In the field of surface decoration in the door industry, copper-like brushed technology is rapidly rising with its unique charm and occupies an important position. Whether it is the durable steel door, lightweight and handy aluminum alloy door, or plastic composite material door, copper wire drawing technology can give it a unique appearance effect, showing unique advantages in enhancing the quality and grade of the door body. In the current consumer trend of the pursuit of personality and quality, from focusing on the warmth and texture of the civil home door, to emphasize the unity of functionality and aesthetics of the commercial premises door, and then the pursuit of the ultimate artistic taste of high-end customized doors, copper imitation brushed technology by virtue of its realistic presentation of the texture of the metal and the flexibility of the process of adaptability, a perfect match for all kinds of complex and changing design needs, for the door products into the luxury and unique aesthetic value.

The implementation of brushed bronze technology is both flexible and precise. According to the design theme of the door and the use of the scene, you can choose a different thickness, texture direction of the brushed effect, with a variety of imitation copper tone, from the rustic bronze to bright bronze, etc., but also to achieve personalized color and texture customization. With the help of advanced professional equipments, the operator can present the delicate and realistic brushed copper effect on the surface of the door body by precisely regulating the core elements such as grinding strength, speed and spraying parameters of the copper-like coating. Advanced equipment with intelligent feedback and automatic adjustment function, according to the characteristics of the door body material, the complexity of the desired effect, automatically optimize the process parameters, to ensure that the copper wire drawing effect is uniform, delicate and accurate. Even inexperienced operators, after a short period of professional training, can master the operating skills and efficiently complete the copper wire drawing process. This standardized and intelligent operation mode effectively avoids uneven texture, color deviation and other problems caused by differences in human operation, and ensures that the copper imitation brushed decorative effect of each door can reach high quality standards and realize the stability and unity of product appearance.

In terms of customized production, copper wire drawing technology shows outstanding cost and efficiency advantages. Enterprises do not need to carry out large-scale equipment upgrading and transformation, only need to configure the basic copper wire drawing equipment and the corresponding consumables, you can quickly open the production of diversified door products. Compared with the traditional pure copper cladding or complex metal engraving and other decorative methods, copper wire drawing technology in response to different design needs, without a large number of expensive raw material inputs and cumbersome processing processes, only a small amount of replacement molds, adjust the parameters of the equipment, you can realize the different styles of copper wire drawing effect of the rapid conversion. This feature not only significantly reduces material and labor costs, but also significantly shortens the production cycle. Enterprises are able to quickly build up a strong customization capacity of copper-like brushed production line within a limited budget, timely response to the market demand for diversified orders, and seize the first opportunity in the highly competitive door market, helping enterprises to enhance market competitiveness, and realize the prosperous development of the business and high-end brand image shaping.

Home Security Doors

Clean Doors

Medical Doors

Industrial Fire Doors

Fire Doors

1）Pre-treatment pool: after phosphating pool treatment, remove the surface oil, dust, rust

2) Workpiece on line: manually hang the door frame/fan that needs to be sprayed with powder onto the conveyor line.

3）Pre-heating channel: remove the moisture on the surface of door frame/fan to increase the adhesion of plastic powder.

4）Manual spraying room: Spraying the powder evenly onto the surface of door frame/door by hand.

5) Curing baking channel: through high temperature baking, make the powder coating melting, leveling, curing

6）Manual paint spraying room: the paint is evenly sprayed onto the surface of the door frame/door by hand.

7) Curing baking tunnel: through high temperature baking, make the paint curing.

8) Workpiece off-line: manually take down the door frame/door after baking.

9) Imitation copper wire drawing: manually carry out the imitation copper wire drawing process.

10) Workpiece on the line: manually hang the door frame/door to be painted on the conveyor line.

11）Automatic spraying room: the automatic spraying system will evenly spray the protective paint on the surface of the door frame/fan.

12) Curing baking tunnel: through high-temperature baking, make the top coat curing

13) Workpiece off the line: the robot will take down the finished door frame/fan.

1) Workpiece off the line: the robot will take down the door frame/door after baking.

2) Copper imitation drawing: manual copper imitation drawing process.

3) Workpiece on line: the robot will hang the door frame/door to be painted on the conveyor line.

4) Artificial spraying room: the manpower will spray the protective paint evenly to the surface of the door frame/door.

5) Curing baking channel: through high temperature baking, make the top coat curing

6）Workpiece offline: the robot will take down the finished door frame/door

7) Curing baking tunnel: through high temperature baking, make the paint curing.

8) Workpiece off-line: manually take down the door frame/door after baking.

9) Imitation copper wire drawing: manually carry out the imitation copper wire drawing process.

10) Workpiece on the line: manually hang the door frame/door to be painted on the conveyor line.

11）Automatic spraying room: the automatic spraying system will evenly spray the protective paint on the surface of the door frame/fan.

12) Curing baking tunnel: through high-temperature baking, make the top coat curing

13) Workpiece off the line: the robot will take down the finished door frame/fan.

Profit generating factors

Applicable structures

Preheating aisle

Curing aisle

Equipment investment

Employee requirements

Average daily production

Average wages

Equipment footprint

Turnover space

Probability of failure

Probability of scrap

Corporate image

Manual painting line

All structures available

35m

35m

80~120 million

12~15 people

100~120 gigs

7000~8000

500m²~600m²

100m²~180m²

low

low

Lean manufacturing plant

Automatic painting line

All structures are optional

35m

35m

2~3 million

2~4 people

150~200 gigs

5000~6000

500m²~600m²

100m²~180m²

low

low

Automation factory

Manual drawing + manual painting solution: small batch customized production.

Manual drawing+automatic painting solution: batch customized production.

Recommended Requirements

Profit generating factors

Applicable structures

Preheating aisle

Curing aisle

Equipment investment

Employee requirements

Average daily production

Average wages

Equipment footprint

Turnover space

Probability of failure

Probability of scrap

Corporate image

Manual painting line

All structures available

35m

35m

80~120 million

12~15 people

100~120 gigs

7000~8000

500m²~600m²

100m²~180m²

low

low

Lean manufacturing plant

Automatic painting line

All structures are optional

35m

35m

2~3 million

2~4 people

150~200 gigs

5000~6000

500m²~600m²

100m²~180m²

low

low

Automation factory

Manual drawing + manual painting solution: small batch customized production.

Manual drawing+automatic painting solution: batch customized production.

Recommended Requirements

On the pieces: the use of electric hoist to lift the door plate and door frame smoothly, lifting to the phosphating pool above. Electric hoist has the function of lifting, lowering, horizontal movement, etc., can accurately control the position of the workpiece, and slowly put it into the phosphating tank on the hanging or bracket, to ensure that the workpiece is well fixed to facilitate the subsequent processing.

Lowering: After completing the phosphating treatment and water washing, the door plate and door frame will be lifted up smoothly from the phosphating pool by the electric hoist and transported to the designated area for subsequent treatment, such as drying and painting. In the whole process, the stable operation and accurate positioning of the electric hoist ensures the smooth running of the pre-treatment process of door panels and frames, and improves the production efficiency and product quality.

Phosphating tank / electric hoist

Electric hoist with the use of pre-treatment process

Phosphate pool role

Enhance the coating bonding force: through the chemical and electrochemical reaction on the metal surface of the door plate and door frame, a layer of phosphate chemical conversion film, i.e. phosphate film is formed. This film can significantly enhance the subsequent coating film (such as paint, spray coating, etc.) and the workpiece bonding force, so that the coating more firmly attached to the door and door frame, reducing the risk of coating off .

Enhance corrosion resistance: phosphating film can be isolated to a certain extent from the air, moisture and other corrosive media and metal substrate contact, effectively preventing the door and door frame corrosion, extend the service life of the door products.

Improve the decorative effect: after phosphating the surface of the workpiece, can make the subsequent coating color more uniform, full, improve the appearance of door products decorative.

Selection and preparation of hooks and conveyor lines

Hooks: generally made of stainless steel or carbon steel, should have enough strength and rigidity to withstand the weight of the door body and not deformed. Before use, carefully check the hooks, support parts have no wear and tear, fracture, there are problems in time to repair or replace. In order to ensure good contact between the door body and the hooks, and to prevent problems with the coating, the surface of the hooks should be clean and dry, without oil and rust, and if necessary, degreased and descaled pre-treatment.

Conveyor line: Conveyor line is common chain, roller conveyor type and other types. When the door body is sprayed with plastic, it should be reasonably selected according to the size, weight and production scale of the door body. Before start-up, comprehensively check the chain, sprocket, motor and other mechanical transmission parts, add or replace the lubricant to ensure smooth transmission without abnormal sound. Calibrate the running speed of the conveyor line to ensure smooth and even movement of the door body. At the same time, check the electrical control system to ensure that the control buttons, sensors and other normal work, no short circuit, disconnection fault.

Workpiece on the piece

Pre-heating baking channel

Remove the moisture on the surface of the door body: After the door body is washed and drained after pre-treatment, there may still be residual moisture. When preheating, the temperature rises so that the water evaporates. If moisture remains, spraying will prevent the powder coating from adhering, resulting in bubbles, pinholes and other problems in the coating, affecting the quality and adhesion of the coating.

Improve the adhesion of powder coating: The suitable preheating temperature changes the metal lattice structure on the surface of the door body and enhances its surface activity, which prompts the resin and other components in the powder coating to form chemical bonds with the surface of the door body better after spraying and greatly improves the adhesion between the powder coating and the door body to ensure that the coating is not easy to come off in the long term.

Promote the leveling of powder coating: After the door body is preheated to a suitable temperature, the powder coating sprayed can flow and spread more smoothly under the action of gravity and heat, filling the slight bumps on the surface of the door body, making the coating more flat and smooth, and improving the appearance of the door body's decorative and protective properties.

Start the heating system of the main drying channel, and increase the temperature in the furnace to about 185℃ at the rate of 5 - 10℃/minute. If the temperature rises too quickly, the surface of the powder coating will be cured first, and the solvent inside will be difficult to evaporate, resulting in bubbles and pinholes; if it is too slow, the production cycle will be prolonged. The temperature control system monitors the temperature in real time and adjusts the heating power according to the temperature change to ensure the temperature rises smoothly.

Artificial spray booth/curing oven

Electrostatic spraying machine utilizes high voltage electrostatic generator to form a strong electrostatic field at the head of the spray gun. When the powder coating is sprayed out from the gun, it will rub against the electrode inside the gun, making the powder particles negatively charged. And the grounded door body serves as the positive pole, under the action of electrostatic field, the negatively charged powder coating will move quickly to the surface of the door body, thus realizing uniform adsorption.

Manual spraying/curing oven

Paint contains a large amount of solvent, which evaporates slowly at room temperature. Increased temperature in the oven accelerates the thermal movement of solvent molecules, causing them to rapidly evaporate from the paint coating into the air, creating conditions for the paint to cure. For example, common nitro lacquers, in which the solvent quickly detaches from the paint film at high temperatures.

The spray gun is used for spraying the top coat, which is required to be uniform and delicate to avoid defects such as hanging, leakage or bubbles. The thickness of the topcoat is generally around 30 - 40 microns.

The painted door frames and door panels will be offline

Workpiece off the line - surface drawing

Surface cleaning: Before drawing, it is necessary to ensure that the surface of the security door is clean and free of oil, dust and impurities. You can use special cleaners and wiping tools for cleaning to ensure that the drawing effect is uniform.

Add wire drawing water: Pour the appropriate amount of drawing water into a special container, and then through the spray device or brush and other tools, the water will be evenly sprayed or coated in the security door need to draw the parts. You can also soak the drawing cloth in the drawing water, so that it fully absorbs the drawing water before the drawing operation. When adding wire drawing water, pay attention to the amount of control, too much wire drawing water may lead to the door surface is too wet, affecting the effect of wire drawing, may also cause a waste of wire drawing water; too little can not play a good role in lubrication and cleaning.

Drawing tools: choose different mesh drawing cloth, the smaller the mesh, the coarser the grit, the greater the drawing strength; the larger the mesh, the finer the grit, the more delicate the drawing effect. General roughing can choose 100 - 200 mesh sand belt, finishing with 400 - 800 mesh sand belt.

Determine the direction of drawing: according to the design requirements of the security door and aesthetic effect, to determine the direction of drawing. Common drawing directions are horizontal, vertical, oblique or round. Once the direction is determined, the entire drawing process should be consistent in order to form a uniform, neat pattern.

Workpiece on line / top coat spraying

Protective paint evenly sprayed on the door frame, door surface, protective paint can make the door surface smoother, increase the gloss of the door, enhance the overall beauty of the door, so that the door looks more upscale, exquisite.

And make the surface of the door, easy to clean, put scratch, waterproof and moisture-proof, can make the door life greatly increased.

The door frame and door leaf, which are completed by drawing process, will be hung on the spraying line again.

Once again into the drying channel, so that the varnish drying.

Curing baking channel/workpiece off the line

Take down the finished door frame and door from the assembly line.

Manipulator Handling

Selection and Preparation of Industrial Manipulators and Hanging Tools and Conveyor Lines

Industrial Robot: It is the key equipment of modern automated production. Through preset programs or real-time control, industrial robots can accurately perform handling tasks, greatly improving production efficiency and accuracy, reducing labor costs and human error.

Hooks: generally made of stainless steel or carbon steel, should have sufficient strength and rigidity, can withstand the weight of the door and not deformed. Before use, carefully check the hooks, support parts have no wear and tear, fracture, there are problems in time to repair or replace. In order to ensure good contact between the door body and the hooks, and to prevent problems with the coating, the surface of the hooks should be clean and dry, without oil and rust, and if necessary, degreased and descaled pre-treatment.

Conveyor line: Conveyor line is common chain, roller conveyor type and other types. When the door body is sprayed with plastic, it should be reasonably selected according to the size, weight and production scale of the door body. Before start-up, comprehensively check the chain, sprocket, motor and other mechanical transmission parts, add or replace the lubricant to ensure smooth transmission without abnormal sound. Calibrate the running speed of the conveyor line to ensure smooth and even movement of the door body. At the same time, check the electrical control system to ensure that the control buttons, sensors and other normal work, no short circuit, circuit breakers.

Pre-treatment assembly line: This assembly line is mainly composed of conveying system, spraying system and circulating filtration system. The principle is to use mechanical scouring to accelerate the chemical reaction, in the door body with the conveying system in the process of moving, spraying system will be uniformly sprayed on the surface of the door body, and oil, rust and other reactions and scouring to remove. The circulating filtration system ensures that the treatment liquid is continuously clean and can be recycled.

Efficient production: automated continuous operation, the door body passes through each treatment process sequentially on the assembly line, which greatly shortens the treatment time, improves the production efficiency and meets the demand of mass production.

Stable quality: Precise control of treatment liquid concentration, temperature, spraying pressure and other parameters, avoiding differences in manual operation, ensuring the same surface treatment effect for each door body, and improving the stability of product quality.

Pre-treatment

Pre-heating drying channel

Remove the moisture on the surface of the door body: After the door body is washed and drained after pre-treatment, there may still be residual moisture. When preheating, the temperature rises so that the water evaporates. If moisture remains, spraying will prevent the powder coating from adhering, causing bubbles, pinholes and other problems in the coating, affecting the quality and adhesion of the coating.

Improve the adhesion of powder coating: The suitable preheating temperature changes the metal lattice structure on the surface of the door body and enhances its surface activity, which prompts the resin and other components in the powder coating to form chemical bonds with the surface of the door body better after spraying and greatly improves the adhesion between the powder coating and the door body to ensure that the coating is not easy to come off in the long term.

Promote the leveling of powder coating: After the door body is preheated to a suitable temperature, the powder coating sprayed can flow and spread more smoothly under the action of gravity and heat, filling the slight bumps on the surface of the door body, making the coating more smooth and even, and improving the appearance of the door body's decorative and protective properties.

Electrostatic adsorption principle: Electrostatic spraying machine utilizes high voltage electrostatic generator to form a strong electrostatic field at the head of the spray gun. When the powder coating is sprayed from the spray gun, it will rub with the electrode inside the spray gun, making the powder particles take negative charge. And the grounded door body serves as the positive pole, under the action of electrostatic field, the negatively charged powder coating will move quickly to the surface of the door body, thus realizing uniform adsorption.

Equipment inspection and commissioning: Before formal spraying, the electrostatic spraying machine needs to be fully inspected and commissioned. Check whether the gun head is clogged, if so, need to be cleaned in time to ensure that the powder coating can be sprayed smoothly. Test whether the electrostatic generator of the spray gun is working properly. At the same time, debug the powder supply system of the spraying machine, check whether the powder coating conveying pipeline is smooth, and the conveying volume of the powder pump should be adjusted according to the actual spraying demand, to ensure that the powder supply is uniform and stable.

Automatic spray booth

Curing oven

Heating stage: Start the heating system of the main drying channel and raise the temperature in the furnace to about 185℃ at the rate of 5-10℃/min. If the temperature rises too fast, the surface of the powder coating is easy to be cured first, and the solvent inside is difficult to evaporate, resulting in bubbles and pinholes; if it is too slow, the production cycle will be prolonged. When warming up, the temperature control system monitors and adjusts the heating power according to the temperature change in real time to ensure that the temperature rises smoothly.

Holding phase: After the temperature inside the furnace reaches about 185℃, it enters the holding phase for about 15 minutes. During the period to maintain a stable temperature, fluctuations control within ± 5 ℃, hot air circulation system continues to operate, so that the hot air circulation, to ensure that the door body is heated evenly. Insulation is used to allow the powder coating to fully melt, level and cross-link to form a hard coating film. Different powder coatings require different curing temperatures and times due to differences in chemical composition and properties, and should be operated according to the parameters of the coating supplier. Special function coatings such as super weathering, high abrasion resistance, etc., may require higher temperatures or longer holding times.

Spray gun: is the core component, there are different types, such as air spray gun, airless spray gun and so on. Air spray gun uses compressed air to atomize the paint; airless spray gun relies on a high-pressure pump to directly extrude the paint from the nozzle to atomize it, which is suitable for high-viscosity paints.

Paint supply system: including paint drum, paint delivery pipe, filter, etc. It is responsible for storing and delivering paint, ensuring stable supply of paint and filtering impurities.

Control system: consists of sensors, controllers, etc., which can accurately adjust the speed of gun movement, the amount of paint sprayed, the spray shape and other parameters to realize automation and precision spraying.

High efficiency: compared with manual spraying, automatic spraying equipment can work continuously and spray fast, which can greatly improve the production efficiency, especially suitable for mass production scenarios.

Good uniformity: It can accurately control the spraying parameters, so that the coating thickness is uniform and the color is consistent, effectively avoiding the problems that are prone to occur in manual operation, such as hanging and leakage, and improving the appearance quality of the product.

Save paint: precise parameter control can reduce the waste of paint and lower the production cost. At the same time, automated operation can also reduce labor costs.

High safety: It can be carried out in a closed environment, which reduces the contact between the operator and the harmful components in the paint (such as organic solvents, volatile organic compounds, etc.), improves the working environment and protects the health of workers.

Automatic Paint Spraying

Curing Oven

Heating stage: After spraying the top coat, the door frame and door leaf enter the curing oven for high temperature curing. The curing temperature is usually 120 - 150°C and the time is 20 - 30 minutes, so that the topcoat forms a hard, wear-resistant coating. The temperature and curing time depends on the type of paint.

Selection and Preparation of Industrial Manipulators and Hangers and Conveyor Lines

Industrial Robot: It is the key equipment for modern automated production. Through preset programs or real-time control, industrial robots can accurately perform handling tasks, greatly improving production efficiency and precision, reducing labor costs and human error.

Material receiver: It usually adopts special material rack or material box, and the material is mostly made of high-strength alloy steel or engineering plastics. The material frame should have a reasonable structural design, sufficient load-bearing capacity and stability to withstand the weight of the workpiece and not deformed. Before use, the frame structure should be fully inspected to see if there are any cracks, deformation and other conditions, and whether the connection parts are firm.

Mechanical Handling

Transfer Area

Surface Cleaning: Before drawing, it is necessary to ensure that the surface of the security door is clean and free of oil, dust and impurities. Specialized cleaners and wiping tools can be used for cleaning to ensure an even drawing effect.

Add wire drawing water: Pour the appropriate amount of drawing water into a special container, and then through the spray device or brush and other tools, the water will be evenly sprayed or coated in the security door need to draw the parts. You can also soak the drawing cloth in the drawing water, so that it fully absorbs the drawing water before the drawing operation. When adding wire drawing water, pay attention to the amount of control, too much wire drawing water may lead to the door surface is too wet, affecting the effect of wire drawing, may also cause a waste of wire drawing water; too little can not play a good role in lubrication and cleaning.

Drawing tools: choose different mesh drawing cloth, the smaller the mesh, the coarser the grit, the greater the drawing strength; the larger the mesh, the finer the grit, the more delicate the drawing effect. General roughing can choose 100 - 200 mesh sand belt, finishing with 400 - 800 mesh sand belt.

Determine the direction of drawing: according to the design requirements of the security door and aesthetic effect, to determine the direction of drawing. Common drawing directions are horizontal, vertical, oblique or round. Once the direction is determined, the entire drawing process should be consistent in order to form a uniform, neat grain.

Selection and Preparation of Industrial Manipulators and Hanging Tools and Conveyor Lines

Industrial Robot: It is the key equipment for modern automated production. Industrial robots can accurately perform handling tasks through preset programs or real-time control, greatly improving production efficiency and precision, reducing labor costs and human error.

Hooks: generally made of stainless steel or carbon steel, should have sufficient strength and rigidity, can withstand the weight of the door and not deformed. Before use, carefully check the hooks, support parts have no wear and tear, fracture, repair or replacement in a timely manner. In order to ensure good contact between the door body and the hooks to prevent problems with the coating, the surface of the hooks should be clean, dry, no oil and rust, degreasing and descaling pre-treatment when necessary.

Conveyor line: Conveyor line is common chain, roller conveyor type and other types. When the door body is sprayed with plastic, it should be reasonably selected according to the size, weight and production scale of the door body. Before start-up, comprehensively check the chain, sprocket, motor and other mechanical transmission parts, add or replace the lubricant to ensure smooth transmission without abnormal sound. Calibrate the running speed of the conveyor line to ensure smooth and even movement of the door body. At the same time, check the electrical control system to ensure that the control buttons, sensors, etc. work properly without short-circuit or disconnection faults.

Manipulator Loading

Automatic spraying

Automatic spraying varnish (protective paint)

Anti-corrosion: the varnish can form a dense protective film on the surface of the anti-theft door, blocking the oxygen in the air, moisture, acid and alkali substances, etc. in direct contact with the door metal, effectively preventing rust and corrosion, prolonging the service life of the anti-theft door, especially suitable for the door of the humid or industrially polluted environment.

Wear-resistant and anti-scratch: daily use, security doors are susceptible to friction, scratching, varnish can increase the surface hardness, enhance wear resistance, reduce the key, handling items caused by scratches, to maintain the appearance of the door intact.

Enhance the gloss: varnish can give the security door a brighter shine, so that the door looks more texture and grade, according to the needs of the choice of high-gloss, semi-matte, matte and other different gloss varnish, suitable for different decoration styles.

Retaining the base color: For the security door with imitation copper, imitation wood grain and other special finishes, the varnish can not change the base color and texture on the basis of enhanced color saturation and clarity, so that the texture is more vivid and natural.

Easy to clean and maintain: smooth varnish surface is not easy to adsorb dust, stains, cleaning with a damp cloth to remove dirt, reducing the difficulty of cleaning, saving time and energy.

Moisture and waterproof: can effectively prevent moisture from penetrating into the interior of the security door, to prevent deformation caused by moisture, mold and other problems, to protect the structural stability of the door.

Heating stage: after spraying varnish (protective paint), the door frame and door leaf enter the curing oven for high temperature curing. The temperature and curing time depends on different types of paint.

Curing oven

Workpieces off the line

Selection and preparation of industrial robots and hangers and conveyor lines

Industrial robots: it is the key equipment of modern automated production. Through preset programs or real-time control, industrial robots can accurately perform handling tasks, greatly improving production efficiency and precision, reducing labor costs and human error.

Material receiver: It usually adopts special material rack or material box, and the material is mostly made of high-strength alloy steel or engineering plastics. The material frame needs to have a reasonable structural design, sufficient load-bearing capacity and stability to withstand the weight of the workpiece and not deformed. Before use, it is necessary to carry out a comprehensive inspection of the frame structure, to see whether there are cracks, deformation and other conditions, whether the connection parts are solid.

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