Bladder Spray System Case Study

Our customer selected Pioneer to build an automated bladder spray cell. This aligned well with our expertise in green tire spraying and tire handling solutions. The patented Pioneer Precision Fluid Delivery System (PFDS) was utilized to spray the bladders with a uniform coating. The PFDS can adjust the fluid spray pattern and volume based on the bladder dimensions. Bladders were hung on a gripping chuck mounted on a chain conveyor. As the bladders moved along the path a light curtain measured its dimensions sending this information to the PFDS system which optimizes the spray recipe for the bladder as it enters the spray booth. Once the bladder is sprayed it continued around the path to the unload station.

After providing the customer with a proposal that included advantages of our robotic solution and cycle time analysis, the customer was able to sell the tire marking machine to leadership. It was approved within the budget, met the required specifications, and a PO was issued.

Pioneer started its defined Machine Building Process. This process involved detailed engineering kickoffs, where we worked closely with the customer on getting signed approvals for mechanical layouts, electrical schematics, and programming structure. As the project came together on the floor, consistent updates were sent to the customer. Once it was completed, the customer came on-site for a full day of runoff at Pioneer’s facility, putting the machine through its paces and completing both the customer’s checklist, maintainability standards, and Pioneer’s own internal checklist. The customer had the chance to make a few minor tweaks, but due to the communication at the front and throughout the project, minimal changes were required before shipment. After the customer runoff, the machine was disassembled, shipped, and Pioneer’s engineer went on-site to supervise the installation of the equipment. Since the design was modular, the installation was completed in only five days. The engineer then stayed on-site the following week to connect our system to the plant conveyors and higher-level server and a few days of commissioning and training for the operator, maintenance, and plant engineer.

The customer was given machine drawings, a detailed machine manual, the latest copies of the robot and PLC programs, and a spare parts list all on a memory stick. A 6-month complimentary maintenance was scheduled, in which the fluid system was recalibrated, the spray gun cleaned and adjusted, and the system was given a thorough inspection. A trip report was completed and submitted to the customer with a quote for a return service visit and any additional spare parts required.