Automatic hole closure for bodyshells

Automatic hole closure for bodyshells

In cooperation with well-known manufacturers of adhesive pads, SAR has automated the application of the pads to openings in body shells.
SAR’s “automatic hole sealing” is characterized by significantly higher precision and process monitoring compared to the conventional method. There are numerous openings in bodyshells that are necessary for the coating process but must be reliably closed again afterwards.
Until now, these have been closed by hand using so-called “paint plugs”.
These are manually pressed into the openings and snap into place.

The conventional solution

The challenges of the current manual setting process with conventional paint stoppers:

• The quality of the hole closure depends on the worker and is not reproducible
• The workstations are ergonomically very stressful for workers
• The precisely fitting plug must be selected and placed manually for each opening; there is no process control
• An incorrectly positioned hole plug can lead to corrosion damage to the vehicle

The solution from SAR

Well-known material manufacturers have developed sealing materials that make it possible to automate the setting process.
Adhesive pads are positioned on the holes at high speed with repeat accuracy using a robot.
A corresponding protrusion ensures a stable and permanent adhesive bond.
As a general contractor, SAR integrates a simple and functional solution into both existing and new systems in the paint shop environment.

Safety for series production through test setups and feasibility studies using simulation

SAR carries out a feasibility study using robot simulation in order to guarantee customers the greatest possible safety in the run-up to a series project.
SAR also offers test setups.
Here, series material is applied to customer bodies or test panels and made available for material release tests.

Realized for the first time in 2017

As early as 2017, SAR developed an applicator for their hole seals in cooperation with FAIST ChemTec and realized a system for applying pads (see also brochure “Automatisch.Dicht.”).
Since then, we have continuously developed the concept further and can use and apply new applicators from other manufacturers – such as the tesa® EfficienSeal – and process tesa® Sealing Patches from the roll.
In 2019, for example, a series project was carried out at Porsche.

Future potential

SAR sees great potential in the area of “automatic hole sealing”, as the current process is ergonomically questionable and poses a quality risk.
The SAR solution can both reduce costs and improve quality.
Projects realized so far:

• Audi – Series system in production
• Porsche – Standard system under construction
• Feasibility studies and test setups for various vehicles

For further information, please contact us at ofs@sar.biz.