INPRO Innovationsgesellschaft mbH Berlin

The painting process for vehicle bodies is complex. After different painting steps, the entire body is heated in ovens, which are up to 100 metres long at temperatures of up to 108° C in order to dry the paint. Appropriate heating is a essential for optimal paintfinish.

In 2003, INPRO began to work on simulations of heating and drying processes. A simulation model was developed on the basis of physical principles, which factored in all heating and evaporation phenomena as well as their complex interactions. The simulation approach was successfully verified on a Golf A5 bodywork section as well as in a real continuous dryer. 

As a result, the temperature and paint moisture anywhere on the bodywork could be determined with great accuracy at any time during the drying process. The drying and baking process simulations made it possible to determine the impact of humidity, air circulation, component changes or temperature on the paintwork results.

Critical bodywork areas, such as door rebates could be identified in advance and measures taken to improve the paintwork based on their suitability. INPRO's drying simulation has become a central element of process chain simulation, with the goal of using calibration-free simulation software as a planning tool. This was developed in collaboration with our shareholders until 2007.

The goal was to demonstrate the simulation's suitability for this purpose. Simulation of drying and baking processes within the painting process for vehicle bodies is an important step to the future simulation of complete process chains in the digital factory.

This applies to planning of new and optimization of existing facilities, as well as for the introduction of new vehicle models. The preproduction process, in particular, can be shortened and the number of prototypes reduced.