Optimize powder coating quality and material efficiency by connecting process actuators and a digital twin

Important results from the project

The goal has been to optimize the powder coating process by developing new actuators and a digital twin. Simulation models and a software prototype have been developed and been used to conceptually show how simulation and optimization can improve powder coating. A complete integrated system in a paint factory was not achieved, but lab results show great potential for savings and improvements when used within the manufacturing industry. A commercial tool for simulation of powder coating will be developed after the project.

Expected long term effects

Mathematical models and numerical methods to enable simulation of powder coating have been developed. A methodology for efficient simulation has been proposed and a software prototype implementing the models and methods has been built. A physical test lab and a demonstrator have been constructed and a large number of tests has been carried out to verify the digital models. A workflow using simulations has been developed to improve the quality, reduce the powder consumption and to reduce the commissioning time for new products.

Approach and implementation

Initially, the focus was on development of the individual modules, a choice reflecting the ongoing pandemic making physical meetings impossible. Simulation models and measurement methodology were developed; actuators designed and tested; a workflow for simulation input data generation created; algorithms were implemented in a software prototype. To verify models and algorithms a significant number of experiments was carried out in a demonstrator. An identical setup was built virtually as a digital twin in the software prototype to enable validation of the project results.