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Automotive Painting Technology Kimio Toda • Abraham Salazar • Kozo Saito Editors Automotive Painting Technology A Monozukuri-Hitozukuri Perspective 1 3 Editors Mr. Kimio Toda Prof. Kozo Saito Asahi Sunac Corporation Institute of Research for Technology Owariasahi, Aichi Development Japan College of Engineering University of Kentucky Dr. Abraham Salazar Lexington, KY Institute of Research for Technology USA Development College of Engineering University of Kentucky Lexington, KY USA ISBN 978-94-007-5094-4 ISBN 978-94-007-5095-1 (eBook) DOI 10.1007/978-94-007-5095-1 Springer Dordrecht Heidelberg London New York Library of Congress Control Number: 2012952151 © Springer Science+Business Media Dordrecht 2013 No part of this work may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, microfilming, recording or otherwise, without written permission from the Publisher, with the exception of any material supplied specifically for the purpose of being entered and executed on a computer system, for exclusive use by the purchaser of the work. Printed on acid-free paper Springer is part of Springer Science+Business Media (www.springer.com) Foreword: Monozukuri-based Automotive Painting Science and Technology I would like to send my sincere congratulations to the 10th anniversary of the Uni- versity of Kentucky’s Painting Technology Workshop directed by Professor Kozo Saito and his hard working and talented IR4TD staff members. I very much wel- come a special publication of an anniversary volume: Monozukuri-based automobile painting technology to celebrate this occasion. My company, Asahi Sunac has been working on innovative solutions to global environmental and energy problems through spray paint equipment and technology development for the past 55 years. When looking back at the past 55 years, we have made technology developments mainly based on our experience, by accumulat- ing a series of experiments and a large collection of data; largely through our own small continuous effort, known as Kaizen, since we could not find resources and help available in lectures or scientific research from academic institutions around the world. That unfortunate trend eventually came to end when we found that the University of Kentucky had initiated the first Painting Technology Workshop (PTW 2000) in the year 2000. I have been thrilled to find the new and exciting scientific research results that PTW has produced. I had the good fortune to invite Professor Saito for Asahi Sunac’s 50th anniversary lecture, and followed with collaborative research on spray painting technology conducted at the Institute of Research for Technology Development (IR4TD) at the University of Kentucky. I am also very pleased to see Mr. Toda, an internationally recognized expert in automobile painting technology who has played a key role in production engineering at Toyota and NUMMI, became a regular lecturer for PTW. In his introduction, Mr. Toda addresses automobile painting technology based on his extensive knowledge and experience. Then, in later sections, IR4TD researchers bring a scientific approach to the experience based technology, making this book very unique and valuable. Mr. Toda also played an important role as a facilitator in making IR4TD’s scientific research available to solve industry problems in automobile painting processes, systems and equipment. I am confident that this unique book will help engineers, researchers and students interested in learning both basics and applications of automobile painting technology. Masahiko Amari President of Asahi Sunac Corp. Japan v Preface The University of Kentucky’s Institute of Research for Technology Development (IR4TD) operates through interdependent and sustainable partnership with industry. This unique institute is a good example of University of Kentucky’s (UK) effort to seek a new and better way of doing research, education, and service. At IR4TD, we began a series of scientific studies on automobile coating technology around 1993 in response to a request from Toyota which is interested in finding scientific reasoning for the largely experience-based automobile painting technology area, as explained by Kimio Toda in his chapter in this book. I was totally un- familiar with automobile painting technology at that time, since my research back- ground was scale modeling and combustion. Therefore, I needed to visit a newly opened Toyota Georgetown plant to ask questions: What are the scientific principles to support a rotary bell sprayer, why so much over-sprayed paint fumes are created? How to collect these over-sprayed fumes? Why they need such a large size spray paint booth? What is the paint film thickness and how many different layers of paint is required and why? These are all questions coming from a totally novice point of view but they helped us to create a baseline for our scientific research. Following the Genchi-Genbutsu principle, I made a frequent visit to the automobile plant to collect various data and obtain discussions with engineers and operators, then conducted simple scale model laboratory experiments at the University of Kentucky. During this initial three year phase, we formed a small research team consisting of a graduate student, an industrial extension engineer and myself as a faculty researcher and head of the team. Around 1996, Abraham Salazar joined our team, accelerating this research with his expertise in CFD (Computational Fluid Dynamics) model calculations analyz- ing the airflow pattern containing paint particles and the capturing mechanism of typical conventional wet scrubbers used by automobile manufacturers to capture over-sprayed paint. It was our first breakthrough to quantitatively estimate energy usage, relative efficiency, and fluid dynamics of particle capturing of existing wet scrubbers. Our next task was focused on how to improve the performance of wet scrubbers. This task required new ideas through thinking outside-the-box and a paradigm shift. We learned from nature that sand dune structure in a desert can be the most efficient vii vviiiiii Preface way to capture paint particles with minimum energy consumption. This approach led our team to invent Vortecone in collaboration with Toyota and Trinity engineers. Vortecone wet scrubber is 30–50 % energy efficient and has a higher capturing capability than other similar products available on the market. Our team’s success lies in the combination of the following factors: basic research to understand the capturing mechanisms, thinking outside-the-box, paradigm shift, and Toyota’ continuous and steady funding support. Without any of the above elements, I doubt this invention would have been possible. In this case, the box was technology, that is, the outcome if human thought combined with engineering principles. We shifted our focus to nature, another source for models of how to make things efficiently. This initial success attracted other companies to pay attention to our automobile coating research, leading to the establishment of UK’s Painting Technology Consortium (PTC) in 1999. In the following year, we initiated the annual Painting Technology Workshop with the following aims: (1) to provide a place where industry engineers, government agency regulatory personnel, and academic researchers meet and discuss coating research and technology development; (2) to share common problems in coating technology and seek win-win solutions; and (3) to provide educational and training opportunity. Around 2005, Kimio Toda, an internationally renowned automobile painting technology expert joined PTW as a special lecturer bringing his thirty two years experience at Toyota. Based on this Toda-UK PTW collaboration, we created a two-day special short course on automobile painting technology which produced rich documentation on automobile painting technology. This course led to the idea to publish a more com- prehensive book on automobile painting technology. As a result, this book was born. Kozo Saito Contents 1 Introduction ................................................................................................ 1 Kozo Saito Part I Painting Technology—The Empirical Approach 2 What Is Spray Coating? ............................................................................ 5 Kimio Toda Part II Painting Technology: Numerical Simulation and Scale Modeling 3 Computational Modeling of Relevant Automotive Rotary Spray Painting Process .............................................................................. 47 Abraham J. Salazar 4 The Use of Scale Model to Study Film Flow in a Rotary Atomizer Cup ......................................................................... 97 Vedanth Srinivasan, Abraham J. Salazar and Kozo Saito Part III Painting Technology—Visualization and Characterization 5 Automotive Paint Spray Characterization and Visualization ........................................................................................ 121 Nelson K. Akafuah Part IV Painting Technology—Research and Education— An Integrative Approach 6 Hitozukuri and Monozukuri in Relation to Research and Development in Surface Coating ....................................................... 169 K. Saito, A. J. Salazar, K. Kreafle and E. Grulke ix Contributors Nelson K. Akafuah Institute of Research for Technology Development, College of Engineering, University of Kentucky, KY 40506-0503, Lexington, USA e-mail: [email protected] Eric Grulke Institute of Research for Technology Development, College of Engineering, University of Kentucky, Lexington, KY 40506-0503, USA e-mail: [email protected] Ken Kreafle Institute of Research for Technology Development, College of Engineering, University of Kentucky, Lexington, KY 40506-0503, USA e-mail: [email protected] Kozo Saito Institute of Research for Technology Development, College of Engineering, University of Kentucky, Room: RGAN 179, Lexington, KY 40506- 0503, USA e-mail: [email protected] Abraham J. Salazar Institute of Research for Technology Development, College of Engineering, University of Kentucky, Lexington, KY 40506-0503, USA e-mail: [email protected] V. Srinivasan ANSYS FLUENT, 15915 Katy Freeway, Suite 550, Houston, TX 77094, USA e-mail: [email protected] Kimio Toda Asahi Sunac Corporation, Asahimae-cho 5050, Owariasahi, 488-8688 Aichi, Japan e-mail: [email protected] xi Chapter 1 Introduction Kozo Saito Abstract It is sometimes claimed that industry and academia are two very different cultures, with the former concerned with how to deliver reasonably-priced high quality products to customers in a timely fashion, while the latter focus on education, research, and service. Yet this difference does not mean there is no common ground. A common mission does exist between companies that value hitozukuri (education and training) and monozukuri (roughly, manufacturing) and academic institutions that focus on education and research. A win-win relationship, therefore, is possible between academia and industry in research and technology development. This book was created as a successful example of this win-win relationship between a world class automobile maker and University of Kentucky to study surface coating and inspection technology. Monozukuri, a Japanese term which appears in the title of this book, may require some explanation. Monozukuri consists of “mono” which means “products,” and “zukuri” which means “process of making or creation." But the word means more than simply making something; it has overtones of excellence, skill, spirit, zest, and pride in the ability to make things, good things, very well. Monozukuri is not mindless repetition; it requires creative minds and is often related to craftsmanship which can be earned through lengthy apprenticeship rather than the structured cur- ricula taught at traditional schools. Monozukuri represents the maker’s philosophy of how to make things—the philosophy deeply rooted in Japanese and East Asian traditions, for example, in Zen and in the Analects of Confucius. Monozukuri is therefore a philosophy rather than technique or method but provides a clear and vis- ible guiding principle for Japanese engineers. On the other hand, the Scientific Method, based on the Western model of logi- cal thinking, also guides engineers by providing theory, experiment, and numerical methods to solve engineering problems associated with automobile painting technology. One focus of this book is to show the combination of these two different K. Saito () Institute of Research for Technology Development, College of Engineering, University of Kentucky, Room: RGAN 179, Lexington, KY 40506-0503, USA e-mail: [email protected] K. Toda et al. (eds.), Automotive Painting Technology, 1 DOI 10.1007/978-94-007-5095-1_1, © Springer Science+Business Media Dordrecht 2013 2 K. Saito methods—Monozukuri and Scientific Method—can make for a very beneficial result that would not be possible by one method alone. Therefore, this book is structured to show Monozukuri at the beginning (Sect. 1) and in the end (Sect. 4), with Scientific Method addressed in the middle (Sects. 2 and 3). More specifically, this book, the collection of our past work on automobile painting technology, consists of four different Sections, Sect. 1: The empirical approach; Sect. 2: Numerical simulation and scale modeling; Sect. 3: Visualization and characterization; and Sect. 4: An integrative approach—Hitozukuri and Monozukuri. Section 1 offers practical aspects of automobile painting technology and was written by Kimio Toda who worked at Toyota’s surface coating division for 32 years as an engineer and later manager. This unique Section is written for general engineers and university engineering students to grasp the overall nature of this technology and helps to prepare for more technical Sects. 2 and 3 where computational fluid dynamic simulations and scale modeling, and infrared thermography application for paint spray characterization are presented. These Sects. 2 and 3, written by former and current members of the University of Kentucky’s painting technology research team, may require knowledge of advanced numerical simulation, fluid dynamics, heat transfer, and experimental methods. The final Sect. 4 offers the Monozukuri concept, a unique product of Japanese culture, which significantly influenced Japanese technology development including automobile painting technology. This Section offers a picture of this unique thinking process associated with technology development and improvement, known as Kaizen (a small incremental improvement) and the thinking associated with Kaikau (a quantum leap breakthrough). The author of this Section intends to show readers automobile painting technology as part of Monozukuri culture, so that they may be able to see by their own interpretation the trend and direction of the current and future technology. I hope readers enjoy and benefit from reading this unique Monozukuri-based automobile painting technology book and use the method and the thinking addressed in this book to solve and improve their problems related in automobile painting technology.