vertically hanged up; a formation
Every powder coating job will probably require at least one
section of an anticorrosive coating on the Surface of the enlarged
and maybe several different masking techniques. The purpose
piece; a drying section of the enlarged piece on which the coating
of masking in powder coating, is to keep the powder from
has been formed; a masking section wherein some portions of the
reaching certain areas of the item being coated. Powder coating is
piece are covered; a paint application section wherein the
a dry finishing process that uses finely ground particles of
enlarged piece is coated with paint; an unmasking section of the
pigment and resin that are electrostatically charged and sprayed
piece in which the previous masked portions are uncovered;
onto electrically grounded parts. The charged powder particles
wherein the elevated conveyor continuous and vertically conveys
adhere to the part and are held there until melted and fused into a
the enlarged pieces along each of the sections in the installation.
uniform coating in a curing oven. The product to be coated is
exposed to cleaning and pretreatment operations to ensure that
3.Jerime Blackman studied the “apparatus and system for
surfaces to be coated are clean and free of grease, dust, oils, rust
cleaning paint masking devices.” A paint removal apparatus for
and other contaminants.
cleaning paint from masking devices includes a support base
having a plurality of engagement features that are each
1.Painting: The most common way to apply powder coating
configured to securely engage at least one paint masking device.
materials requires a spray device with a powder delivery system
A spray nozzle is aimed in
and electrostatic spray gun. A spray booth with a powder
a fixed direction toward the support base and configured for
recovery system is used to enclose the application process and
spraying a pressurized stream of water at a desired velocity that
collect any over-sprayed powder.
removes paint from an exterior surface of at least one of the
masking devices engaged at the support base. The support base is
2.Masking: Masking is the term we use when we want to shield
configured to successively move the masking devices engaged at
fairly large areas of a part during the powder coating process. For
the engagement features into the pressurized stream of water,
powder coating masking, a high-temperature masking material is
such as to provide a generally
required.
continuous cleaning operation of
 masking devices. During
movement or rotation of the

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support base, an exposed portion of the support base may extend 1.Cycle Time:
from a spray enclosure for removing cleaned plugs from and Masking : 35 sec/job.
loading painted plugs onto such an exposed portion. Painting : 15 sec/job
De-masking : 40 sec/job.
4.Jones et al. studied the “methods of masking a workpiece for
painting and method for masking to facilitate painting of a
workpiece.” 2.Man-Power required:
Masking : 2 labors
Painting : 1 labor
5.Matthews et al. studied the “Paint defect automated seek and De-masking : 1 labor
repaired assembly and method”. He finds the method of detecting  
and repairing paint defects on a workpiece.
3.Rejection:
III. PROBLEM STATEMENT First Time Rejection (FTR) : 52%
Rework : 25%
The present technique of masking of component is manually Total rejection : 30% to 40%
operated, which is more time consuming. It requires more labors
and also there are chances of damaging the powder coating
during de-masking of the component. The quality of product
developed and powder coating is not good.

IV. OBJECTIVE

1.To design the automatic technique for the powder coating

process.
2.To reduce the process time.
3.To reduce the total time required for masking and demasking.
4.To increase the productivity of the system.
5.To increase the accuracy of the process and to reduce the
process cost

V. METHODOLOGY 3.Analyse:
Causes of Rejection-
To get the solution we follow the DMAIC Principle. For develop i. Dent/ Damage
an automatic technique we carried a trial on one component ii. Missing mask
which are coded as ‘P44’. We develop an automatic system for
iii. Over spray
masking and demasking of the P44 component.
iv. Paint dust
v. Mishandling of component
And many more other reasons.

4.Improve:
We have designed the automatic system based on electromagnet
concept for masking and demasking. The main advantage of
electromagnet is that the magnetic field can be quickly changed
by controlling the amount of electric current in the winding. The
pick and place system can be easily designed by using
electromagnetic system. In this project we have used the
electromagnet for holding the mask while masking and to release
the mask while returning after masking and vice-versa.

Electromagnet design:
For this prototype design we have considered the one side for
masking and demasking. This side consists of three masks which
are-
75 mm diameter silicon rubber mask.
3 mm diameter silicon rubber mask.
4 mm diameter silicon rubber mask.
A common tractive electromagnet is a uniformly wound solenoid
and the iron core. In this system we have wound the solenoid
(copper wire 26 gauge) on the mild steel rod which are mounted
1.Define: The present technique of masking is manually on the side plate of the prototype.
operated which is more time consuming, it requires more labors
and also there are chances of damaging the powder coating Mask design:
during de-masking of the component. As per new designed method of powder coating process,
the component with mask is
2.Measure: The numbers of masking components required for going into IR (Infrared Oven) at
P44 component are given below. nearly 80-90℃ temperature.

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 International Journal of Recent Technology and Engineering (IJRTE)
ISSN: 2277-3878, Volume-X, Issue-X, July 2019

Therefore, we designed the masks which are made up of

material of Silicon Rubber which can sustain the
temperature of 80-90℃. Also, due to electromagnet
arrangement we give the metal plate behind every mask.
For proper alignment of the masks with component we give
the taper shape on every mask.

5.Control
In this project we have controlled the amount of error (like
missing mask and mishandling of component, etc.). Also, we
control the misalignment of the mask in the prototype. We also
control the problems which are occurs due to electromagnet like
heating of copper coil.

Prototype development
A prototype has been developed for the masking and demasking
of the component to check the proper working of the process. t is
done to check the alignment of the masking arms and the
component to be masked. To check the electromagnet strength of
the machine for the masking and demasking process. From the
trials done on the prototype, we conclude that the automatic
Masking and the De-masking of the component it possible using
electromagnet. We can control the electromagnetic force by
changing the parameters such as, Current, No. of turns of the
coil, etc. Heating problem of the electromagnet can be resolve by
giving a proper insulation to copper coil. For the proper
alignment and smoothening of the operation we can use proper
guide ways on the Base plate. As per outputs of the prototype
company can developed the automatic machine for the Masking
and De-masking. Proper guide ways can be giving on the fixture
to reduce the vibrations in the machine and to avoid
misalignment of the masks. Pneumatic system can be used to
operate the Side plate and Base plate as per speed of the
conveyer.
VI. RESULT AND DISCUSSION

Advantages and Disadvantages:

1.By using this method we are reducing the process time.
2.Due to automatic process the productivity and quality
increases.
3.By applying this method the number of skilled labor
requirement can be reduced.

Applications:
This method can be used for various components for
masking and demasking during powder coating.

Comparison Between Previous and New Method for Cycle

Time

Cycle Before After

Masking 60 sec/job 30 sec/job

Painting 15 sec/job 15 sec/job

Demasking 45 sec/job 15 sec/job

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 Paper of the Title

Comparison Between Previous and New Method for Labor

Requirement Mr. Praveen Wakchaure, Student of Mechanical
oto
Engineering from Dr. D. Y. Patil Institute of Technology,
Pimpri- 18.

Mr. Sundaram Singh, Student of Mechanical Engineering

from Dr. D. Y. Patil Institute of Technology, Pimpri- 18.

Mr. Kundlik B. Kshirsagar, Professor at Mechanical

Engineering department of Dr. D. Y. Patil Institute
of Technology, Pimpri- 18.

VII. CONCLUSION

1.Overall accuracy of the product will increase.

2.Time required will be reduced by 50% (and will reduce

further after the overlapping of components on conveyor).

3.Man power requirement will reduce by 50%. Productivity

will be increased due to reduction in process time.

4.Rejection will be minimized due to lack of human error.

REFERENCES

1.Jones et al., “Methods of masking a workpiece for

painting”, United States Patent, 4,313,970, (1982)

2.Waldron et al., “Automatic powder spray apparatus and

method for spraying the inside surfaces of containers”,
United States Patent, 3,904,930, (1975)

3.Matthews et al., “Paint defect automated seek and repair

assembly and method”, United States Patent, 6,714,831,
B2, (2004)

4.Timothy J. Schrum, “Method for applying powdered

coatings”, United States Patent, 4,495,217, (1985)

AUTHORS PROFILE

Mr. Ajay Kurhade, Student of Mechanical Engineering

from Dr. D. Y. Patil Institute of Technology, Pimpri- 18.

Mr. Ajinkya Potbhare, Student of Mechanical

Engineering from Dr. D. Y. Patil Institute of Technology,
Pimpri- 18.

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