Robotic coating of rail car

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Spray SB-2K primer & topcoat with robotic electrostatic bell

Automate, save up to 50% of paint, 30% of cycle time and obtain better finishing quality with Sames Nanocoat robotic electrostatic rotary bell spraying combined with a process arm 2K antenna embedded onto the robot.

Description

A fully sealed, 7-axis robotic 2K electrostatic spraying system ensures precise mixing, efficient application, and complete rail car coverage with minimal waste. All colors and hardener are pumped and circulated at low pressure up to the robot's process arm.

The entire hardener circulation system is fully sealed to prevent moisture exposure. When spraying is triggered, the selected color and hardener are released from the Upside color-change block. 
Upstream volumetric gear pumps precisely control the flow of both components into the 2K rotary bell. Mixing occurs at the final stage through an integrated 2K static mixer, the paint is electrostatically charged and at last sprayed by the rotating bell cup.


The robot operates in sync with up to two external axes, creating a 8-axis robotic system capable of reaching nearly all rail car surfaces. A final manual touch-up is performed if necessary.

Interactive diagram for information purposes

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Main benefits

Productivity: Automate your coating process and achieve over a 30% increase in production capacity.

Efficiency: Achieve up to 50% savings in paint compared to non-electrostatic conventional coating technologies.

Coating Quality: Achieve consistent coating thickness and superior coverage, thanks to Sames’ advanced electrostatic technology.

Flexible Solutions: Select from integration packages offered without control, with optional control systems, or as a complete turnkey solution for end customers.

Robotic painting process of rail car Solution FAQ

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  • Are there any specific railway standards relative to coatings?

    Yes, railway coatings must comply with strict standards for durability, corrosion resistance, and fire safety. While many national and operator-specific standards exist, the upcoming ISO 9466 aims to unify global requirements, simplifying compliance across the industry.

  • How can a robot manage to access such a large part like a railcar?

    A 6-axis robot, mounted on additional 7th and 8th linear axes, moves along the length and height of the railcar. These extra axes are fully synchronized, ensuring precise and efficient coating of even the largest surfaces. With deep expertise in complex robotic kinematics, Sames delivers advanced solutions for seamless automation in railway coating.

  • Why choose a 2K rotary bell, such as the PPH 707, for railway coating applications?

    The PPH 707 SB-2K rotary bell delivers high productivity (up to 800 cc/min), superior finish quality, and reduced material waste. Its electrostatic efficiency and symmetrical round spray pattern simplify robotic trajectories, making it far more efficient than spray guns for coating large surfaces like railcars.

  • Can the same robot spray both epoxy primer and PU topcoat?

    Using the same fluid circuit for both epoxy primer and PU topcoat is strongly discouraged because their hardeners are chemically incompatible, which can cause serious quality issues. However, alternative solutions are available depending on application constraints.

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