Automation solutions
for cavity preservation
in the automotive industry

Spraying, flooding, fogging, and air-mix / air-less.

As a leading supplier in the automotive industry, IPR not only develops components, processes and application technologies on a worldwide basis but also sets up complete systems for innovative cavity protection. Our spraying, flooding, fogging and air-mix / air-less processes offer our customers precisely coordinated solutions that efficiently protect the car body against corrosion. We offer a unique combination of spraying, fogging and air-mix/air-less processes. Diverse processes involving the development of suitable nozzles make our portfolio unique.

Tools for Cavity Protection

For cavity preservation and especially for optimizing corrosion resistance in structurally critical areas such as cavities, folds and sheet metal seams, two techniques are applicable: the spraying method and the flooding method. We offer a wide range of appropriate spraying tools for the spraying process. These consist of a nozzle head or bar and individual nozzles.

Mono Nozzle Head Nozzle Change Head (DWK)Nozzle Spray Bar Rotation Spray Bar Accessories Nozzle Manufacturing

Mono Nozzle Head

Nozzle head with low-disruptive contour design to accommodate one nozzle.

Multiple nozzle changes possible through tool changing system
Special model for low pressure application
Material pressure: 65 – 120 bar

Nozzle Change Head (DWK)

Interchangeable head with swivel mounts for 4 or 6 nozzles.

Several process steps possible without having to change tools
Two versions: DWK-6 (left picture) and DWK-4 (right picture)
Interchangeable through tool changing system
Material pressure: 65 – 120 bar

Nozzle Spray Bar

Robot-supported nozzle bar with up to 14 nozzles.

Up to two nozzles can be applied at the same time
Application area: frames and underbody
Robot payload: 120 – 150 kg
Material pressure: up to 250 bar

Rotation Spray Bar

Rotating system with nozzle bar for a stationary application.

Max. 4 nozzle bars per system
Simultaneous application of several nozzles
Rotary motion: +/- 360 °
Linear stroke: 400 mm

Accessories

Numerous accessories are available for the spraying tools.

Manual test station
Geometry control station
Automatic cleaning system
Nozzle inline cleaning

Nozzle Manufacturing

We design and manufacture nozzles in a three-step process:

Transfer of the CAD data
Simulation of the spray pattern
Validation of the results and definition of the amount of wax by means of spray tests in our own application center

Spraying

The IPR spraying process covers the complete range of services for the application of protective wax layers on a sprayable body. Regardless of how cavity preservation is carried out – manually, robot-controlled or stationary. The targeted application of the material with various spray nozzles meets all customer requirements for flexibility and ease of maintenance. Due to IPR’s in-house development and production of nozzles, we are able to achieve the highest quality of nozzle cavities and geometries. All components are characterized by extraordinary precision and reliability in continuous operation and deliver a perfect coating result.

High level of flexibility
Outstanding ease of maintenance
Targeted material application

Flooding

IPR provides a wide range of processes for fully-automated cavity preservation for both hot and cold floodable auto bodies. All IPR technologies applied create maximum performance and increased efficiency. Whether it’s a matter of saving energy, material and space or rebuilding with changing frames for greater type flexibility. Let us assemble your tailor-made system for your flooding process from our diverse product portfolio.

Process reliability
High quality
Full automation
Hot or cold flooding

Fogging

With the fogging process, IPR has developed an innovative atomization technology for corrosion protection of the entire bodywork. Especially complex and difficult to reach geometries, such as door panels, can be perfectly protected with this new process. The specific droplet size, velocity and distribution also allows surfaces that are facing away from the fog stream – e.g. undercuts – to be coated.

Small footprint
High level of flexibility
Low consumption
Cold application
High efficiency

Air-mix / Air-less

In the Air-Mix / Air-Less process, the protective wax layer is applied to attachments, doors and flaps by means of a special robot. The combined Air-Mix / Air-Less application head achieves targeted narrow coverage of welding and soldering seams as well as targeted flat coverage of welding spots, forgings and screw connections. This is accomplished in one application, avoiding the need to change nozzles or tools.

High level of flexibility
Material savings
Seam coating
Surface coating

Contact us!

Personal contact with you is important to us! If you have any questions or suggestions, you can contact us at any time. We look forward to your inquiry!

IPR - Intelligente Peripherien für Roboter GmbH
Jakob-Dieffenbacher-Str. 4/2, 75031 Eppingen

T +49 7262 9239-100
F +49 7262 9239-400
E info@iprworldwide.com

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Automation solutions for cavity preservation in the automotive industry