What the Project Is
THE FUTURE OF INDUSTRIAL COATING APPLICATION is here – a bold step into applying protective coatings with virtually no overspray. Qlayers is developing innovative robotic solutions for coating large industrial assets using an environmentally friendly, safe and highly precise method. This unique technology overcomes the limitations of manual coating and significantly increases the efficiency and productivity of coating maintenance projects… Imagine the potential when industrial coating becomes faster, more accurate, and environmentally responsible.
Main Benefits
The benefits of this revolutionary project are impressive. The core advantages include:
- Up to >80% reduction of working hours at heights
- Virtually no overspray outside the patented shielding system
- Up to 20% paint savings by applying accurate layer thickness
- Reach speeds of up to 200 m²/h in application
- Automated quality control and consistent application
- Environmentally friendly coating process by minimizing overspray
Technology & Innovation
At the heart of this initiative is a patented spray shielding system designed to coat surfaces with high precision. The technology extracts the minuscule paint spray that isn’t transferred to the surface, thereby preventing it from being released into the environment. The robots consistently apply long-lasting coating layers that safeguard valuable assets from corrosion damage. Whether coating steel storage tanks, vessels or wind turbine blades, the solution is tailored to each asset’s specific requirements – all while ensuring high transfer efficiency (up to 90%).
Magnetic Crawler & Trailer Solutions
The innovative approach incorporates a magnetic crawler that moves along the asset’s exterior, securely held in place with magnets and a fall arrestor. This crawler, coupled with the patented spray shielding system and advanced sensors, ensures both speed and precision – coating at a remarkable speed of up to 200 m²/h. Additionally, the operator can drive the crawler safely from the ground using an intuitive, user-friendly remote control. Complementing the crawler is the trailer, a powerhouse that provides power, air, and paint supply. The trailer integrates an airless 2k pump, a control system with an intuitive HMI, a suction pump to collect paint reminders, and a paint conditioning system which allows for flexible temperature adjustments to handle operations in a broader range of climates.
Customer Success Stories
The success stories highlight the transformative effect of automation in industrial coating. For instance, a full-scale field test on a real paid-for project by customer MOT confirmed that automation not only improves safety and quality but also significantly minimizes risks associated with working at heights. Another key testimonial comes from Shell, which praises Qlayers’ 10Q robot for its seamless integration into their robotics roadmap. The advanced method using an airless gun ensured high-quality application, reduced working hours on heights, and demonstrated higher performance and environmental conservation by preventing the emission of vapours. These stories reinforce that the future of coating application is indeed already here.
Design and Operational Efficiency
Qlayers robotic technology is an embodiment of smart innovation where every element is designed for operational efficiency and safety. The system’s ability to collect process data simultaneously allows for automated quality control and predictive maintenance, making it easier to monitor performance continually. The architectural design not only makes coating more effective but also improves the overall safety of industrial projects. The blend of advanced robotics with intuitive control interfaces hints at a new era where technology and functionality merge seamlessly.
Project Impact: Sustainable Development Goals
- SDG 8: Decent Work and Economic Growth – by reducing working hours in hazardous conditions
- SDG 9: Industry, Innovation and Infrastructure – through cutting-edge robotic applications
- SDG 12: Responsible Consumption and Production – by minimizing paint waste and overspray
- SDG 13: Climate Action – through environmentally friendly processes that reduce harmful emissions
Looking Ahead
The journey into the future of industrial coating application is dynamic and evolving. With innovative technology and smart design, coating operations transform into a safer, more efficient process that not only protects valuable assets but also champions environmental responsibility. This initiative shows that advanced robotics, when coupled with thoughtful engineering, can set new industry standards. As industry challenges continue to change, the adoption of such technologies is paving the way for a more sustainable and automated future, where efficiency and environmental care go hand in hand… The project stands as a stimulating example of what it means to innovate for a better tomorrow.
