WO2025181363A1 - Powder coating composition selection and application - Google Patents
Powder coating composition selection and applicationInfo
- Publication number
- WO2025181363A1 WO2025181363A1 PCT/EP2025/055576 EP2025055576W WO2025181363A1 WO 2025181363 A1 WO2025181363 A1 WO 2025181363A1 EP 2025055576 W EP2025055576 W EP 2025055576W WO 2025181363 A1 WO2025181363 A1 WO 2025181363A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- parameter
- oven
- coating
- powder coating
- powder
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Classifications
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/41875—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by quality surveillance of production
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/02—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
- B05D3/0254—After-treatment
- B05D3/0272—After-treatment with ovens
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B12/00—Arrangements for controlling delivery; Arrangements for controlling the spray area
- B05B12/08—Arrangements for controlling delivery; Arrangements for controlling the spray area responsive to condition of liquid or other fluent material to be discharged, of ambient medium or of target ; responsive to condition of spray devices or of supply means, e.g. pipes, pumps or their drive means
- B05B12/085—Arrangements for controlling delivery; Arrangements for controlling the spray area responsive to condition of liquid or other fluent material to be discharged, of ambient medium or of target ; responsive to condition of spray devices or of supply means, e.g. pipes, pumps or their drive means responsive to flow or pressure of liquid or other fluent material to be discharged
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B5/00—Electrostatic spraying apparatus; Spraying apparatus with means for charging the spray electrically; Apparatus for spraying liquids or other fluent materials by other electric means
- B05B5/08—Plant for applying liquids or other fluent materials to objects
- B05B5/081—Plant for applying liquids or other fluent materials to objects specially adapted for treating particulate materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D2401/00—Form of the coating product, e.g. solution, water dispersion, powders or the like
- B05D2401/30—Form of the coating product, e.g. solution, water dispersion, powders or the like the coating being applied in other forms than involving eliminable solvent, diluent or dispersant
- B05D2401/32—Form of the coating product, e.g. solution, water dispersion, powders or the like the coating being applied in other forms than involving eliminable solvent, diluent or dispersant applied as powders
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/37—Measurements
- G05B2219/37073—Workpiece surface covered with shielding coating, against disturbing fields
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/45—Nc applications
- G05B2219/45013—Spraying, coating, painting
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/49—Nc machine tool, till multiple
- G05B2219/49056—Control of flow of fluid or temperature as function of speed for uniform coating
Definitions
- Powder coatings typically give smooth, uniform and hard surfaces.
- the powder coating is electrostatically sprayed onto the object, often a metallic object, in an oven at high temperatures, typically in the range 100 to 300°C.
- Triboelectric guns may also be used. When the powder coating reaches the target temperature the powder particles melt together. For thermoset powder coatings curing will then take place. For UV curing, UV light is needed to start the curing process.
- a method of applying a powder coating to an object comprising: performing a computer implemented powder coating evaluation method comprising: 14567648-1 obtaining at least one object parameter associated with the object; obtaining at least one oven parameter associated with an oven to be used to apply the powder coating to an object; for each of a plurality of powder coatings: obtaining at least one coating parameter associated with the powder coating; determining at least one performance parameter associated with applying the powder coating to the object, wherein determining each of the at least one performance parameter is based on: (i) one or more of the at least one object parameter, (ii) one or more of the at least one oven parameter, and (iii) one or more of the at least one coating parameter; providing an evaluation output based on the at least one performance parameter of each of the plurality of powder coatings; wherein the method further comprises: selecting a computer implemented powder coating evaluation method comprising: 14567648-1 obtaining at least one object parameter associated with the object; obtaining at least one oven parameter associated with an oven to be used to apply the powder coating to an object
- the at least one object parameter may comprise one or any combination of: a type of material of the object, a material thickness of the object, an object type of the object, a surface area of the object to be coated, a target thickness of the powder coating at one or more surface areas of the object, a mass of the object, a coating scheme for the object, and a surface preparation of the object.
- the at least one oven parameter may comprise one or any combination of: a heating mechanism type of the oven, a design type of the oven, an energy source of the oven, a material of the oven, one or more dimensions of the oven, a heat transfer type of the oven, one or more settings of a component of the oven, a material of a component of the oven, and a mass of a component of the oven.
- the at least one coating-dependent oven parameter may comprise one or any combination of: a temperature of air enclosed with the oven, a line speed of the oven, and one or more settings of a component of the oven.
- Determining the at least one coating-dependent oven parameter may be further based on one or more of the at least one object parameter.
- the at least one performance parameter may comprise an energy usage performance parameter indicating the energy required to apply the powder coating to the object.
- Determining the energy usage performance parameter may comprise: determining an energy required to heat the oven using: one or more of the at least one oven parameter, and one or more of the at least one coating parameter; determining an energy required to heat the object using: one or more of the at least one object parameter, one or more of the at least one oven parameter, and one or more of the at least one coating parameter; determining energy losses due to heat loss of air used for heating the object using: one or more of the at least one oven parameter, and one or more of the at least one coating parameter; and d etermining the energy usage performance parameter by summing the energy required to heat the oven, the energy required to heat the object; and the energy losses.
- the at least one performance parameter may comprise a productivity performance parameter indicating the productivity of the oven when applying the powder coating to the object.
- the computer implemented powder coating evaluation method may comprise determining the productivity performance parameter using a coating process speed and 14567648-1 conversion factor which converts the coating process speed into the productivity performance parameter.
- the method may comprise determining the coating process speed using: one or more of the at least one object parameter, one or more of the at least one oven parameter, and one or more of the at least one coating parameter.
- the at least one performance parameter may comprise an environmental emissions performance parameter indicating the environmental emissions that will result from applying the powder coating to the object.
- the determining the environmental emissions performance parameter may comprise: determining an energy usage performance parameter indicating the energy required to apply the powder coating to the object based on: (i) one or more of the at least one object parameter, (ii) one or more of the at least one oven parameter, and (iii) one or more of the at least one coating parameter; and converting the energy usage performance parameter into the environmental emissions performance parameter
- the determining the environmental emissions performance parameter may comprise: determining an energy usage performance parameter indicating the energy required to apply the powder coating to the object based on: (i) one or more of the at least one object parameter, (ii) one or more of the at least one oven parameter, and (iii) one or more of the at least one coating parameter; determining a quantity of the powder coating required to coat the object based on one or more of the at least one object parameter, and one or more of the at least one coating parameter; and d etermining the environmental emissions performance parameter using the energy usage performance parameter and the quantity of the powder coating.
- the method may further comprise including the quantity of the powder coating of one or more of the plurality of powder coatings in the evaluation output.
- the computer implemented powder coating evaluation method may further comprise selecting a powder coating from the plurality of powder coatings based on the at least one performance parameter of each of the plurality of powder coatings, wherein the evaluation output comprises the selected powder coating.
- the computer implemented powder coating evaluation method may further comprise assigning a ranking value to each of the plurality of powder coatings based on the at least one performance parameter of each of the plurality of powder coatings; wherein the evaluation output comprises the plurality of powder coatings and the ranking values associated with each of the plurality of powder coatings.
- a non-transitory computer-readable storage medium comprising instructions which, when executed by a processor of a computing device, cause the processor to perform the computer implemented powder coating evaluation method according to any of the implementations as described herein.
- a computing device comprising a processor configured to perform the computer implemented powder coating evaluation method according to any of the implementations as described herein.
- a method of applying a powder coating system to an object comprising: p erforming a computer implemented powder coating system evaluation method comprising: obtaining at least one object parameter associated with the object; 14567648-1 obtaining at least one oven parameter associated with an oven to be used to apply the powder coating to an object; for each of a plurality of powder coating systems: for each of a plurality of powder coatings of the powder coating system: obtaining at least one coating parameter associated with the powder coating; determining at least one performance parameter associated with applying the powder coating to the object, wherein determining each of the at least one performance parameter is based on: (i) one or more of the at least one object parameter, (ii) one or more of the at least one oven parameter, and (iii) one or more of the at least one coating parameter; d etermining a powder coating system performance parameter of the powder coating system based on the at least one performance p arameter of each of the plurality of powder coatings of the powder coating system
- a computing device comprising a processor configured to perform the computer implemented powder coating system evaluation method according to any of the implementations as described herein.
- a non-transitory computer-readable storage medium comprising instructions which, when executed by a processor of a computing device, cause the processor to perform the computer implemented powder coating system evaluation method according to any of the implementations as described herein. 14567648-1
- the instructions referred to herein may be provided on a carrier such as a disk, CD- or DVD-ROM, programmed memory such as read-only memory (Firmware), or on a data carrier such as an optical or electrical signal carrier.
- Code (and/or data) to implement embodiments of the present disclosure may comprise source, object or executable code in a conventional programming language (interpreted or compiled) such as C, or assembly code, code for setting up or controlling an ASIC (Application Specific Integrated Circuit) or FPGA (Field Programmable Gate Array), or code for a hardware description language.
- a conventional programming language interpreted or compiled
- ASIC Application Specific Integrated Circuit
- FPGA Field Programmable Gate Array
- Figure 1 is a schematic block diagram of the computing device
- Figure 2 illustrates a method of applying one or more powder coatings to an object in accordance with embodiments of the invention
- Figure 3 illustrates a computer implemented powder coating evaluation method that may be performed by the computing device in the method shown in Figure 2
- Figure 4a illustrates steps in the computer implemented powder coating evaluation method that may be performed to determine an environmental emissions performance parameter
- Figure 4b illustrates steps in the computer implemented powder coating evaluation method that may be performed to determine an environmental emissions performance parameter
- Figure 5 illustrates another computer implemented powder coating evaluation method that may be performed by the computing device in the method shown in Figure 2
- Figure 6 illustrates a method of configuring an oven for use in applying a powder coating to an object in accordance with embodiments of the invention
- 14567648-1 Figure 7 illustrates a computer implemented coating-dependent oven parameter determination method that may be performed by the computing
- Embodiments of the present disclosure include the execution of computer implemented methods. Some embodiments of the present disclosure relate to a computer implemented powder coating evaluation method which provides an evaluation output. A user can then use this output to select a particular powder coating composition in order to optimise a powder coating composition application process. Other embodiments of the present disclosure relate to a computer implemented coating- dependent oven parameter determination method which outputs at least one coating- dependent oven parameter. A user can then configure an oven using the coating- dependent oven parameter in order to optimise a powder coating composition application process. Other embodiments of the present disclosure relate to a computer implemented oven parameter evaluation method which outputs at least one performance parameter associated with at least one user selected coating-dependent oven parameter.
- binder coating composition refers to dry, free flowing powder which when applied to a surface and heated, e.g. cured, forms a coating thereon.
- the particles that constitute the powder have an average diameter of 3-150 ⁇ m.
- the powder may first be applied to 14567648-1 the object and then the object is heated, or the object can be preheated and then the powder is applied to the preheated object.
- a powder coating composition may be thermoset, thermoplastic or UV curable.
- the powder coating composition comprises at least one binder.
- ingredients that may be present are curing agent(s), colour pigment(s), effect pigment(s) (e.g. pearlescent, metallic), filler(s), degassing agent(s), flow agent(s), levelling agent(s), matting agent(s), optical brightener(s), antioxidant(s), phosphate(s), borate(s), adhesion promotor(s) (e.g. silane(s), amino alcohol(s)), texture additive(s), intumescent additive(s), biocide(s) (e.g. anti-viral agent(s)) and/or catalyst(s).
- curing agent(s) e.g. silane(s), amino alcohol(s)
- texture additive(s) e.g. anti-viral agent(s)
- biocide(s) e.g. anti-viral agent(s)
- catalyst(s e.g. anti-viral agent(s)
- the binder present in the powder coating composition may be polyester, epoxy binder, polyorganosiloxane, poly(meth)acrylic, polycarbonate, fluorovinylidene or combinations thereof.
- the binder is selected from epoxy binder, polyester, poly(meth)acrylic, fluorovinylidene and combinations thereof.
- the curing agents used in powder coating compositions may be polyisocyanates, phenolic based, triglycidyl isocyanurate (TGIC), amines, carboxylic acids and carboxylic acid functional resins, hydroxy functional resins, amides such as hydroxyalkyl amide, guanidines such as dicyandiamide, imidazoles and imidazole (epoxy) adducts, imidazoline, imidazolidine, anhydrides, dihydrazides and combinations thereof.
- TGIC triglycidyl isocyanurate
- amines carboxylic acids and carboxylic acid functional resins
- hydroxy functional resins amides such as hydroxyalkyl amide
- guanidines such as dicyandiamide
- imidazoles and imidazole (epoxy) adducts imidazoline, imidazolidine, anhydrides, dihydrazides and combinations thereof.
- Powder coating compositions are for example described in WO2018210849, WO2023180292, WO2017186870, WO2019234139, WO2012110451, WO2021074342, WO2018050774, WO2015063024, WO2022266647 and WO2022256784.
- powder coatings are made by first weighing and mixing together a mixture of binder and other ingredients, to obtain a homogenous premix. The premix is then melted, mixed and dispersed in for example a single screw or a twin screw extruder into a homogenous melted mixture. The melted mixture is then cooled, tableted and broken.
- a powder coating composition referred to herein may be a homogenous mixture or a mix of powders with different components (for example two, three or more).
- the components can be processed fully separately, and then dry blended together to obtain the components mix as one powder.
- the components can be produced separately, and then blended and processed together from the grinding step and onwards.
- Powder coating compositions may be described by its particle size distribution (PSD).
- the particle size of the powder coating composition can be measured and described by for example D10, D50, D90, D98 and/or D99.
- D10 refers to the size at which 10% of the particles have a diameter smaller than the value recited.
- D50 refers to the size at which 50% of the particles have a diameter smaller than the value recited.
- D90 refers to the size at which 90% of the particles have a diameter smaller than the value recited.
- D98 refers to the size at which 98% of the particles have a diameter smaller than the value recited.
- D 99 refers to the size at which 99% of the particles have a diameter smaller than the value recited.
- the particle size distribution can be described by using at least two of the particle size values, e.g.
- a powder coating composition can be applied as a single layer to an object.
- different powder coating compositions can be applied in different layers to an object, whereby a “coating system” defines the multiple powder coating compositions and the order in which they are applied to the object.
- a coating system may define that a powder coating composition 1 is first applied to the object (as a base layer) and after this a powder coating composition 2 is applied thereby providing the object with two different powder coating layers.
- the computer implemented methods described herein are performed on a computing device.
- FIG. 1 illustrates a simplified view of a computing device 100 which may perform the computer implemented evaluation methods described herein.
- the computing device 100 comprises a central processing unit (“CPU”) 102, to which is connected a memory 104.
- the functionality of the CPU 102 described herein may be implemented in code (software) stored on a memory (e.g. 14567648-1 memory 104) comprising one or more storage media, and arranged for execution on a processor comprising on or more processing units.
- the storage media may be integrated into and/or separate from the CPU 102.
- the code is configured so as when fetched from the memory and executed on the processor to perform operations in line with embodiments discussed herein.
- the computing device 100 may comprise an input device 106 coupled to the CPU 102.
- the input device 106 allows a user of the computing device 100 to provide inputs and control the operation of the computing device 100.
- the input device 106 may be keypad, keyboard, a touch-screen display, and/or a microphone.
- the computing device 100 may comprise an output device 108 coupled to the CPU 102.
- the output device 108 allows the computing device 100 to provide outputs to a user operating the computing device 100.
- the output device 108 may comprise a display (for example the touch-screen display referred to above) and/or a speaker.
- the input device 106 and output device 108 may be integrated into the computing device 100 as shown in Figure 1. In other embodiments, one or both of the input device 106 and output device 108 may not be integrated into the computing device 100 and may be connected to the computing device 100 (and thereby the CPU 102) via respective interfaces. Such interfaces may be wired (e.g. a USB interface) or wireless.
- the computing device 100 may comprise a communication interface 110 coupled to the CPU 102.
- the communication interface 110 allows the computing device 100 to transmit data, and/or receive data.
- the communication interface 110 may be a wireless communication interface and/or a wired communication interface.
- FIG. 2 illustrates a method 200 of applying one or more powder coatings to an object. That is, the method 200 may be performed to apply a single powder coating to an object. Alternatively the method 200 may be performed to apply multiple powder coatings to an object, whereby the multiple powder coatings form a coating system.
- the method 200 comprises performing a computer implemented powder coating evaluation method.
- the computer implemented powder coating evaluation method may be performed by the computing device 100.
- the computer implemented powder coating evaluation method performed at step S202 may be performed by the CPU 102.
- Figure 3 illustrates a computer implemented powder coating evaluation method that is performed at step S202 to evaluate multiple powder coatings as candidates for being used to coat an object as a single layer.
- the CPU 102 obtains one or more parameters of an object that is to be coated with a powder coating.
- the object that is to be coated with a powder coating may comprise one or more materials including metal (e.g. steel, galvanized steel, aluminium), wood, MDF, HDF, plywood, fibreboard, particleboard, plastic, glass, ceramic, composite materials, graphite-filled composites and so on.
- the object may for example be a washing machine, radiator, frame etc. It will be appreciated that these are merely examples and embodiments of the present disclosure are not limited to any particular object.
- the object parameter(s) influence the ability of the object to be heated. That is, the energy needed to get to a certain surface temperature depends on these parameters.
- the object parameter(s) may comprise one or any combination of: a type of material of the object (e.g. a type of metal, wood, MDF etc.), a material thickness of the object, an object type of the object (e.g. washing machine, radiator, frame etc.), a surface preparation of the object (e.g. chemical cleaning, mechanical cleaning), a surface area of the object to be coated, a target thickness of the powder coating at one or more surface areas of the object, a mass of the object, and a coating scheme for the object.
- a type of material of the object e.g. a type of metal, wood, MDF etc.
- a material thickness of the object e.g. a type of metal, wood, MDF etc.
- an object type of the object e.g. washing machine, radiator, frame etc.
- a surface preparation of the object e.g. chemical cleaning, mechanical cleaning
- a target thickness of the powder coating at one or more surface areas of the object e.g. a mass of the object
- the target 14567648-1 thickness may be unique to the object.
- a target thickness may be specified for all objects belonging to a specific object group.
- an object group may be defined as “washing machines” such that the target thickness specifies that all washing machines are to have a layer of powder coating, which is formed after the powder coating has been applied, at the required thickness.
- an object group may be defined as “washing machine model number 001” such that the target thickness specifies that all washing machines having the model number 001 are to have a layer of powder coating, which is formed after the powder coating has been applied, at the required thickness.
- coating scheme defines one or more surface areas of an object that are to be coated, and may optionally define a thickness of the coating in the one or more surface areas.
- a coating scheme may define that all surface areas of the object are to be coated, or the object is to be only coated in certain surface areas leaving other surface areas uncoated (interior/exterior/one side).
- a coating scheme may define that an object is to be coated with even thickness in all surface areas.
- a coating scheme may define that a certain surface area is to have different coating thickness than other surface areas (interior/exterior/one side).
- the CPU 102 may obtain the object parameter(s) by various mechanisms.
- the CPU 102 may obtain one or more of the object parameter(s) by retrieving them from memory 104. Alternatively or additionally, the CPU 102 may obtain one or more of the object parameter(s) by receiving them via the input device 106 (e.g. based on them being input by a user using the input device 106. Alternatively or additionally, the CPU 102 may obtain one or more of the object parameter(s) by receiving them via the communication interface 110 (e.g. by retrieving them from a remote database that is external to the computing device 100). At step S304, the CPU 102 obtains one or more parameters of an oven that is to be used to apply the powder coating to the object.
- the term “oven” refers to any type of equipment that enables the powder coating to be applied to the object and form a film thereon.
- the oven may comprise an enclosure in which an object to be coated is placed or which the object travels though during the powder coating application process.
- the oven is configured to melt and cure the powder coating that has been or is to be applied to an object.
- the oven may cure the 14567648-1 powder coating using conventional thermal energy heating through the air, IR, induction, or using ultraviolet (UV) light.
- UV ultraviolet
- thermoplastic powder coatings for which there is no curing as the powder particles melt in the oven but do not chemically crosslink
- the oven is configured to melt the powder coating that has been applied or is to be applied to the object.
- the oven may melt the powder coating using conventional thermal energy heating through the air, IR, induction or combinations thereof. That is, the oven may employ a combination of one or more heating mechanisms.
- the oven may also comprise a component (e.g. a spray gun) to apply the powder coating to the object prior to curing.
- the oven parameter(s) may comprises a heating mechanism type of the oven e.g. whether the heating mechanism is via convection, infrared, induction or whether the oven employs a combination of one or more heating mechanisms (e.g. a combination of infrared and convection, or a combination of convection and induction.
- the oven parameter(s) may comprises a design type of the oven (e.g.
- the oven parameter(s) may comprises an energy source of the oven (e.g. electricity, LPG, diesel, bunker oil, wood etc.).
- the oven parameter(s) may comprises a material of the oven (e.g. a type of metal used and/or a type of insulation used).
- the oven parameter(s) may comprises one or more dimensions of the oven (e.g. the oven’s height and/or length, a thickness of walls of the oven, a thickness of any insulation used in the oven).
- the oven parameter(s) may comprise a heat transfer type of the oven (e.g. direct fire, heat exchanger etc.).
- the oven parameter(s) may comprise one or more settings of a component of the oven (e.g. settings of an air circulation device of the oven, settings of a spray gun etc.).
- the oven parameter(s) may comprise a material of a component of the oven (e.g. for a conveyor oven, a material of a conveyor forming part of the oven used to transport the object through the oven; for a batch oven, a material of a trolley used to support the object during insertion/removal of the object from the oven and during the curing process).
- the oven parameter(s) may comprise a mass of a component of the oven (e.g.
- the oven parameter(s) may comprises a length of time the oven is operational in a given time period (e.g. a length of time the oven is operational in one day).
- the oven parameter(s) may comprise a temperature of the air (Tair) enclosed with the oven. 14567648-1
- component of the oven refers to a component that is coupled to, or housed within the oven during operation. A component of the oven may be in a fixed position after installation of the oven e.g. a conveyor. Alternatively a component of the oven may be removable from the oven e.g. a trolley.
- One or more of the oven parameter(s) may be static (i.e. cannot be varied) e.g. - heating mechanism type of the oven - design type of the oven - energy source of the oven - settings of a component of the oven (e.g. one or more settings of a spray gun may be fixed such as the gun type which is coating independent) - material of the oven - dimensions of the oven - heat transfer type of the oven - material of a component of the oven - mass of a component of the oven.
- One or more of the oven parameter(s) may not be static (i.e. can be varied) e.g. - length of time the oven is operational in a given time period - temperature of the air enclosed with the oven.
- the CPU 102 may obtain the oven parameter(s) by various mechanisms.
- the CPU 102 may obtain one or more of the oven parameter(s) by retrieving them from memory 104.
- the CPU 102 may obtain one or more of the oven parameter(s) by receiving them via the input device 106 (e.g. based on them being input by a user using the input device 106.
- the CPU 102 may obtain one or more of the oven parameter(s) by receiving them via the communication interface 110 (e.g. by retrieving them from a remote database that is external to the computing device 100). For each of a plurality of powder coatings to be evaluated, the CPU 102 obtains at least one coating parameter associated with the powder coating, and then determines at least 14567648-1 one performance parameter associated with applying the powder coating to the object. The determining of each of the at least one performance parameter associated with applying the powder coating to the object is based on: (i) one or more of the object parameter(s), (ii) one or more of the oven parameter(s), and (iii) one or more of the coating parameter(s).
- the performance parameter referred to herein relates to performance in relation to the application of a particular powder coating to an object by the oven.
- the performance parameter referred to herein may relate to performance that the oven will exhibit when applying a particular powder coating to an object.
- a unique identifier of each of the plurality of powder coatings to be evaluated is accessible to the CPU 102.
- the unique identifier of each of the plurality of powder coatings to be evaluated may be stored in memory 104.
- a user may select the plurality of powder coatings to be evaluated using the input device 106.
- a user may select the plurality of powder coatings to be evaluated from a list of powder coatings (which comprises the plurality of powder coatings and additional powder coatings) using the input device 106.
- the unique identifier of each of the plurality of powder coatings may for example be a product name, and/or a numerical or alphanumerical code.
- Figure 3 illustrates the steps performed by the CPU 102 when two powder coatings (coating 1 and coating 2) are evaluated. It will be appreciated that any number of powder coatings may be evaluated using the computer implemented powder coating evaluation method of Figure 3.
- the CPU 102 obtains one or more parameters of a first powder coating (coating 1) that is to be evaluated as a candidate for being used to coat the object.
- the coating parameter(s) may comprise a temperature to be used in an oven when applying the powder coating. This temperature may be a minimum temperature of an object that is necessary so that the powder coating can be applied to the object. This temperature may alternatively be a maximum temperature of the air enclosed in the oven (e.g. to avoid degradation of the powder coating).
- the coating 14567648-1 parameter(s) may comprise a coating thickness of the powder coating.
- the coating parameter(s) may comprise a specific gravity which refers to the ratio of the weight of a given volume of powder coating to the weight of an equal volume of water. In particular, specific gravity is a measure of the density of the powder compared to water and may be measured in g/cm3 or the SI unit kg/cm3.
- the coating parameter(s) may comprise a powder coating coverage (m2 / kg) which refers to an area that will be covered with 1 kg of powder coating to achieve a desired film thickness.
- the coating parameter(s) may comprise a particle size distribution of the powder coating.
- coating thickness refers to a thickness of the layer of powder coating (that is formed after the powder coating has been applied to the object) that can be achieved when using the particular powder coating.
- the coating thickness may be defined by a minimum coating thickness or a maximum coating thickness.
- the coating thickness may be defined by range between a minimum coating thickness and a maximum coating thickness. It will be appreciated that if an object parameter of an object defines a target thickness, then for coating the object it is necessary to use a powder coating that can achieve the target thickness (based on the coating thickness of the powder coating). For example, it is necessary for the target thickness to be within a range defined by a minimum coating thickness and a maximum coating thickness.
- the CPU 102 may obtain the coating parameter(s) by various mechanisms.
- the CPU 102 may obtain one or more of the coating parameter(s) by retrieving them from memory 104. Alternatively or additionally, the CPU 102 may obtain one or more of the coating parameter(s) by receiving them via the input device 106 (e.g.
- the CPU 102 may obtain one or more of the coating parameter(s) by receiving them via the communication interface 110 (e.g. by retrieving them from a remote database that is external to the computing device 100). 14567648-1 It will be appreciated by persons skilled in the art that coating parameter(s) such as those referred to above, are typically included in technical data sheet (TDS) of a powder coating and/or can be obtained by measurement. At step S308, the CPU 102 determines at least one performance parameter associated with applying the first powder coating (coating 1) to the object.
- TDS technical data sheet
- each of the performance parameters is based on: (i) one or more of the object parameter(s) obtained at step S302, (ii) one or more of the oven parameter(s) obtained at step S304, and (iii) one or more of the coating parameter(s) of coating 1 obtained at step S306.
- the performance parameter(s) determined at step S308 relate to the performance of the process of applying the first powder coating (coating 1) to the object.
- the dependency of the performance parameter P on the oven parameter(s) p ov can typically be established by referring to the oven information from oven manufacturers.
- the dependency of the performance parameter P on the object parameter(s) p obj and coating parameter(s) p coat , and the interrelation between oven, object and coating parameters is typically established experimentally for the given oven or a similar oven, for the given object or similar objects and for the coating or an equivalent coating.
- Various performance parameters may be determined by the CPU 102 at step S308.
- one or more of: an energy usage performance parameter, a productivity performance parameter, and environmental emissions performance parameter may be determined by the CPU 102 at step S308.
- One or more of the performance parameters may be computed by the CPU 102 by computing a coating-dependent oven parameter.
- a coating-dependent oven parameter is a parameter of the oven that depends on both the oven and the coating.
- the CPU 102 may compute the coating-dependent oven parameter using one or more oven parameter, and one or more coating parameter.
- a coating-dependent oven parameter may further depend on the object (i.e. on one or more object parameter). 14567648-1
- the performance parameter may then be computed by the CPU 102 using (i) the coating- dependent oven parameter (ii) one or more object parameter (which may be the same or different to the object parameter(s) used to compute the coating-dependent oven parameter), (iii) one or more oven parameter (which may be the same or different to the oven parameter(s) used to compute the coating-dependent oven parameter), and (iv) one or more coating parameter (which may be the same or different to the coating parameter(s) used to compute the coating-dependent oven parameter).
- Examples of a coating-dependent oven parameter include: - a temperature of the air (Tair) enclosed with the oven. This may be a minimum or maximum temperature value. - a line speed of the oven, i.e. the moving speed of a conveyor of a conveyor oven usually measured in meters per second. - one or more settings of a component of the oven (e.g. one or more settings of a spray gun of the oven may be controllable) A number of settings of the spray gun may be controlled in dependence on the particular powder coating being used.
- Tair temperature of the air enclosed with the oven. This may be a minimum or maximum temperature value.
- - a line speed of the oven i.e. the moving speed of a conveyor of a conveyor oven usually measured in meters per second.
- - one or more settings of a component of the oven e.g. one or more settings of a spray gun of the oven may be controllable
- a number of settings of the spray gun may be controlled in dependence on the particular powder coating being used.
- the controllable settings of the spray gun include: a powder flow rate, a quantity of air required, a voltage, a current, a gun distance (distance between gun and object), a speed of movement of the spray gun, type of nozzle, size of nozzle.
- a coating-dependent oven parameter that are also dependent on object parameter(s) of the object include some settings of the spray gun, e.g. the gun distance and the speed of movement of the spray gun.
- Energy usage performance parameter One example performance parameter that may be determined in embodiments of the present disclosure is an energy usage performance parameter.
- the energy usage performance parameter defines how much energy would be used to apply the particular powder coating to the particular object.
- the energy usage performance parameter may be a value of kilowatt hours (kWh).
- the energy usage performance parameter may be computed using at least one coating- dependent oven parameter.
- a coating-dependent oven parameter for the first powder coating (coating 1) is a parameter of the oven that depends on (i) one or more of the oven parameter(s) of coating 1 obtained at step S304, and (ii) one or more of the coating parameter(s) of coating 1 obtained at step S306.
- a coating-dependent oven parameter for the first powder coating (coating 1) may further depend on (iii) one or more of the object parameter(s) obtained at step S302. We refer to an example below whereby the coating-dependent oven parameters of air temperature (Tair) and line speed are used in the determination of the energy usage performance parameter.
- the energy usage performance parameter is dependent on one or more coating parameters of the particular powder coating e.g. a minimum temperature of the object surface so that the powder coating can melt (Tmet).
- the minimum object surface temperature Tmet determines the air temperature (Tair) of the air enclosed within the oven (that is used to heat up the object) has to have.
- the air temperature Tair will always need to be at least the object surface temperature T met .
- the temperature the air needs to have also depends on the line speed of the oven. The higher the line speed, the higher the air temperature required.
- T air f(line speed)
- the line speed in turn also depends on the speed of application of the powder coating by the spray gun of the oven to the object surface. For example, a slow application speed by the spray gun reduces the overall line speed as the object would need to be sprayed for a longer period to achieve the required powder coating thickness. A slower line speed then in turn influences the temperature settings, especially the air temperature and by that the energy requirements. Parameters influencing the application speed are gun settings of the spray gun e.g. powder flow rate, gun movement, gun distance.
- the CPU 102 may use one or more static oven parameters and one or more coating parameters.
- a coating-dependent oven parameter is computed using one or more oven parameters and one or more coating parameters.
- the energy required to heat the oven Ereq,oven may be computed by the CPU 102 by determining a coating-dependent oven parameter using one or more of the static oven parameters and one or more coating parameters. To determine the energy required to heat the oven Ereq,oven, the CPU 102 may use the coating-dependent oven parameter with or without one or more oven parameters and/or one or more coating parameters. 14567648-1
- the minimum object surface temperature Tmet depends on the chosen coating. All other input parameters in this equation are static oven parameters.
- a coating-dependent oven parameter is computed using one or more oven parameters and one or more coating parameters (and optionally one or more object parameters).
- the energy required to heat the object Ereq,object may be computed by the CPU 102 by determining a coating-dependent oven parameter using the one or more of 14567648-1 the static oven parameters and one or more coating parameters (and optionally one or more object parameters).
- the CPU 102 may use the coating-dependent oven parameter with or without one or more oven parameters and/or one or more coating parameters and/or one or more object parameters.
- the minimum object surface temperature Tmet depends on the chosen coating.
- ⁇ object depends on a coating-dependent oven parameter e.g. the line speed. All other input parameters in this equation are static settings for the specific object or oven (T0).
- the energy losses Elosses may be computed by the CPU 102 by determining a coating-dependent oven parameter using the one or more of the static oven parameters and one or more coating parameters. To determine the energy losses Elosses, the CPU 102 may use the coating-dependent oven parameter with or without one or more oven parameters and/or one or more coating parameters. Tair depends on Tmet (Tair always > Tmet) and the oven specifics and a coating-dependent oven parameter like line speed (the higher the line speed the higher Tair). All other input parameters in this equation are static settings for the specific oven (T0).
- the energy consumption E req,total for a given oven, given object and a given coating may be computed by the CPU 102 considering relevant energy consuming steps of the coating process.
- Examples of relevant energy consuming steps for a powder coating process are energy consumption of oven components during the application (and curing if thermal curing is used) process E oven1 (e.g. energy consumption of spray gun, air pump), and energy absorbed by the oven and its components E oven2 (e.g. energy is absorbed by the oven material), energy needed for the melting (and curing if thermal curing is used) of the powder coating on the object surface E req,obj (e.g. energy absorbed by the object), and energy losses that occur in the process E losses (e.g.
- E req,tot E oven1 + E oven2 + E req,obj + E losses whereby Eoven2 corresponds to Ereq,oven above.
- the dependency of the oven energy terms Eoven1 (if used) and Eoven2 and Elosses on the oven parameters can typically be established by referring to the oven information from oven manufacturers.
- productivity performance parameter Another example performance parameter that may be determined in embodiments of the present disclosure is a productivity performance parameter.
- the productivity performance parameter defines the productivity of the oven when a particular powder coating is used to coat a particular object.
- the productivity performance parameter may define the quantity of objects coated Q Coated-material in a certain time frame t.
- the coating process speed can be expressed e.g. as objects per hours.
- the conversion factor converts the coating process speed into the chosen metric to measure the productivity, e.g.
- the dependency of the coating process speed on the oven, object and coating parameters and the interrelation between oven, object and coating parameters is typically established experimentally for the given oven or a similar oven, for the given object or similar objects and for the coating or an equivalent coating.
- the coating process speed depends on an object parameter (dimensions of the object).
- Another factor which impacts the coating process speed is the time needed for the powder coating to set/cure on the object which is dependent on the temperature that the object has been heated (dictated by a coating parameter - a minimum temperature of an object that is necessary so that the powder coating can be applied to the object). For objects with high heat capacity, the time taken for the powder coating to set/cure takes longer, thus the setting/curing time increases, which in turn reduces the coating process speed.
- the productivity performance parameter is therefore a function of the mass of the objects ⁇ object and the coating process speed scoating.
- line speed refers to the moving speed of the conveyor, usually measured in meters per second.
- line speed (a coating-dependent oven parameter) relates directly to coating process speed for a specific object.
- the coating process speed s coating and the temperature required at the object surface are related (higher coating process speed is possible if lower temperature required) and are coating dependent. It is clear that the above productivity performance parameter is only applicable when the oven is operating.
- the overall productivity QCoated ⁇ material, achieved /t is therefore a function of the operational conditions, which can be expressed as the percentage of time of activity f a .
- fa is an activity factor, ranging from 0 to 100%.
- the coating process speed scoating may be determined using: one or more object parameter, one or more oven parameter, and one or more coating parameter.
- a coating-dependent oven parameter is computed using one or more oven parameters and one or more coating parameters (and optionally one or more object parameters).
- the coating process speed scoating may be computed by the CPU 102 by determining a coating-dependent oven parameter using one or more oven parameters and one or more coating parameters (and optionally one or more object parameters).
- the CPU 102 may use the coating- 14567648-1 dependent oven parameter with or without one or more oven parameters and/or one or more coating parameters and/or one or more object parameters.
- Environmental emissions performance parameter Another example performance parameter that may be determined in embodiments of the present disclosure is an environmental emissions performance parameter.
- the environmental emissions parameter defines environmental emissions produced by the oven when a particular powder coating is used to coat a particular object.
- the environmental emissions parameter may be a value of CO2 emissions (e.g. kg of CO2) or other greenhouse gases. We refer herein to CO2 emissions as an example.
- the carbon emissions EM CO2 for a given oven, given object and a given coating may be computed by the CPU 102 by considering elements of the coating process that generate CO2 emissions.
- Examples of relevant elements to consider in the selection and application of a powder coating that generate CO2 emissions are steps that consume energy during the coating process and thus emit an amount of CO2 EM CO2,process (e.g. energy needed for heating object and oven, energy consumed by oven components like spray gun or air pump) and CO2 emissions related to using a given coating EM CO2,coating (e.g.
- EM CO2 EM CO2, process + EM CO2, coating
- Ereq,tot can either be computed (for example as described herein) or be measured experimentally for a given oven, object, coating; and a set of oven, object and coating parameters, and stored in memory accessible to the CPU 102. 14567648-1
- the CO2 emissions related to using a given coating EMCO2,coating are available e.g. in environmental product declarations (EPD), and may be stored in memory accessible to the CPU 102.
- the environmental emissions parameter may be determined in a number of ways. An example method of determining the environmental emissions parameter is shown in Figure 4a.
- determining an environmental emissions parameter may comprise the CPU 102 determining, at step S402, an energy usage performance parameter based on: (i) one or more of the object parameter(s), (ii) one or more of the oven parameter(s), and (iii) one or more of the coating parameter(s) of a specific coating.
- the CPU 102 may compute the total energy required (E req,tot ) for coating the specified object with the specified oven.
- step S308 of determining an environmental emissions parameter for coating 1 may comprise the CPU 102 determining, at step S402, an energy usage performance parameter based on: (i) one or more of the object parameter(s) obtained at step S302, (ii) one or more of the oven parameter(s) obtained at step S304, and (iii) one or more of the coating parameter(s) of coating 1 obtained at step S306.
- the step S308 of determining an environmental emissions parameter may comprise the CPU 102 determining, at step S404, the environmental emissions parameter by converting the energy usage performance parameter determined at step S402 into an environmental emissions parameter which indicates the environmental emissions due to the fuel (energy source) of the oven.
- the CPU 102 may compute the quantity of environmental emissions (e.g.
- CE fuel Q fuel /EF fuel
- Emission factors for various fuels are publicly available. Table 4 below shows the emission factors mentioned in the UK Govt Green House Gas Report 2023. M aterial Emission Quantity factor (EF) kg-co2/quantity D iesel 2.82 L LPG/Propane 2.89 kg Natural gas 2.12 mtr3 Bunker Oil 2.87 L Clean energy 0.36 kWh (Electricity) E lectricity 0.86 kWh Table 4 Another example method of determining the environmental emissions parameter is shown in Figure 4b.
- determining an environmental emissions parameter may comprise the CPU 102 determining, at step S406, an energy usage performance parameter based on: (i) one or more of the object parameter(s), (ii) one or more of the oven parameter(s), and (iii) one or more of the coating parameter(s) of a specific coating.
- the CPU 102 may compute the total energy required (Ereq,tot) for coating the specified object with the specified oven.
- the step S308 of determining an environmental emissions parameter may comprise the CPU 102 determining, at step S406, an energy usage performance parameter based on: (i) one or more of the object parameter(s) obtained at step S302, 14567648-1 (ii) one or more of the oven parameter(s) obtained at step S304, and (iii) one or more of the coating parameter(s) of coating 1 obtained at step S306.
- Determining an environmental emissions parameter may comprise the CPU 102 determining, at step S408, how much powder of the specific coating (Qpowder) is needed to coat the specific object using: one or more of the object parameter(s), and one or more of the coating parameter(s) of the specific coating.
- the step S308 of determining an environmental emissions parameter may comprise the CPU 102 determining, at step S408, how much powder of coating 1 (Qpowder1) is needed to coat the specific object using: one or more of the object parameter(s) obtained at step S302, and one or more of the coating parameter(s) of coating 1 obtained at step S306.
- the Acoating value may be defined as an object parameter accessible by the CPU 102.
- the CPU 102 may obtain an object parameter defining a surface area of the object to be coated and thereby obtain the Acoating value.
- the CPU 102 may obtain an object parameter defining a coating scheme for the object and thereby obtain the Acoating value. 14567648-1
- the Qloss value for the specific object is accessible to the CPU 102 e.g. retrieved from memory by the CPU 102.
- the QPwd value for the specific object is accessible to the CPU 102 e.g.
- the object may also be retrieved from memory by the CPU 102.
- the object may be defined as belonging to a specific object group (e.g. an appliance, a building component, item of furniture etc.). Table 5 below shows how different objects may belong to the same object group.
- the QPwd values (and optionally Qloss values) for different coatings for a particular object group and for a particular coating scheme may be stored in memory and be retrievable by the CPU 102.
- Determining an environmental emissions parameter may comprise the CPU 102 determining, at step S410, the environmental emissions parameter using the energy usage performance parameter (Ereq,tot) determined at step S406, and the quantity of the specific coating (Qpowder) determined at step S408.
- the step S308 of determining an environmental emissions parameter may comprise the CPU 102 determining, at step S410, the environmental emissions parameter using the energy usage performance parameter (Ereq,tot) determined at step S406, and the quantity of coating 1 (Qpowder1) determined at step S408.
- the CPU 102 may compute the quantity of environmental emissions (e.g. CO2 emissions) due to the fuel (energy source) of the oven (CEfuel) as described above in connection with step S404.
- the CPU 102 may further compute the quantity of environmental emissions (e.g. CO2 emissions) due to the powder quantity requirement (CEpowder) using the quantity of the specific powder (Qpowder) determined at step S408.
- the emissions factor EFpowder of powder coatings is available in EPD (environmental product declaration) databases, other databases, or can be specifically measured.
- the CPU 102 may compute an environmental emissions parameter (CEtotal) which indicates the total environmental emissions due to both the environmental emissions of the fuel (energy source) of the oven (CEfuel), and the environmental emissions of the powder quantity requirement (CEpowder).
- the object parameter(s) used in the determination at step S406 may be the same or different to the object parameter(s) used in the determination at step S408.
- the coating parameter(s) used in the determination at step S406 may be the same or different to the coating parameter(s) used in the determination at step S408.
- multiple performance parameters associated with applying the first powder coating (coating 1) to the object may be determined. In embodiments where multiple performance parameters are determined at step S308, the determination of the multiple performance parameters may use the same, or different object parameter(s).
- the determination of the multiple performance parameters may use the same, or different oven parameter(s). In embodiments where multiple performance parameters are determined at step S308, the determination of the multiple performance parameters may use the same, or different coating parameter(s).
- the evaluation of the first powder coating (coating 1) may optionally further comprise the CPU 102 determining, at step S310, how much powder of coating 1 is needed to coat the specific object using: one or more of the object parameter(s) obtained at step S302, and one or more of the coating parameter(s) of coating 1 obtained at step S306. It will be appreciated that in embodiments whereby step S408 is performed at step S308, it is not necessary to determine the quantity of the coating 1 again at step S310.
- a coating-dependent oven parameter is computed using one or more oven parameters and one or more coating parameters (and optionally one or more object parameters).
- the energy usage performance parameter may be computed by the CPU 102 at step S402 and/or step S406 by determining a coating-dependent oven parameter using one or more oven parameters and one or more coating parameters (and optionally one or more object parameters).
- the CPU 102 may use the coating-dependent oven parameter with or without one or more oven parameters and/or one or more coating parameters and/or one or more object parameters. 14567648-1
- the CPU 102 obtains one or more parameters of a second coating (coating 2) that is to be evaluated as a candidate for being used to coat the object.
- the coating parameter(s) of the second coating may include any of those described above in connection with step S306.
- the coating parameter(s) of the second coating may be obtained using any of the mechanisms described above in connection with step S306.
- the CPU 102 determines at least one performance parameter associated with applying the second powder coating (coating 2) to the object. The determination of each of the performance parameters is based on: (i) one or more of the object parameter(s) obtained at step S302, (ii) one or more of the oven parameter(s) obtained at step S304, and (iii) one or more of the coating parameter(s) of coating 2 obtained at step S316.
- any of the performance parameters described above with reference to step S308, may be performed at step S318 for the second powder coating (coating 2).That is, the same performance parameter(s) are determined for all of powder coatings being evaluated.
- the determination of the multiple performance parameters may use the same, or different object parameter(s).
- the determination of the multiple performance parameters may use the same, or different oven parameter(s).
- the determination of the multiple performance parameters may use the same, or different coating parameter(s).
- the determination of a performance parameter at step S308 for coating 1 may use the same or different object parameter(s) to the object parameter(s) used in the determination of the corresponding performance parameter at step S318 for coating 2.
- the determination of a performance parameter at step S308 for coating 1 may use the same or different oven parameter(s) to the oven parameter(s) used in the determination of the corresponding performance parameter at step S318 for coating 2.
- the determination of a performance parameter at step S308 for coating 1 may use the same or different coating parameter(s) to the coating parameter(s) used in the determination of the corresponding performance parameter at step S318 for coating 2.
- the evaluation of the second powder coating (coating 2) may optionally further comprise the CPU 102 determining, at step S320, how much powder of coating 2 is needed to coat the specific object using: one or more of the object parameter(s) obtained at step S302, and one or more of the coating parameter(s) of coating 2 obtained at step S316. It will be appreciated that in embodiments whereby step S408 is performed at step S318 (for coating 2), it is not necessary to determine the quantity of the coating 2 again at step S320.
- the CPU 102 provides an evaluation output based on the performance parameter(s) of each of the plurality of powder coatings. The CPU 102 may output the evaluation output to a user of the computing device 100 via the output device 108.
- the CPU 102 may transmit the evaluation output to a display of the computing device 100.
- the CPU 102 may select a single powder coating from the plurality of powder coatings that is to be used to coat the object based on the performance parameter(s) of each of the plurality of powder coatings, and provide this selected single powder coating in the evaluation output.
- a first environmental emissions performance parameter is determined at step S308 for coating 1
- a second environmental emissions performance parameter is determined at step S318 for coating 2 (which is higher than the first environmental emissions performance parameter indicating that more environmental emissions will be produced when using coating 2)
- the CPU 102 may select coating 1 and provide coating 1 in the evaluation output.
- the quantity of the selected powder coating may also be included in the evaluation output.
- the CPU 102 may assign a ranking value to each of the plurality of powder coatings being evaluated based on the performance parameter(s) of each of the plurality of powder coatings.
- the evaluation output may comprise the plurality of powder coatings (e.g. identified by their unique identifier) and the ranking values associated with each of the plurality of powder coatings.
- the evaluation 14567648-1 output may comprise a list of the plurality of powder coatings with an indication of the ranking value assigned to each of the plurality of powder coatings.
- the plurality of powder coatings may be arranged in the list in an order dependent on their ranking values.
- the CPU 102 may output a list comprising the unique identifier of coating 1 and the unique identifier of coating 2 in the evaluation output, with coating 1 having a higher ranking value than coating 2.
- the list may be ordered so that coating 1 appears at the top of the list above coating 2.
- this single performance parameter is used by the CPU 102 at step 324 to either select a single powder coating or to assign a ranking value to each of the plurality of powder coatings. For example, if an energy usage performance parameter is used to evaluate the plurality of powder coatings, the CPU 102 may select a single powder coating having the lowest energy usage or provide the list of powder coatings in an order (ascending or descending) dependent on the energy usage values. In embodiments whereby a multiple performance parameters are used to evaluate the plurality of powder coatings the CPU 102 may compute an overall performance parameter Poverall of each of the plurality of powder coatings.
- Pi are scaled individual performance parameters where the scaling to be performed is to a common scale. Taking an example combine an energy usage performance parameter in kWh/y and a productivity performance parameter in tons of material coated per year T/y the CPU 102 would apply scaling of both to e.g.
- the weighting parameters could e.g.
- the method 200 further comprises a step S204 of a user selecting a powder coating to apply to the object based on the evaluation output.
- step S204 comprises the user selecting the powder coating included in the evaluation output.
- the evaluation output comprises the plurality of powder coatings and a ranking value associated with each of the plurality of powder coatings
- step S204 may comprise the user selecting the powder coating from the plurality of powder coatings based on the ranking values (e.g. the powder coating that has the highest ranking value). For example, coating the object with the powder coating with the highest ranking value may result in the lowest energy usage.
- the method 200 further comprises applying the selected powder coating to the object.
- step S206 comprises operating the oven such that the selected powder coating is applied to the object thereby forming a coating film and thereby forming a coating on the object.
- the object is coated with the selected powder coating.
- Figure 5 illustrates a computer implemented powder coating evaluation method that is performed at step S202 to evaluate multiple powder coating systems as candidates for being used to coat an object. 14567648-1
- the CPU 102 obtains one or more object parameters of an object that is to be coated with the powder coatings of a powder coating system.
- Step S502 may correspond to step S302 described above with the difference being that the object is to be coated with a powder coating system rather than a single powder coating.
- the CPU 102 obtains one or more parameters of an oven that is to be used to apply the powder coating system to the object.
- Step S504 may correspond to step S304 described above with the difference being that the oven is to be used to apply a powder coating system to the object rather than used to apply a single powder coating to the object.
- a unique identifier of each of the plurality of powder coating systems to be evaluated is accessible to the CPU 102.
- the unique identifier of each of the plurality of powder coating system to be evaluated may be stored in memory 104.
- a user may select the plurality of powder coating system to be evaluated using the input device 106.
- a user may select the plurality of powder coating systems to be evaluated from a list of powder coating systems (which comprises the plurality of powder coating systems and additional powder coating systems) using the input device 106.
- the unique identifier of each of the plurality of powder coating systems may for example be a coating system name, and/or a numerical or alphanumerical code.
- Figure 5 illustrates the steps performed by the CPU 102 when two powder coating systems (coating system A and coating system B) are evaluated.
- powder coating system A comprises two powder coatings (powder coatings 1 and 2)
- powder coating system B also comprises two powder coatings (powder coating 3 and 4).
- any number of powder coating systems may be evaluated using the computer implemented powder coating system evaluation method of Figure 5. Whilst the example coating systems referred to in Figure 5 comprise two powder coatings, this is an example and a coating system may define more than two powder coatings. Furthermore, whilst the example coating systems referred to in Figure 5 comprise different powder coatings to each other, there may be some overlap in the powder 14567648-1 coatings of the coating systems evaluated using the computer implemented powder coating evaluation method of Figure 5.
- the CPU 102 determines a powder coating system performance parameter of each powder coating system being evaluated. The CPU 102 determines a powder coating system performance parameter of each powder coating system based on at least one performance parameter of each of the plurality of powder coatings of the powder coating system.
- the CPU 102 obtains one or more parameters of the first powder coating (coating 1) of coating system A.
- the CPU 102 determines at least one performance parameter associated with applying the powder coating 1 to the object. The determination of each of the performance parameters is based on: (i) one or more of the object parameter(s) obtained at step S502, (ii) one or more of the oven parameter(s) obtained at step S504, and (iii) one or more of the coating parameter(s) of powder coating 1 obtained at step S506.
- the performance parameter(s) determined at step S508 relate to the performance of the process of applying the powder coating 1 to the object.
- Various performance parameters may be determined by the CPU 102 at step S508 in accordance with the methods described herein.
- one or more of an energy usage performance parameter, a productivity performance parameter, and environmental emissions performance parameter may be determined at step S508.
- the CPU 102 obtains one or more parameters of the powder coating 2 of coating system A.
- the CPU 102 determines at least one performance parameter associated with applying powder coating 2 to the object. The determination of each of the performance parameters is based on: (i) one or more of the object parameter(s) obtained at step S502, (ii) one or more of the oven parameter(s) obtained at step S504, and (iii) one or more of the coating parameter(s) of powder coating 2 obtained at step S510.
- the 14567648-1 performance parameter(s) determined at step S512 relate to the performance of the process of applying the powder coating 2 to the object.
- the same performance parameter(s) are determined for all of the powder coatings of a coating system, and for all of the coating systems being evaluated.
- the CPU 102 determines a powder coating system performance parameter of coating system A using the performance parameter(s) determined at step S508 and the performance parameter(s) determined at step S512.
- the CPU 102 combines the performance parameter determined for each of the plurality of powder coatings to determine the powder coating system performance parameter of the particular powder coating system.
- the CPU 102 may combine a performance parameter determined at step S508 for powder coating 1 with a performance parameter determined at step S512 for the powder coating 2 to determine the powder coating system performance parameter of the powder coating system A.
- the CPU 102 may compute an overall performance parameter P overall of each of the plurality of powder coatings, and then combines the overall performance parameter Poverall determined for each of the plurality of powder coatings to determine the powder coating system performance parameter of the particular powder coating system.
- the CPU 102 may combine multiple performance parameters determined at step S508 for the powder coating 1 to compute an overall performance parameter Poverall1 for the powder coating 1 using any of the methods described herein, and combine multiple performance parameters determined at step S512 for the powder coating 2 to compute an overall performance parameter Poverall2 for the powder coating 2 using any of the methods described herein.
- the CPU 102 may then combine the overall performance parameters Poverall1 and Poverall2 to determine the powder coating system performance parameter of powder coating system A. 14567648-1
- the CPU 102 obtains one or more parameters of powder coating 3 of coating system B.
- the CPU 102 determines CPU 102 determines at least one performance parameter associated with applying the powder coating 3 to the object.
- each of the performance parameters is based on: (i) one or more of the object parameter(s) obtained at step S502, (ii) one or more of the oven parameter(s) obtained at step S504, and (iii) one or more of the coating parameter(s) of powder coating 3 obtained at step S516.
- the performance parameter(s) determined at step S518 relate to the performance of the process of applying the powder coating 3 to the object. As noted above, the same performance parameter(s) are determined for all of the powder coatings of a coating system, and for all of the coating systems being evaluated.
- the CPU 102 obtains one or more parameters of the powder coating 4 of coating system B.
- the CPU 102 determines at least one performance parameter associated with applying powder coating 4 to the object.
- the determination of each of the performance parameters is based on: (i) one or more of the object parameter(s) obtained at step S502, (ii) one or more of the oven parameter(s) obtained at step S504, and (iii) one or more of the coating parameter(s) of powder coating 4 obtained at step S520.
- the performance parameter(s) determined at step S522 relate to the performance of the process of applying the powder coating 4 to the object.
- the CPU 102 determines a powder coating system performance parameter of coating system B using the performance parameter(s) determined at step S518 and the performance parameter(s) determined at step S522.
- the CPU 102 may combine a performance parameter determined at step S518 for powder coating 3 with a performance parameter determined at step S522 for the powder coating 4 to determine the powder coating system performance parameter of the powder coating system B. 14567648-1 At step S524, the CPU 102 may combine multiple performance parameters determined at step S518 for the powder coating 3 to compute an overall performance parameter Poverall3 for the powder coating 3 using any of the methods described herein, and combine multiple performance parameters determined at step S522 for the powder coating 4 to compute an overall performance parameter Poverall4 for the powder coating 4 using any of the methods described herein. At step S524, the CPU 102 may then combine the overall performance parameters Poverall3 and Poverall4 to determine the powder coating system performance parameter of powder coating system B.
- the CPU 102 provides an evaluation output based on the performance parameter(s) of each of the plurality of powder coating systems.
- the CPU 102 may output the evaluation output to a user of the computing device 100 via the output device 108.
- the CPU 102 may transmit the evaluation output to a display of the computing device 100.
- the CPU 102 may select a single powder coating system from the plurality of powder coating systems that is to be used to coat the object based on the powder coating system performance parameter of each of the plurality of powder coating systems, and provide this selected single powder coating system in the evaluation output.
- a first environmental emissions powder coating system performance parameter is determined at step S514 for coating system A
- a second environmental emissions powder coating system performance parameter is determined at step S524 for coating system B (which is higher than the first environmental emissions powder coating system performance parameter indicating that more environmental emissions will be produced when using coating system B)
- the CPU 102 may select coating system A and provide coating system A in the evaluation output.
- the required quantity of the powder coatings of the selected coating system may be determined using methods described herein and included in the evaluation output.
- the CPU 102 may assign a ranking value to each of the plurality of powder coating systems being evaluated based on the powder coating system performance parameter of each of the plurality of powder coating systems.
- the evaluation output may comprise the plurality of powder coating systems (e.g. identified by their unique identifier) and the ranking values associated with each of the plurality of 14567648-1 powder coating systems.
- the evaluation output when the evaluation output is transmitted to a display of the computing device 100, the evaluation output may comprise a list of the plurality of powder coating systems with an indication of the ranking value assigned to each of the plurality of powder coating systems.
- the plurality of powder coatings may be arranged in the list in an order dependent on their ranking values.
- the CPU 102 may output a list comprising the unique identifier of coating system A and the unique identifier of coating system B in the evaluation output, with coating system A having a higher ranking value than coating system B.
- the list may be ordered so that coating system A appears at the top of the list above coating system B.
- the required quantity of the powder coatings of each of the plurality of coating systems may be determined using methods described herein and included in the evaluation output.
- the method 200 further comprises a step S204 of a user selecting a powder coating system to apply to the object based on the evaluation output. That is, the user sources and/or supplies the powder coatings of the powder coating system from one or more location(s) to the oven, ready to be applied to the object.
- step S204 comprises the user selecting the powder coating system included in the evaluation output.
- step S204 may comprise the user selecting the powder coating system from the plurality of powder coating systems based on the ranking values (e.g. the powder coating system that has the highest ranking value). For example, coating the object with the powder coating system with the highest ranking value may result in the lowest energy usage. 14567648-1
- the method 200 further comprises applying the powder coatings of the selected powder coating system to the object. That is, step S206 comprises operating the oven such that the powder coatings of the selected powder coating system are applied to the object (in an order defined by selected powder coating system) thereby forming a coating film (of multiple layers) and thereby forming a coating on the object.
- the object is coated with the powder coatings of the selected powder coating system.
- Configuring an oven for use in applying a powder coating to an object FIG. 6 illustrates a method 600 of configuring an oven for use in applying a powder coating to an object
- the method 600 comprises performing a computer implemented coating-dependent oven parameter determination method.
- the computer implemented coating-dependent oven parameter determination method may be performed by the computing device 100.
- the computer implemented coating-dependent oven parameter determination method performed at step S602 may be performed by the CPU 102.
- Figure 7 illustrates a computer implemented coating-dependent oven parameter determination method that is performed at step S602.
- the CPU 102 receives a user selection of a powder coating.
- the user may select a powder coating using the input device 106. For example the user may select the powder coating from a plurality of powder coatings displayed to the user via a display.
- the CPU 102 obtains one or more parameters of an object that is to be coated with the selected powder coating, examples of the object parameter(s) have been described herein.
- the CPU 102 obtains one or more parameters of an oven that is to be used to apply the powder coating to the object, examples of the oven parameter(s) have been described herein. 14567648-1
- the CPU 102 obtains one or more parameters of the selected powder coating. Examples of the coating parameter(s) have been described herein.
- the CPU 102 identifies one or more coating-dependent oven parameter to optimize at least one performance parameter.
- coating-dependent oven parameter(s) have been described herein.
- the performance parameter(s) may be any of those described herein.
- the performance parameter(s) to be optimized may comprise one or more of: an energy usage performance parameter, a productivity performance parameter, and environmental emissions performance parameter.
- optimizing the energy usage performance parameter as minimizing the energy usage performance parameter i.e. determining the coating-dependent oven parameter(s) that minimize the energy usage performance parameter when applying the selected powder coating to the object.
- optimizing the productivity performance parameter as maximizing the productivity performance parameter i.e.
- the CPU 102 may compute an overall performance parameter Poverall using the coating- dependent oven parameter(s) and optimizing the overall performance parameter P overall may comprise minimizing or maximizing the overall performance parameter Poverall.
- the performance parameter(s) to be optimized may be predetermined.
- the CPU 102 may receive a user selection of the performance parameter(s). The user may select the performance parameter(s) using the input device 106.
- a range of values for the coating-dependent oven parameter is accessible to the CPU 102 e.g. stored in memory 104 or a remote storage location.
- line speed is used as coating-dependent oven parameter
- a range of values from a minimum line speed value Line speedmin to a maximum line speed value Line speedmax would be accessible to the CPU 102.
- air temperature (Tair) of the air enclosed with the oven is used as coating-dependent oven parameter
- a range of values from a minimum air temperature Tair, min to a maximum air temperature Tair, max would be accessible to the CPU 102.
- the CPU 102 is configured to identify a single coating-dependent oven parameter (e.g.
- the CPU 102 would be configured with access to the allowed range of values for the coating-dependent oven parameter.
- the CPU 102 is configured to vary the value of the coating- dependent oven parameter within the allowed range and compute the performance parameter for each of the values of the coating-dependent oven parameter using (i) the coating-dependent oven parameter (ii) one or more object parameter (which may be the same or different to the object parameter(s) used to compute the coating-dependent oven parameter), (iii) one or more oven parameter (which may be the same or different to the oven parameter(s) used to compute the coating-dependent oven parameter), and (iv) one or more coating parameter (which may be the same or different to the coating parameter(s) used to compute the coating-dependent oven parameter).
- the CPU 102 is configured to identify the coating- dependent oven parameter value which optimizes the performance parameter(s), and the performance parameter(s) derived using the coating-dependent oven parameter value. For example, at step S710 the CPU 102 may vary line speed values (line speedi) in the allowed range, determine the corresponding energy usage performance parameter values Ereg,i, and identify the minimal energy usage performance parameter value in the set ⁇ Ereg,i ⁇ together with the optimal line speed value. 14567648-1 In an example whereby the CPU 102 is configured to identify multiple coating-dependent oven parameters (e.g.
- the CPU 102 would be configured with access to the allowed range of values for each the coating-dependent oven parameters, a functional dependency between the multiple coating-dependent oven parameters.
- the functional dependency may be stored in memory 104 or a remote storage location.
- the CPU 102 is configured to identify multiple coating-dependent oven parameters (e.g. line speed and air temperature (Tair) of the air enclosed with the oven) which will optimize at least one performance parameter, the CPU 102 would be configured with access to the allowed range of values for each the coating-dependent oven parameters, a functional dependency between the multiple coating-dependent oven parameters.
- the functional dependency may be stored in memory 104 or a remote storage location.
- the CPU 102 is configured to vary the values of the coating-dependent oven parameter within the allowed ranges and according to the functional dependency between them, and compute the performance parameter for the values of the coating-dependent oven parameters using (i) the coating-dependent oven parameters (ii) one or more object parameter (which may be the same or different to the object parameter(s) used to compute the coating-dependent oven parameters), (iii) one or more oven parameter (which may be the same or different to the oven parameter(s) used to compute the coating-dependent oven parameters), and (iv) one or more coating parameters (which may be the same or different to the coating parameter(s) used to compute the coating-dependent oven parameters).
- the CPU 102 is configured to identify the coating- dependent oven parameter values which optimizes the performance parameter(s), the 14567648-1 performance parameter(s) derived using the coating-dependent oven parameter values. For example, at step S710 the CPU 102 may vary the air temperature and line speed values in the allowed ranges and according to the functional dependency between them, and determine the corresponding energy usage performance parameter values Ereg,i, and identify the minimal energy usage performance parameter in the set ⁇ Ereg,i ⁇ together with the optimal air temperature Tair and line speed value. At step S712, the CPU 102 outputs the one or more coating-dependent oven parameter values which optimizes the performance parameter(s).
- the CPU 102 may additionally output the values of the performance parameter(s) associated with the one or more coating-dependent oven parameter values which optimizes the performance parameter(s).
- the CPU 102 may provide this output to a user of the computing device 100 via the output device 108.
- the CPU 102 may transmit the one or more coating- dependent oven parameters (and optionally the performance parameter(s) associated with the one or more coating-dependent oven parameter values) to a display of the computing device 100.
- the method 600 further comprises a step S604 of a user configuring the oven using the one or more coating-dependent oven parameters which optimizes the performance parameter(s).
- the CPU 102 receives a user selection of a powder coating.
- the user may select a powder coating using the input device 106.
- the user may select the powder coating from a plurality of powder coatings displayed to the user via a display.
- the CPU 102 obtains a set of parameters.
- the CPU 102 obtains one or more parameters of an object that is to be coated with the selected powder coating, examples of the object parameter(s) have been described herein.
- the CPU 102 obtains one or more parameters of an oven that is to be used to apply the powder coating to the object, examples of the oven parameter(s) have been described herein.
- the CPU 102 obtains one or more parameters of the selected powder coating. Examples of the coating parameter(s) have been described herein.
- the set of parameters obtained at step S903 comprises the at least one object parameter obtained at step S904, the at least one oven parameter obtained at step S906, and the at least one coating parameter obtained at step S908.
- the CPU 102 receives a user selection of at least one coating-dependent oven parameter. Examples of coating-dependent oven parameter(s) have been described herein. The user may select a powder coating using the input device 106.
- the CPU 102 determines at least one performance parameter using the set of parameters obtained at step S903 and the at least one user selected coating- dependent oven parameter.
- the CPU 102 determines the at least one performance parameter using (i) the at least one coating-dependent oven parameter (ii) the object parameter(s), (iii) the oven parameter(s), and (iv) the coating parameter(s).
- the performance parameter(s) may be any of those described herein.
- the performance parameter(s) may comprise one or more of: an energy usage performance parameter, a productivity performance parameter, and environmental emissions 14567648-1 performance parameter.
- the CPU 102 may determine the at least one performance parameter according to any of the methods described herein.
- the CPU 102 outputs the at least one performance parameter.
- the CPU 102 may additionally output the at least one coating-dependent oven parameter in association with the at least one performance parameter e.g. indicating that the performance parameter will be achieved if the oven is configured with the at least one coating-dependent oven parameter.
- the CPU 102 may provide this output to a user of the computing device 100 via the output device 108.
- the CPU 102 may transmit the at least one performance parameter (and optionally the at least one coating-dependent oven parameter) to a display of the computing device 100.
- the computer implemented oven parameter evaluation method may loop back to step S910 where the CPU 102 receives a further user selection of at least one coating-dependent oven parameter.
- step S912 may be performed again such that the CPU 102 determines at least one performance parameter using the set of parameters obtained at step S903 and the at least one further user selected coating- dependent oven parameter.
- the coating-dependent oven parameter is a line speed
- the computer implemented coating-dependent oven parameter evaluation method enables a user to select different values of the line speed (at each time step S910 is performed) and to be presented with at least one performance parameter associated with using the different values of the line speed.
- the method 800 further comprises a step S804 of a user configuring the oven using coating- dependent oven parameters selected by the user at step S910.
- Step S804 may comprise the user configuring the oven by controlling a line speed, an air temperature (Tair) of the air enclosed with the oven, and/or one or more settings of a spray gun of the oven.
- a parameter e.g. a performance parameter and/or or a coating-dependent oven parameter
- the CPU 102 receiving a user selection of parameter (e.g.
- a performance parameter and/or or a coating-dependent oven parameter this refers to the CPU 102 receiving a user selection of a value of the parameter.
- a parameter e.g. a performance parameter and/or or a coating-dependent oven parameter
- a method of configuring an oven for use in applying a powder coating to an object comprising: p erforming a computer implemented coating-dependent oven parameter determination method comprising: receiving a user selection of a powder coating; o btaining at least one oven parameter associated with the oven; obtaining at least one coating parameter associated with the powder coating; obtaining at least one object parameter associated with the object; i dentifying at least one coating-dependent oven parameter that optimizes at least one performance parameter that is determined using (i) the at least one c oating-dependent oven parameter (ii) one or more of the at least one object parameter, (iii) one or more of the at least one oven parameter, and (iv) one or more of the at least one coating parameter; and outputting the at least one coating-dependent oven parameter; wherein the method further comprises: 14567648-1 configuring the oven using the at least one coating dependent oven parameter.
- the at least one object parameter comprises one or any combination of: a type of material of the object, a material thickness of the object, an object type of the object, a surface area of the object to be coated, a target thickness of the powder coating at one or more surface areas of the object, a mass of the object, a coating scheme for the object, and a surface preparation of the object.
- the at least one oven parameter comprises one or any combination of: a heating mechanism type of the oven, a design type of the oven, an energy source of the oven, a material of the oven, one or more dimensions of the oven, a heat transfer type of the oven, one or more settings of a component of the oven, a material of a component of the oven, and a mass of a component of the oven.
- the at least one coating parameter comprises one or any combination of: a temperature to be used in the oven when applying the powder coating, a coating thickness of the powder coating, a specific gravity of the powder coating, and a particle size distribution of the powder coating.
- the at least one coating-dependent oven parameter comprises one or any combination of: a temperature of air enclosed with the oven, a line speed of the oven, one or more settings of a component of the oven.
- the computer implemented coating-dependent oven parameter determination method further comprises: receiving a user selection of the at least one performance parameter.
- the computer implemented coating-dependent oven parameter determination method further comprises: determining each of the at least one performance parameter based on: (i) the at least one coating-dependent oven parameter (ii) one or more of the at least one object parameter, (iii) one or more of the at least one oven parameter, and (iv) one or more of the at least one coating parameter. 14567648-1 A8.
- the computer implemented coating-dependent oven parameter determination method further comprises: outputting the at least one performance parameter that is optimized using the at least one coating-dependent oven parameter. A9.
- the at least one performance parameter comprises an energy usage performance parameter indicating the energy required to apply the powder coating to the object when using the at least one coating- dependent oven parameter.
- determining the energy usage performance parameter comprises: d etermining an energy required to heat the oven using: one or more of the at least one oven parameter, and one or more of the at least one coating parameter; determining an energy required to heat the object using: one or more of the at least one object parameter, one or more of the at least one oven parameter, and one or more of the at least one coating parameter; determining energy losses due to heat loss of air used for heating the object using: one or more of the at least one oven parameter, and one or more of the at least one coating parameter; and d etermining the energy usage performance parameter by summing the energy required to heat the oven, the energy required to heat the object; and the energy losses.
- the at least one performance parameter comprises an environmental emissions performance parameter indicating the environmental emissions that will result from the use of the at least one coating- dependent oven parameter when applying the powder coating to the object.
- determining the environmental emissions performance parameter comprises: determining an energy usage performance parameter indicating the energy required to apply the powder coating to the object based on: (i) one or more of the at least one object parameter, (ii) one or more of the at least one oven parameter, and (iii) one or more of the at least one coating parameter; and 14567648-1 converting the energy usage performance parameter into the environmental emissions performance parameter.
- the determining the environmental emissions performance parameter comprises: determining an energy usage performance parameter indicating the energy required to apply the powder coating to the object based on: (i) one or more of the at least one object parameter, (ii) one or more of the at least one oven parameter, and (iii) one or more of the at least one coating parameter; determining a quantity of the powder coating required to coat the object based on one or more of the at least one object parameter, and one or more of the at least one coating parameter; and d etermining the environmental emissions performance parameter using the energy usage performance parameter and the quantity of the powder coating.
- the at least one performance parameter comprises a productivity performance parameter indicating the productivity of the oven that will result from the use of the at least one coating-dependent oven parameter when applying the powder coating to the object.
- the computer implemented coating- dependent oven parameter determination method comprises determining the productivity performance parameter using a coating process speed and conversion factor which converts the coating process speed into the productivity performance parameter.
- the computer implemented coating- dependent oven parameter determination method comprises determining the coating process speed using: one or more of the at least one object parameter, one or more of the at least one oven parameter, and one or more of the at least one coating parameter.
- the computer implemented coating-dependent oven parameter determination method comprises: 14567648-1 varying a value of the coating-dependent oven parameter within a range and determining the performance parameter for each of the values of the coating-dependent oven parameter.
- the computer implemented coating-dependent oven parameter determination method comprises: varying a value of each of the multiple coating-dependent oven parameters within a range associated with the coating-dependent oven parameter, and according to a functional dependency between the multiple coating-dependent oven parameters; and determining the performance parameter for each of the values of the multiple coating-dependent oven parameters A19.
- a non-transitory computer-readable storage medium comprising instructions which, when executed by a processor of a computing device, cause the processor to perform the computer implemented coating-dependent oven parameter determination method of any of clauses A1-A18. A20.
- a computing device comprising a processor configured to perform the computer implemented coating-dependent oven parameter determination method of any of any of clauses A1-A18.
- B1. A method of configuring an oven for use in applying a powder coating to an object, the method comprising: p erforming a computer implemented oven parameter evaluation method comprising: receiving a user selection of a powder coating; obtaining a set of parameters, the set of parameters comprising: at least o ne object parameter associated with the object, at least one oven parameter associated with the oven, at least one coating parameter associated with the powder coating; r eceiving a user selection of at least one coating-dependent oven parameter; 14567648-1 determining at least one performance parameter associated with applying t he powder coating to the object using the set of parameters and the at least one coating-dependent oven parameter; and outputting the at least one performance parameter; wherein the method further comprises: c onfiguring the oven using the at least one coating-dependent oven parameter.
- the at least one object parameter comprises one or any combination of: a type of material of the object, a material thickness of the object, an object type of the object, a surface area of the object to be coated, a target thickness of the powder coating at one or more surface areas of the object, a mass of the object, a coating scheme for the object, and a surface preparation of the object.
- the at least one oven parameter comprises one or any combination of: a heating mechanism type of the oven, a design type of the oven, an energy source of the oven, a material of the oven, one or more dimensions of the oven, a heat transfer type of the oven, one or more settings of a component of the oven, a material of a component of the oven, and a mass of a component of the oven.
- the at least one coating parameter comprises one or any combination of: a temperature to be used in an oven when applying the powder coating, a coating thickness of the powder coating, a specific gravity of the powder coating, and a particle size distribution of the powder coating.
- the at least one coating-dependent oven parameter comprises one or any combination of: a temperature of air enclosed with the oven, a line speed of the oven, one or more settings of a component of the oven.
- the at least one performance parameter comprises an energy usage performance parameter indicating the energy required to apply the powder coating to the object when using the at least one coating- dependent oven parameter. 14567648-1 B7.
- determining the energy usage performance parameter comprises: d etermining an energy required to heat the oven using: one or more of the at least one oven parameter, and one or more of the at least one coating parameter; determining an energy required to heat the object using: one or more of the at least one object parameter, one or more of the at least one oven parameter, and one or more of the at least one coating parameter; determining energy losses due to heat loss of air used for heating the object using: one or more of the at least one oven parameter, and one or more of the at least one coating parameter; and d etermining the energy usage performance parameter by summing the energy required to heat the oven, the energy required to heat the object; and the energy losses.
- the at least one performance parameter comprises an environmental emissions performance parameter indicating the environmental emissions that will result from the use of the at least one coating- dependent oven parameter when applying the powder coating to the object.
- determining the environmental emissions performance parameter comprises: determining an energy usage performance parameter indicating the energy required to apply the powder coating to the object based on: (i) one or more of the at least one object parameter, (ii) one or more of the at least one oven parameter, and (iii) one or more of the at least one coating parameter; and c onverting the energy usage performance parameter into the environmental emissions performance parameter.
- determining the environmental emissions performance parameter comprises: determining an energy usage performance parameter indicating the energy required to apply the powder coating to the object based on: (i) one or more of the at least one object parameter, (ii) one or more of the at least one oven parameter, and (iii) one or more of the at least one coating parameter; 14567648-1 determining a quantity of the powder coating required to coat the object based on one or more of the at least one object parameter, and one or more of the at least one coating parameter; and d etermining the environmental emissions performance parameter using the energy usage performance parameter and the quantity of the powder coating.
- the at least one performance parameter comprises a productivity performance parameter indicating the productivity of the oven that will result from the use of the at least one coating-dependent oven parameter when applying the powder coating to the object.
- the computer implemented oven parameter evaluation method comprises determining the productivity performance parameter using a coating process speed and conversion factor which converts the coating process speed into the productivity performance parameter.
- the computer implemented oven parameter evaluation method comprises determining the coating process speed using: one or more of the at least one object parameter, one or more of the at least one oven parameter, and one or more of the at least one coating parameter.
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Abstract
A method of applying a powder coating to an object, the method comprising: performing a computer implemented powder coating evaluation method comprising: obtaining at least one object parameter; obtaining at least one oven parameter; for each of a plurality of powder coatings: obtaining at least one coating parameter; determining at least one performance parameter associated with applying the powder coating to the object, wherein determining each of the at least one performance parameter is based on: (i) one or more of the object parameter(s), (ii) one or more of the oven parameter(s), and (iii) one or more of the coating parameter(s); providing an evaluation output based on the at least one performance parameter of each of the plurality of powder coatings. The method further comprises: selecting a powder coating based on the evaluation output; and applying the selected powder coating to the object.
Description
POWDER COATING COMPOSITION SELECTION AND APPLICATION BACKGROUND Objects are coated to protect them from for example corrosion, UV degradation but also for aesthetic purposes. It is known to apply powder coatings to an object. Powder coatings typically give smooth, uniform and hard surfaces. Typically the powder coating is electrostatically sprayed onto the object, often a metallic object, in an oven at high temperatures, typically in the range 100 to 300°C. Triboelectric guns may also be used. When the powder coating reaches the target temperature the powder particles melt together. For thermoset powder coatings curing will then take place. For UV curing, UV light is needed to start the curing process. One benefit with powder coatings in comparison to liquid coatings is that there are no solvents and therefore no VOC (volatile organic compounds) emissions. Many countries have VOC regulations which limit the amount of VOC that can be present in coating compositions and it may also limit the amount of VOC emissions from a production site. Another benefit with powder coatings is that the coating loss is low as large parts of the over-sprayed powder coating can be collected, recycled and used again. For Liquid coatings the over-spray cannot be collected. Powder coatings also give more durable and less porous films than liquid coatings which enables fewer and thinner layers to be applied. The drawback with powder coatings is that the application process can consume significant power (i.e. is very energy demanding). Increased energy demand results in increased environmental emissions such as CO2 emissions. There is a desire to make coated objects as environmentally friendly as possible. The application process of powder coatings is complex where many parameters influence the outcome. SUMMARY According to an aspect of the present disclosure there is provided a method of applying a powder coating to an object, the method comprising: performing a computer implemented powder coating evaluation method comprising: 14567648-1
obtaining at least one object parameter associated with the object; obtaining at least one oven parameter associated with an oven to be used to apply the powder coating to an object; for each of a plurality of powder coatings: obtaining at least one coating parameter associated with the powder coating; determining at least one performance parameter associated with applying the powder coating to the object, wherein determining each of the at least one performance parameter is based on: (i) one or more of the at least one object parameter, (ii) one or more of the at least one oven parameter, and (iii) one or more of the at least one coating parameter; providing an evaluation output based on the at least one performance parameter of each of the plurality of powder coatings; wherein the method further comprises: selecting a powder coating based on the evaluation output; and applying the selected powder coating to the object. The at least one object parameter may comprise one or any combination of: a type of material of the object, a material thickness of the object, an object type of the object, a surface area of the object to be coated, a target thickness of the powder coating at one or more surface areas of the object, a mass of the object, a coating scheme for the object, and a surface preparation of the object. The at least one oven parameter may comprise one or any combination of: a heating mechanism type of the oven, a design type of the oven, an energy source of the oven, a material of the oven, one or more dimensions of the oven, a heat transfer type of the oven, one or more settings of a component of the oven, a material of a component of the oven, and a mass of a component of the oven. The at least one coating parameter may comprise one or any combination of: a temperature to be used in an oven when applying the powder coating, a coating thickness of the powder coating, a specific gravity of the powder coating, and a particle size distribution of the powder coating. 14567648-1
Determining one or more the at least one performance parameter may comprise: determining at least one coating-dependent oven parameter using (i) one or more of the at least one oven parameter and (ii) one or more of the at least one coating parameter; and determining the performance parameter is further based on the at least one coating- dependent oven parameter. The at least one coating-dependent oven parameter may comprise one or any combination of: a temperature of air enclosed with the oven, a line speed of the oven, and one or more settings of a component of the oven. Determining the at least one coating-dependent oven parameter may be further based on one or more of the at least one object parameter. The at least one performance parameter may comprise an energy usage performance parameter indicating the energy required to apply the powder coating to the object. Determining the energy usage performance parameter may comprise: determining an energy required to heat the oven using: one or more of the at least one oven parameter, and one or more of the at least one coating parameter; determining an energy required to heat the object using: one or more of the at least one object parameter, one or more of the at least one oven parameter, and one or more of the at least one coating parameter; determining energy losses due to heat loss of air used for heating the object using: one or more of the at least one oven parameter, and one or more of the at least one coating parameter; and determining the energy usage performance parameter by summing the energy required to heat the oven, the energy required to heat the object; and the energy losses. The at least one performance parameter may comprise a productivity performance parameter indicating the productivity of the oven when applying the powder coating to the object. The computer implemented powder coating evaluation method may comprise determining the productivity performance parameter using a coating process speed and 14567648-1
conversion factor which converts the coating process speed into the productivity performance parameter. The method may comprise determining the coating process speed using: one or more of the at least one object parameter, one or more of the at least one oven parameter, and one or more of the at least one coating parameter. The at least one performance parameter may comprise an environmental emissions performance parameter indicating the environmental emissions that will result from applying the powder coating to the object. The determining the environmental emissions performance parameter may comprise: determining an energy usage performance parameter indicating the energy required to apply the powder coating to the object based on: (i) one or more of the at least one object parameter, (ii) one or more of the at least one oven parameter, and (iii) one or more of the at least one coating parameter; and converting the energy usage performance parameter into the environmental emissions performance parameter The determining the environmental emissions performance parameter may comprise: determining an energy usage performance parameter indicating the energy required to apply the powder coating to the object based on: (i) one or more of the at least one object parameter, (ii) one or more of the at least one oven parameter, and (iii) one or more of the at least one coating parameter; determining a quantity of the powder coating required to coat the object based on one or more of the at least one object parameter, and one or more of the at least one coating parameter; and determining the environmental emissions performance parameter using the energy usage performance parameter and the quantity of the powder coating. The method may further comprise including the quantity of the powder coating of one or more of the plurality of powder coatings in the evaluation output. The computer implemented powder coating evaluation method may further comprise, for each of the plurality of powder coatings: determining a quantity of the powder coating required to coat the object based on one or more of the at least one object parameter 14567648-1
and one or more of the at least one coating parameter; and including the quantity of the powder coating of one or more of the plurality of powder coatings in the evaluation output. Determining a quantity of the powder coating required to coat the object may be further based on: a powder coating loss parameter indicating an amount of the powder coating that becomes surplus during applying the powder coating to the object that cannot be captured from within the oven and reused in applying the powder coating to the object. The computer implemented powder coating evaluation method may further comprise selecting a powder coating from the plurality of powder coatings based on the at least one performance parameter of each of the plurality of powder coatings, wherein the evaluation output comprises the selected powder coating. The computer implemented powder coating evaluation method may further comprise assigning a ranking value to each of the plurality of powder coatings based on the at least one performance parameter of each of the plurality of powder coatings; wherein the evaluation output comprises the plurality of powder coatings and the ranking values associated with each of the plurality of powder coatings. According to another aspect of the present disclosure there is provided a non-transitory computer-readable storage medium comprising instructions which, when executed by a processor of a computing device, cause the processor to perform the computer implemented powder coating evaluation method according to any of the implementations as described herein. According to another aspect of the present disclosure there is provided a computing device comprising a processor configured to perform the computer implemented powder coating evaluation method according to any of the implementations as described herein. According to another aspect of the present disclosure there is provided a method of applying a powder coating system to an object, the method comprising: performing a computer implemented powder coating system evaluation method comprising: obtaining at least one object parameter associated with the object; 14567648-1
obtaining at least one oven parameter associated with an oven to be used to apply the powder coating to an object; for each of a plurality of powder coating systems: for each of a plurality of powder coatings of the powder coating system: obtaining at least one coating parameter associated with the powder coating; determining at least one performance parameter associated with applying the powder coating to the object, wherein determining each of the at least one performance parameter is based on: (i) one or more of the at least one object parameter, (ii) one or more of the at least one oven parameter, and (iii) one or more of the at least one coating parameter; determining a powder coating system performance parameter of the powder coating system based on the at least one performance parameter of each of the plurality of powder coatings of the powder coating system; providing an evaluation output based on the powder coating system performance parameter of each of the plurality of powder coating systems; wherein the method further comprises: selecting a powder coating system based on the evaluation output; and applying the plurality of powder coatings of the selected powder coating system to the object. According to another aspect of the present disclosure there is provided a computing device comprising a processor configured to perform the computer implemented powder coating system evaluation method according to any of the implementations as described herein. According to another aspect of the present disclosure there is provided a non-transitory computer-readable storage medium comprising instructions which, when executed by a processor of a computing device, cause the processor to perform the computer implemented powder coating system evaluation method according to any of the implementations as described herein. 14567648-1
The instructions referred to herein may be provided on a carrier such as a disk, CD- or DVD-ROM, programmed memory such as read-only memory (Firmware), or on a data carrier such as an optical or electrical signal carrier. Code (and/or data) to implement embodiments of the present disclosure may comprise source, object or executable code in a conventional programming language (interpreted or compiled) such as C, or assembly code, code for setting up or controlling an ASIC (Application Specific Integrated Circuit) or FPGA (Field Programmable Gate Array), or code for a hardware description language. These and other aspects will be apparent from the embodiments described in the following. It will be appreciated that features from one aspect may be combined with the features of another aspect. The scope of the present disclosure is not intended to be limited by this summary nor to implementations that necessarily solve any or all of the disadvantages noted. BRIEF DESCRIPTION OF THE DRAWINGS For a better understanding of the present disclosure and to show how embodiments may be put into effect, reference is made to the accompanying drawings in which: Figure 1 is a schematic block diagram of the computing device; Figure 2 illustrates a method of applying one or more powder coatings to an object in accordance with embodiments of the invention; Figure 3 illustrates a computer implemented powder coating evaluation method that may be performed by the computing device in the method shown in Figure 2; Figure 4a illustrates steps in the computer implemented powder coating evaluation method that may be performed to determine an environmental emissions performance parameter; Figure 4b illustrates steps in the computer implemented powder coating evaluation method that may be performed to determine an environmental emissions performance parameter; Figure 5 illustrates another computer implemented powder coating evaluation method that may be performed by the computing device in the method shown in Figure 2; Figure 6 illustrates a method of configuring an oven for use in applying a powder coating to an object in accordance with embodiments of the invention; and 14567648-1
Figure 7 illustrates a computer implemented coating-dependent oven parameter determination method that may be performed by the computing device in the method shown in Figure 6; Figure 8 illustrates a method of configuring an oven for use in applying a powder coating to an object in accordance with embodiments of the invention; and Figure 9 illustrates a computer implemented coating-dependent oven parameter evaluation method that may be performed by the computing device in the method shown in Figure 8. DETAILED DESCRIPTION Embodiments will now be described by way of example only. Embodiments of the present disclosure include the execution of computer implemented methods. Some embodiments of the present disclosure relate to a computer implemented powder coating evaluation method which provides an evaluation output. A user can then use this output to select a particular powder coating composition in order to optimise a powder coating composition application process. Other embodiments of the present disclosure relate to a computer implemented coating- dependent oven parameter determination method which outputs at least one coating- dependent oven parameter. A user can then configure an oven using the coating- dependent oven parameter in order to optimise a powder coating composition application process. Other embodiments of the present disclosure relate to a computer implemented oven parameter evaluation method which outputs at least one performance parameter associated with at least one user selected coating-dependent oven parameter. A user can then use this output to configure an oven with the at least one coating-dependent oven parameter in order to optimise a powder coating composition application process. As used herein the term “powder coating composition” (also referred to herein as simply a “powder coating”) refers to dry, free flowing powder which when applied to a surface and heated, e.g. cured, forms a coating thereon. Typically the particles that constitute the powder have an average diameter of 3-150 µm. The powder may first be applied to 14567648-1
the object and then the object is heated, or the object can be preheated and then the powder is applied to the preheated object. A powder coating composition may be thermoset, thermoplastic or UV curable. The powder coating composition comprises at least one binder. Other ingredients that may be present are curing agent(s), colour pigment(s), effect pigment(s) (e.g. pearlescent, metallic), filler(s), degassing agent(s), flow agent(s), levelling agent(s), matting agent(s), optical brightener(s), antioxidant(s), phosphate(s), borate(s), adhesion promotor(s) (e.g. silane(s), amino alcohol(s)), texture additive(s), intumescent additive(s), biocide(s) (e.g. anti-viral agent(s)) and/or catalyst(s). The binder present in the powder coating composition may be polyester, epoxy binder, polyorganosiloxane, poly(meth)acrylic, polycarbonate, fluorovinylidene or combinations thereof. Preferably the binder is selected from epoxy binder, polyester, poly(meth)acrylic, fluorovinylidene and combinations thereof. The curing agents used in powder coating compositions may be polyisocyanates, phenolic based, triglycidyl isocyanurate (TGIC), amines, carboxylic acids and carboxylic acid functional resins, hydroxy functional resins, amides such as hydroxyalkyl amide, guanidines such as dicyandiamide, imidazoles and imidazole (epoxy) adducts, imidazoline, imidazolidine, anhydrides, dihydrazides and combinations thereof. Powder coating compositions are for example described in WO2018210849, WO2023180292, WO2017186870, WO2019234139, WO2012110451, WO2021074342, WO2018050774, WO2015063024, WO2022266647 and WO2022256784. Traditionally, powder coatings are made by first weighing and mixing together a mixture of binder and other ingredients, to obtain a homogenous premix. The premix is then melted, mixed and dispersed in for example a single screw or a twin screw extruder into a homogenous melted mixture. The melted mixture is then cooled, tableted and broken. The crushed materials are then grinded in for example an impact classifying mill or an air classifying mill to obtain the desired particle size distribution of the powder coating. A free flow additive is usually added in the production process to assist in the milling step and enhance fluidization during the application process. 14567648-1
A powder coating composition referred to herein may be a homogenous mixture or a mix of powders with different components (for example two, three or more). In the case of powder coating compositions with different components, the components can be processed fully separately, and then dry blended together to obtain the components mix as one powder. Alternatively, the components can be produced separately, and then blended and processed together from the grinding step and onwards. Powder coating compositions may be described by its particle size distribution (PSD). The particle size of the powder coating composition can be measured and described by for example D10, D50, D90, D98 and/or D99. D10 refers to the size at which 10% of the particles have a diameter smaller than the value recited. D50 refers to the size at which 50% of the particles have a diameter smaller than the value recited. D90 refers to the size at which 90% of the particles have a diameter smaller than the value recited. D98 refers to the size at which 98% of the particles have a diameter smaller than the value recited. D99 refers to the size at which 99% of the particles have a diameter smaller than the value recited. The particle size distribution can be described by using at least two of the particle size values, e.g. D10 and D90 or D10 and D98. If the particle size distribution is narrow it means that there are small variations of particle sizes in the powder. The particle size distribution of the powder coating may influence properties such as fluidity, stability, electrification of the powder coating and coating appearance. A powder coating composition can be applied as a single layer to an object. Alternatively different powder coating compositions can be applied in different layers to an object, whereby a “coating system” defines the multiple powder coating compositions and the order in which they are applied to the object. As an example, a coating system may define that a powder coating composition 1 is first applied to the object (as a base layer) and after this a powder coating composition 2 is applied thereby providing the object with two different powder coating layers. The computer implemented methods described herein are performed on a computing device. Figure 1 illustrates a simplified view of a computing device 100 which may perform the computer implemented evaluation methods described herein. A shown in Figure 1, the computing device 100 comprises a central processing unit (“CPU”) 102, to which is connected a memory 104. The functionality of the CPU 102 described herein may be implemented in code (software) stored on a memory (e.g. 14567648-1
memory 104) comprising one or more storage media, and arranged for execution on a processor comprising on or more processing units. The storage media may be integrated into and/or separate from the CPU 102. The code is configured so as when fetched from the memory and executed on the processor to perform operations in line with embodiments discussed herein. Alternatively, it is not excluded that some or all of the functionality of the CPU 102 is implemented in dedicated hardware circuitry (e.g. ASIC(s), simple circuits, gates, logic, and/or configurable hardware circuitry like an FPGA. The computing device 100 may comprise an input device 106 coupled to the CPU 102. The input device 106 allows a user of the computing device 100 to provide inputs and control the operation of the computing device 100. The input device 106 may be keypad, keyboard, a touch-screen display, and/or a microphone. The computing device 100 may comprise an output device 108 coupled to the CPU 102. The output device 108 allows the computing device 100 to provide outputs to a user operating the computing device 100. The output device 108 may comprise a display (for example the touch-screen display referred to above) and/or a speaker. The input device 106 and output device 108 may be integrated into the computing device 100 as shown in Figure 1. In other embodiments, one or both of the input device 106 and output device 108 may not be integrated into the computing device 100 and may be connected to the computing device 100 (and thereby the CPU 102) via respective interfaces. Such interfaces may be wired (e.g. a USB interface) or wireless. The computing device 100 may comprise a communication interface 110 coupled to the CPU 102. The communication interface 110 allows the computing device 100 to transmit data, and/or receive data. The communication interface 110 may be a wireless communication interface and/or a wired communication interface. Applying a powder coating to an object 14567648-1
Figure 2 illustrates a method 200 of applying one or more powder coatings to an object. That is, the method 200 may be performed to apply a single powder coating to an object. Alternatively the method 200 may be performed to apply multiple powder coatings to an object, whereby the multiple powder coatings form a coating system. As shown in Figure 2, at step S202 the method 200 comprises performing a computer implemented powder coating evaluation method. The computer implemented powder coating evaluation method may be performed by the computing device 100. In particular, the computer implemented powder coating evaluation method performed at step S202 may be performed by the CPU 102. Figure 3 illustrates a computer implemented powder coating evaluation method that is performed at step S202 to evaluate multiple powder coatings as candidates for being used to coat an object as a single layer. At step S302, the CPU 102 obtains one or more parameters of an object that is to be coated with a powder coating. The object that is to be coated with a powder coating may comprise one or more materials including metal (e.g. steel, galvanized steel, aluminium), wood, MDF, HDF, plywood, fibreboard, particleboard, plastic, glass, ceramic, composite materials, graphite-filled composites and so on. The object may for example be a washing machine, radiator, frame etc. It will be appreciated that these are merely examples and embodiments of the present disclosure are not limited to any particular object. The object parameter(s) influence the ability of the object to be heated. That is, the energy needed to get to a certain surface temperature depends on these parameters. The object parameter(s) may comprise one or any combination of: a type of material of the object (e.g. a type of metal, wood, MDF etc.), a material thickness of the object, an object type of the object (e.g. washing machine, radiator, frame etc.), a surface preparation of the object (e.g. chemical cleaning, mechanical cleaning), a surface area of the object to be coated, a target thickness of the powder coating at one or more surface areas of the object, a mass of the object, and a coating scheme for the object. As used herein the term “target thickness” refers to a required thickness of the layer of powder coating that is formed after the powder coating has been applied to the object. The target thickness may be defined by a manufacturer of the object. The target 14567648-1
thickness may be unique to the object. Alternatively, a target thickness may be specified for all objects belonging to a specific object group. In one example, an object group may be defined as “washing machines” such that the target thickness specifies that all washing machines are to have a layer of powder coating, which is formed after the powder coating has been applied, at the required thickness. In another example, an object group may be defined as “washing machine model number 001” such that the target thickness specifies that all washing machines having the model number 001 are to have a layer of powder coating, which is formed after the powder coating has been applied, at the required thickness. As used herein the term “coating scheme” defines one or more surface areas of an object that are to be coated, and may optionally define a thickness of the coating in the one or more surface areas. For example, a coating scheme may define that all surface areas of the object are to be coated, or the object is to be only coated in certain surface areas leaving other surface areas uncoated (interior/exterior/one side). A coating scheme may define that an object is to be coated with even thickness in all surface areas. Alternatively, a coating scheme may define that a certain surface area is to have different coating thickness than other surface areas (interior/exterior/one side). The CPU 102 may obtain the object parameter(s) by various mechanisms. The CPU 102 may obtain one or more of the object parameter(s) by retrieving them from memory 104. Alternatively or additionally, the CPU 102 may obtain one or more of the object parameter(s) by receiving them via the input device 106 (e.g. based on them being input by a user using the input device 106. Alternatively or additionally, the CPU 102 may obtain one or more of the object parameter(s) by receiving them via the communication interface 110 (e.g. by retrieving them from a remote database that is external to the computing device 100). At step S304, the CPU 102 obtains one or more parameters of an oven that is to be used to apply the powder coating to the object. As used herein the term “oven” refers to any type of equipment that enables the powder coating to be applied to the object and form a film thereon. The oven may comprise an enclosure in which an object to be coated is placed or which the object travels though during the powder coating application process. For thermoset and UV curable powder coatings the oven is configured to melt and cure the powder coating that has been or is to be applied to an object. The oven may cure the 14567648-1
powder coating using conventional thermal energy heating through the air, IR, induction, or using ultraviolet (UV) light. For thermoplastic powder coatings (for which there is no curing as the powder particles melt in the oven but do not chemically crosslink) the oven is configured to melt the powder coating that has been applied or is to be applied to the object. The oven may melt the powder coating using conventional thermal energy heating through the air, IR, induction or combinations thereof. That is, the oven may employ a combination of one or more heating mechanisms. The oven may also comprise a component (e.g. a spray gun) to apply the powder coating to the object prior to curing. The oven parameter(s) may comprises a heating mechanism type of the oven e.g. whether the heating mechanism is via convection, infrared, induction or whether the oven employs a combination of one or more heating mechanisms (e.g. a combination of infrared and convection, or a combination of convection and induction. Alternatively or additionally, the oven parameter(s) may comprises a design type of the oven (e.g. batch, conveyor, camel back, power-and-free). Alternatively or additionally, the oven parameter(s) may comprises an energy source of the oven (e.g. electricity, LPG, diesel, bunker oil, wood etc.). Alternatively or additionally, the oven parameter(s) may comprises a material of the oven (e.g. a type of metal used and/or a type of insulation used). Alternatively or additionally, the oven parameter(s) may comprises one or more dimensions of the oven (e.g. the oven’s height and/or length, a thickness of walls of the oven, a thickness of any insulation used in the oven). Alternatively or additionally, the oven parameter(s) may comprise a heat transfer type of the oven (e.g. direct fire, heat exchanger etc.). Alternatively or additionally, the oven parameter(s) may comprise one or more settings of a component of the oven (e.g. settings of an air circulation device of the oven, settings of a spray gun etc.). Alternatively or additionally, the oven parameter(s) may comprise a material of a component of the oven (e.g. for a conveyor oven, a material of a conveyor forming part of the oven used to transport the object through the oven; for a batch oven, a material of a trolley used to support the object during insertion/removal of the object from the oven and during the curing process). Alternatively or additionally, the oven parameter(s) may comprise a mass of a component of the oven (e.g. for a conveyor oven, a mass of the conveyor; for a batch oven, a mass of the trolley). Alternatively or additionally, the oven parameter(s) may comprises a length of time the oven is operational in a given time period (e.g. a length of time the oven is operational in one day). Alternatively or additionally, the oven parameter(s) may comprise a temperature of the air (Tair) enclosed with the oven. 14567648-1
As used herein the term “component” of the oven refers to a component that is coupled to, or housed within the oven during operation. A component of the oven may be in a fixed position after installation of the oven e.g. a conveyor. Alternatively a component of the oven may be removable from the oven e.g. a trolley. One or more of the oven parameter(s) may be static (i.e. cannot be varied) e.g. - heating mechanism type of the oven - design type of the oven - energy source of the oven - settings of a component of the oven (e.g. one or more settings of a spray gun may be fixed such as the gun type which is coating independent) - material of the oven - dimensions of the oven - heat transfer type of the oven - material of a component of the oven - mass of a component of the oven One or more of the oven parameter(s) may not be static (i.e. can be varied) e.g. - length of time the oven is operational in a given time period - temperature of the air enclosed with the oven. - line speed of the oven, i.e. the moving speed of a conveyor of a conveyor oven usually measured in meters per second. - settings of a component of the oven (e.g. one or more settings of a spray gun of the oven and/or an air circulation pump of the oven may be controllable) The CPU 102 may obtain the oven parameter(s) by various mechanisms. The CPU 102 may obtain one or more of the oven parameter(s) by retrieving them from memory 104. Alternatively or additionally, the CPU 102 may obtain one or more of the oven parameter(s) by receiving them via the input device 106 (e.g. based on them being input by a user using the input device 106. Alternatively or additionally, the CPU 102 may obtain one or more of the oven parameter(s) by receiving them via the communication interface 110 (e.g. by retrieving them from a remote database that is external to the computing device 100). For each of a plurality of powder coatings to be evaluated, the CPU 102 obtains at least one coating parameter associated with the powder coating, and then determines at least 14567648-1
one performance parameter associated with applying the powder coating to the object. The determining of each of the at least one performance parameter associated with applying the powder coating to the object is based on: (i) one or more of the object parameter(s), (ii) one or more of the oven parameter(s), and (iii) one or more of the coating parameter(s). As noted above, it is the oven that is used to apply a powder coating to the object, and thus in embodiments of the present disclosure, the performance parameter referred to herein relates to performance in relation to the application of a particular powder coating to an object by the oven. The performance parameter referred to herein may relate to performance that the oven will exhibit when applying a particular powder coating to an object. A unique identifier of each of the plurality of powder coatings to be evaluated is accessible to the CPU 102. For example, the unique identifier of each of the plurality of powder coatings to be evaluated may be stored in memory 104. A user may select the plurality of powder coatings to be evaluated using the input device 106. That is, a user may select the plurality of powder coatings to be evaluated from a list of powder coatings (which comprises the plurality of powder coatings and additional powder coatings) using the input device 106. The unique identifier of each of the plurality of powder coatings may for example be a product name, and/or a numerical or alphanumerical code. As a simple example, Figure 3 illustrates the steps performed by the CPU 102 when two powder coatings (coating 1 and coating 2) are evaluated. It will be appreciated that any number of powder coatings may be evaluated using the computer implemented powder coating evaluation method of Figure 3. At step S306, the CPU 102 obtains one or more parameters of a first powder coating (coating 1) that is to be evaluated as a candidate for being used to coat the object. The coating parameter(s) may comprise a temperature to be used in an oven when applying the powder coating. This temperature may be a minimum temperature of an object that is necessary so that the powder coating can be applied to the object. This temperature may alternatively be a maximum temperature of the air enclosed in the oven (e.g. to avoid degradation of the powder coating). Alternatively or additionally, the coating 14567648-1
parameter(s) may comprise a coating thickness of the powder coating. Alternatively or additionally, the coating parameter(s) may comprise a specific gravity which refers to the ratio of the weight of a given volume of powder coating to the weight of an equal volume of water. In particular, specific gravity is a measure of the density of the powder compared to water and may be measured in g/cm3 or the SI unit kg/cm3. Alternatively or additionally, the coating parameter(s) may comprise a powder coating coverage (m2 / kg) which refers to an area that will be covered with 1 kg of powder coating to achieve a desired film thickness. The powder coating coverage (m²/kg) may be calculated using powder coating coverage (m²/kg) = 1000 / (specific gravity * film thickness (µm). Alternatively or additionally, the coating parameter(s) may comprise a particle size distribution of the powder coating. As used herein the term “coating thickness” refers to a thickness of the layer of powder coating (that is formed after the powder coating has been applied to the object) that can be achieved when using the particular powder coating. The coating thickness may be defined by a minimum coating thickness or a maximum coating thickness. The coating thickness may be defined by range between a minimum coating thickness and a maximum coating thickness. It will be appreciated that if an object parameter of an object defines a target thickness, then for coating the object it is necessary to use a powder coating that can achieve the target thickness (based on the coating thickness of the powder coating). For example, it is necessary for the target thickness to be within a range defined by a minimum coating thickness and a maximum coating thickness. The CPU 102 may obtain the coating parameter(s) by various mechanisms. The CPU 102 may obtain one or more of the coating parameter(s) by retrieving them from memory 104. Alternatively or additionally, the CPU 102 may obtain one or more of the coating parameter(s) by receiving them via the input device 106 (e.g. based on them being input by a user using the input device 106. Alternatively or additionally, the CPU 102 may obtain one or more of the coating parameter(s) by receiving them via the communication interface 110 (e.g. by retrieving them from a remote database that is external to the computing device 100). 14567648-1
It will be appreciated by persons skilled in the art that coating parameter(s) such as those referred to above, are typically included in technical data sheet (TDS) of a powder coating and/or can be obtained by measurement. At step S308, the CPU 102 determines at least one performance parameter associated with applying the first powder coating (coating 1) to the object. The determination of each of the performance parameters is based on: (i) one or more of the object parameter(s) obtained at step S302, (ii) one or more of the oven parameter(s) obtained at step S304, and (iii) one or more of the coating parameter(s) of coating 1 obtained at step S306. The performance parameter(s) determined at step S308 relate to the performance of the process of applying the first powder coating (coating 1) to the object. A performance parameter P depends on oven parameter(s) pov, object parameter(s) pobj and coating parameters (pcoat), which in turn can be interdependent, such that: P = f(pov, pobj, pcoat) and pov = f(pcoat, pobj) and pcoat = f(pobj, pov) The dependency of the performance parameter P on the oven parameter(s) pov can typically be established by referring to the oven information from oven manufacturers. The dependency of the performance parameter P on the object parameter(s) pobj and coating parameter(s) pcoat, and the interrelation between oven, object and coating parameters is typically established experimentally for the given oven or a similar oven, for the given object or similar objects and for the coating or an equivalent coating. Various performance parameters may be determined by the CPU 102 at step S308. In particular, one or more of: an energy usage performance parameter, a productivity performance parameter, and environmental emissions performance parameter may be determined by the CPU 102 at step S308. One or more of the performance parameters may be computed by the CPU 102 by computing a coating-dependent oven parameter. A coating-dependent oven parameter is a parameter of the oven that depends on both the oven and the coating. That is, the CPU 102 may compute the coating-dependent oven parameter using one or more oven parameter, and one or more coating parameter. A coating-dependent oven parameter may further depend on the object (i.e. on one or more object parameter). 14567648-1
The performance parameter may then be computed by the CPU 102 using (i) the coating- dependent oven parameter (ii) one or more object parameter (which may be the same or different to the object parameter(s) used to compute the coating-dependent oven parameter), (iii) one or more oven parameter (which may be the same or different to the oven parameter(s) used to compute the coating-dependent oven parameter), and (iv) one or more coating parameter (which may be the same or different to the coating parameter(s) used to compute the coating-dependent oven parameter). Examples of a coating-dependent oven parameter include: - a temperature of the air (Tair) enclosed with the oven. This may be a minimum or maximum temperature value. - a line speed of the oven, i.e. the moving speed of a conveyor of a conveyor oven usually measured in meters per second. - one or more settings of a component of the oven (e.g. one or more settings of a spray gun of the oven may be controllable) A number of settings of the spray gun may be controlled in dependence on the particular powder coating being used. The controllable settings of the spray gun include: a powder flow rate, a quantity of air required, a voltage, a current, a gun distance (distance between gun and object), a speed of movement of the spray gun, type of nozzle, size of nozzle. Examples of a coating-dependent oven parameter that are also dependent on object parameter(s) of the object include some settings of the spray gun, e.g. the gun distance and the speed of movement of the spray gun. Energy usage performance parameter One example performance parameter that may be determined in embodiments of the present disclosure is an energy usage performance parameter. The energy usage performance parameter defines how much energy would be used to apply the particular powder coating to the particular object. The energy usage performance parameter may be a value of kilowatt hours (kWh). Potential energy savings can be achieved with powder coatings which can be applied at lower temperatures. 14567648-1
The energy usage performance parameter may be computed using at least one coating- dependent oven parameter. A coating-dependent oven parameter for the first powder coating (coating 1) is a parameter of the oven that depends on (i) one or more of the oven parameter(s) of coating 1 obtained at step S304, and (ii) one or more of the coating parameter(s) of coating 1 obtained at step S306. A coating-dependent oven parameter for the first powder coating (coating 1) may further depend on (iii) one or more of the object parameter(s) obtained at step S302. We refer to an example below whereby the coating-dependent oven parameters of air temperature (Tair) and line speed are used in the determination of the energy usage performance parameter. As noted above, the energy usage performance parameter is dependent on one or more coating parameters of the particular powder coating e.g. a minimum temperature of the object surface so that the powder coating can melt (Tmet). The minimum object surface temperature Tmet determines the air temperature (Tair) of the air enclosed within the oven (that is used to heat up the object) has to have. The air temperature Tair will always need to be at least the object surface temperature Tmet. The temperature the air needs to have also depends on the line speed of the oven. The higher the line speed, the higher the air temperature required. The functional form of the dependency between air temperature and line speed may be experimentally determined for the specific oven and object such that: Tair = f(line speed) The line speed in turn also depends on the speed of application of the powder coating by the spray gun of the oven to the object surface. For example, a slow application speed by the spray gun reduces the overall line speed as the object would need to be sprayed for a longer period to achieve the required powder coating thickness. A slower line speed then in turn influences the temperature settings, especially the air temperature and by that the energy requirements. Parameters influencing the application speed are gun settings of the spray gun e.g. powder flow rate, gun movement, gun distance. The functional form of the dependency between gun settings and line speed may be experimentally determined for the specific oven and object such that: 14567648-1
line speed = f(gun settings) And therefore with Tair = f(line speed) Tair = f(gun settings) For computing the total energy required for coating the specified object with the specified oven the CPU 102 may use the energy required to heat the oven Ereq,oven, the energy required to heat the object Ereq,object and the energy losses Elosses due to heat loss of the air used for heating the object: Ereq,tot = Ereq,oven + Ereq,object + Elosses To compute the energy required to heat the oven Ereq,oven the CPU 102 may use one or more static oven parameters and one or more coating parameters. For example, the CPU 102 may compute the energy required to heat the oven Ereq,oven using: Ereq,oven = C · ωoven ·SHoven· (Tmet − To) whereby: ωoven is the oven wall material mass (an oven parameter), SHoven is the specific heat capacity of the oven wall material, C is a consumption factor depending on the type of heating mechanism (e.g. direct fire C = 1.0, indirect fire C =1.2), Tmet is the target temperature of the object to coat (a coating parameter), and T0 is the ambient temperature outside of the oven. As noted above, a coating-dependent oven parameter is computed using one or more oven parameters and one or more coating parameters. The energy required to heat the oven Ereq,oven may be computed by the CPU 102 by determining a coating-dependent oven parameter using one or more of the static oven parameters and one or more coating parameters. To determine the energy required to heat the oven Ereq,oven, the CPU 102 may use the coating-dependent oven parameter with or without one or more oven parameters and/or one or more coating parameters. 14567648-1
The minimum object surface temperature Tmet depends on the chosen coating. All other input parameters in this equation are static oven parameters. The CPU 102 may compute the oven wall material mass using: ωoven = ((L · W · 2) + (L · H · 2) + (W · H · 2)) · SGoven · T for a cubic oven (box with length L, width W, height H) and wall thickness T, made of a material with specific gravity SGoven. All input parameters in this equation are static oven parameters. Table 1 below shows the specific gravity of example materials: Materials Specific gravity [g/cm³ ] Material 1 7.586 Material 2 7.876 Material 3 2.543 Material 4 7.541 Material 5 1.012 Table 1 To compute the energy required to heat the object Ereq,object the CPU 102 may use one or more object parameters, one or more static oven parameters, and one or more coating parameters. For example, the CPU 102 may compute the energy required to heat the object Ereq,object using: Ereq,object = ωobject · SHobject· (Tmet − To) whereby: ωobject is the object material mass, SHobject is the specific heat capacity of the object material, Tmet is the target temperature of the object to coat, and T0 is the ambient temperature outside of the oven. As noted above, a coating-dependent oven parameter is computed using one or more oven parameters and one or more coating parameters (and optionally one or more object parameters). The energy required to heat the object Ereq,object may be computed by the CPU 102 by determining a coating-dependent oven parameter using the one or more of 14567648-1
the static oven parameters and one or more coating parameters (and optionally one or more object parameters). To determine the energy required to heat the object Ereq,object, the CPU 102 may use the coating-dependent oven parameter with or without one or more oven parameters and/or one or more coating parameters and/or one or more object parameters. As noted above the minimum object surface temperature Tmet depends on the chosen coating. ωobject depends on a coating-dependent oven parameter e.g. the line speed. All other input parameters in this equation are static settings for the specific object or oven (T0). Table 2 below shows the specific heat capacity of example materials: Materials Specific heat capacity [kJ/kg ·K] Material 1 0.914 Material 2 0.436 Material 3 0.467 Material 4 0.548 Material 5 0.480 Table 2 To compute the energy losses Elosses the CPU 102 may use one or more static oven parameters, and one or more coating-dependent oven parameters. For example, the CPU 102 may compute the energy losses Elosses using: ELosses = (Qpump · ^ /100)*Densityair · SpecificHeatair · (Tair − To) whereby: Elosses is the energy losses due to heat loss of the air used for heating the objects, Qpump is the maximum air capacity of an air circulation pump of the oven, ^ is the utilisation factor of the air circulation pump, Densityair is the density of air, SpecificHeatair is the specific heat capacity of air, Tair is the required air temperature, and T0 is the ambient temperature outside of the oven. 14567648-1
As noted above, a coating-dependent oven parameter is computed using one or more oven parameters and one or more coating parameters. The energy losses Elosses may be computed by the CPU 102 by determining a coating-dependent oven parameter using the one or more of the static oven parameters and one or more coating parameters. To determine the energy losses Elosses, the CPU 102 may use the coating-dependent oven parameter with or without one or more oven parameters and/or one or more coating parameters. Tair depends on Tmet (Tair always > Tmet) and the oven specifics and a coating-dependent oven parameter like line speed (the higher the line speed the higher Tair). All other input parameters in this equation are static settings for the specific oven (T0). The energy consumption Ereq,total for a given oven, given object and a given coating may be computed by the CPU 102 considering relevant energy consuming steps of the coating process. Examples of relevant energy consuming steps for a powder coating process are energy consumption of oven components during the application (and curing if thermal curing is used) process Eoven1 (e.g. energy consumption of spray gun, air pump), and energy absorbed by the oven and its components Eoven2 (e.g. energy is absorbed by the oven material), energy needed for the melting (and curing if thermal curing is used) of the powder coating on the object surface Ereq,obj (e.g. energy absorbed by the object), and energy losses that occur in the process Elosses (e.g. when air pumped by an air pump is used to heat the object, energy is lost in exhaust air), such that the CPU 102 may compute the total energy required for coating the specified object with the specified oven using: Ereq,tot = Eoven1 + Eoven2 + Ereq,obj + Elosses whereby Eoven2 corresponds to Ereq,oven above. The total energy consumption Ereq,tot and its components depends on oven, object and coating parameters pov, pobj and pcoat, which in turn can be interdependent: 14567648-1
Ereq,tot(pov, pobj, pcoat) = Eoven1(pov, pobj, pcoat) + Eoven2(pov, pobj, pcoat) + Eobject(pov, pobj, pcoat) + Elosses(pov, pobj, pcoat) and pov = f(pcoat, pobj) and pcoat = f(pobj, pov) The dependency of the oven energy terms Eoven1 (if used) and Eoven2 and Elosses on the oven parameters can typically be established by referring to the oven information from oven manufacturers. . The dependency of the energy terms on the object and coating parameters and the interrelation between oven, object and coating parameters is typically established experimentally for the given oven or a similar oven, for the given object or similar objects and for the coating or an equivalent coating. Productivity performance parameter Another example performance parameter that may be determined in embodiments of the present disclosure is a productivity performance parameter. The productivity performance parameter defines the productivity of the oven when a particular powder coating is used to coat a particular object. The productivity performance parameter may define the quantity of objects coated QCoated-material in a certain time frame t. The productivity PR for a given oven, given object and a given coating may be computed by the CPU 102 using a coating process speed scoating and a relevant conversion factor f: PR = scoating ∙ f Coating process speed refers to the number of object units that are coated in the oven per time unit. The coating process speed can be expressed e.g. as objects per hours. The conversion factor converts the coating process speed into the chosen metric to measure the productivity, e.g. if productivity is to be expressed in mass of object coated per hour and the coating process speed is expressed in objects coated per hour, the relevant conversion factor will be based on the mass per object ωobj: PR = scoating ∙ ωobj 14567648-1
The coating process speed depends on oven, object and coating parameters pov, pobj and pcoat, which in turn can be interdependent: scoating = f(pov, pobj, pcoat) and pov = f(pcoat, pobj) and pcoat = f(pobj, pov) The dependency of the coating process speed on the oven, object and coating parameters and the interrelation between oven, object and coating parameters is typically established experimentally for the given oven or a similar oven, for the given object or similar objects and for the coating or an equivalent coating. Taking the example of a batch oven, more objects can be placed on a trolley if they are smaller than if they are big. Thus the coating process speed depends on an object parameter (dimensions of the object). Another factor which impacts the coating process speed is the time needed for the powder coating to set/cure on the object which is dependent on the temperature that the object has been heated (dictated by a coating parameter - a minimum temperature of an object that is necessary so that the powder coating can be applied to the object). For objects with high heat capacity, the time taken for the powder coating to set/cure takes longer, thus the setting/curing time increases, which in turn reduces the coating process speed. The CPU 102 may determine the quantity (number) of objects coated QCoated-material in a certain time frame t using: QCoated-material / t = ωobject * scoating The productivity performance parameter is therefore a function of the mass of the objects ωobject and the coating process speed scoating. In a conveyor oven, line speed refers to the moving speed of the conveyor, usually measured in meters per second. In a conveyor oven, line speed (a coating-dependent oven parameter) relates directly to coating process speed for a specific object. For a conveyor oven, the coating process speed can be defined as the number of objects coated per time: 14567648-1
scoating = QCoated-material / t The line speed can be defined as distance the conveyor moves per time: line speed = distance conveyor moved / t The relation between coating process speed and line speed is therefore given by the number of objects per distance of conveyor (objects per meter of conveyor): scoating = line speed * number of objects / distance of conveyor The coating process speed scoating and the temperature required at the object surface are related (higher coating process speed is possible if lower temperature required) and are coating dependent. It is clear that the above productivity performance parameter is only applicable when the oven is operating. The overall productivity QCoated−material, achieved /t is therefore a function of the operational conditions, which can be expressed as the percentage of time of activity fa.
where fa is an activity factor, ranging from 0 to 100%. The coating process speed scoating may be determined using: one or more object parameter, one or more oven parameter, and one or more coating parameter. As noted above, a coating-dependent oven parameter is computed using one or more oven parameters and one or more coating parameters (and optionally one or more object parameters). The coating process speed scoating may be computed by the CPU 102 by determining a coating-dependent oven parameter using one or more oven parameters and one or more coating parameters (and optionally one or more object parameters). To determine the coating process speed scoating, the CPU 102 may use the coating- 14567648-1
dependent oven parameter with or without one or more oven parameters and/or one or more coating parameters and/or one or more object parameters. Environmental emissions performance parameter Another example performance parameter that may be determined in embodiments of the present disclosure is an environmental emissions performance parameter. The environmental emissions parameter defines environmental emissions produced by the oven when a particular powder coating is used to coat a particular object. The environmental emissions parameter may be a value of CO2 emissions (e.g. kg of CO2) or other greenhouse gases. We refer herein to CO2 emissions as an example. The carbon emissions EMCO2 for a given oven, given object and a given coating may be computed by the CPU 102 by considering elements of the coating process that generate CO2 emissions. Examples of relevant elements to consider in the selection and application of a powder coating that generate CO2 emissions are steps that consume energy during the coating process and thus emit an amount of CO2 EMCO2,process (e.g. energy needed for heating object and oven, energy consumed by oven components like spray gun or air pump) and CO2 emissions related to using a given coating EMCO2,coating (e.g. the amount of CO2 emitted for the production of the powder coating) whereby: EMCO2 = EMCO2, process + EMCO2, coating The CO2 emissions related to the energy consumption of the coating process EMCO2, process may be computed from the energy consumption of the coating process Ereq,tot and a conversion factor fconv to convert energy into CO2 emission for the energy source used to produce Ereq,tot using: EMCO2, process=Ereq,tot ∙fconv fconv can be e.g. obtained from publicly available sources. Ereq,tot can either be computed (for example as described herein) or be measured experimentally for a given oven, object, coating; and a set of oven, object and coating parameters, and stored in memory accessible to the CPU 102. 14567648-1
The CO2 emissions related to using a given coating EMCO2,coating are available e.g. in environmental product declarations (EPD), and may be stored in memory accessible to the CPU 102. The environmental emissions parameter may be determined in a number of ways. An example method of determining the environmental emissions parameter is shown in Figure 4a. As shown in Figure 4a, determining an environmental emissions parameter may comprise the CPU 102 determining, at step S402, an energy usage performance parameter based on: (i) one or more of the object parameter(s), (ii) one or more of the oven parameter(s), and (iii) one or more of the coating parameter(s) of a specific coating. For example, at step S402, the CPU 102 may compute the total energy required (Ereq,tot) for coating the specified object with the specified oven. Thus, step S308 of determining an environmental emissions parameter for coating 1 may comprise the CPU 102 determining, at step S402, an energy usage performance parameter based on: (i) one or more of the object parameter(s) obtained at step S302, (ii) one or more of the oven parameter(s) obtained at step S304, and (iii) one or more of the coating parameter(s) of coating 1 obtained at step S306. The step S308 of determining an environmental emissions parameter may comprise the CPU 102 determining, at step S404, the environmental emissions parameter by converting the energy usage performance parameter determined at step S402 into an environmental emissions parameter which indicates the environmental emissions due to the fuel (energy source) of the oven. At step S404, the CPU 102 may compute a required fuel quantity by dividing the total energy required by the calorific value of the energy source used using: Qfuel= Ereq,tot/Kenergy source Table 3 below shows the calorific value of example energy source: 14567648-1
Energy source Calorific value [kWh/volume or kWh/weight ] Energy Source 1 9.876 Energy Source 2 12.564 Energy Source 3 10.124 Energy Source 4 10.906 Energy Source 5 1.125 Table 3 At step S404, the CPU 102 may compute the quantity of environmental emissions (e.g. CO2 emissions) due to the fuel (energy source) of the oven (CEfuel) using the required fuel quantity (Qfuel) and an emissions factor (EF) of the fuel (energy source) of the oven using: CEfuel=Qfuel/EFfuel Emission factors for various fuels are publicly available. Table 4 below shows the emission factors mentioned in the UK Govt Green House Gas Report 2023. Material Emission Quantity factor (EF) kg-co2/quantity Diesel 2.82 L LPG/Propane 2.89 kg Natural gas 2.12 mtr³ Bunker Oil 2.87 L Clean energy 0.36 kWh (Electricity) Electricity 0.86 kWh Table 4 Another example method of determining the environmental emissions parameter is shown in Figure 4b. As shown in Figure 4b, determining an environmental emissions parameter may comprise the CPU 102 determining, at step S406, an energy usage performance parameter based on: (i) one or more of the object parameter(s), (ii) one or more of the oven parameter(s), and (iii) one or more of the coating parameter(s) of a specific coating. For example, at step S406, the CPU 102 may compute the total energy required (Ereq,tot) for coating the specified object with the specified oven. As shown in Figure 4b, the step S308 of determining an environmental emissions parameter may comprise the CPU 102 determining, at step S406, an energy usage performance parameter based on: (i) one or more of the object parameter(s) obtained at step S302, 14567648-1
(ii) one or more of the oven parameter(s) obtained at step S304, and (iii) one or more of the coating parameter(s) of coating 1 obtained at step S306. Determining an environmental emissions parameter may comprise the CPU 102 determining, at step S408, how much powder of the specific coating (Qpowder) is needed to coat the specific object using: one or more of the object parameter(s), and one or more of the coating parameter(s) of the specific coating. Thus, the step S308 of determining an environmental emissions parameter may comprise the CPU 102 determining, at step S408, how much powder of coating 1 (Qpowder1) is needed to coat the specific object using: one or more of the object parameter(s) obtained at step S302, and one or more of the coating parameter(s) of coating 1 obtained at step S306. The CPU 102 may be configured to compute the quantity of the specific coating (Qpowder) required to coat the specific object using: Qpowder= (Acoating/ QPwd)∙(1+Qloss) whereby: Acoating is the coating area for application of powder coating (m²) QPwd is the utilisation defining how much powder in g you need to cover a certain area in m2 Qloss is the loss factor defining the percentage of powder coating which is lost during application and cannot be recycled. Qloss is an oven and object dependent coating parameter. If the loss factor is not considered in the determination of the quantity of the specific coating (Qpowder) required to coat the specific object, the above equation can be simplified to: Qpowder= Acoating/ QPwd The Acoating value may be defined as an object parameter accessible by the CPU 102. For example, the CPU 102 may obtain an object parameter defining a surface area of the object to be coated and thereby obtain the Acoating value. In another example, the CPU 102 may obtain an object parameter defining a coating scheme for the object and thereby obtain the Acoating value. 14567648-1
The Qloss value for the specific object is accessible to the CPU 102 e.g. retrieved from memory by the CPU 102. The QPwd value for the specific object is accessible to the CPU 102 e.g. may also be retrieved from memory by the CPU 102. The object may be defined as belonging to a specific object group (e.g. an appliance, a building component, item of furniture etc.). Table 5 below shows how different objects may belong to the same object group. Group 1 Group 2 Group3 Group4 Group5 Group6 Group7 Object 1a Object 2a Object 3a Object 4a Object 5a Object 6a Object 7a Object 1b Object 2b Object 3b Object 4b Object 5b Object 6b Object 7b Object 1c Object 2c Object 3c Object 4c Object 5c Object 6c Object 7c Object 1d Object 2d Object 3d Object 4d Object 5d Object 6d Object 7d Table 5 Each object group can be associated with a particular coating scheme, e.g. (i) coating plan 1 - one side coating, (ii) coating plan 2 - both side coating (same thickness), (iii) coating plan 3 - both side coating (different thickness). Table 6 below shows that for each object group, one or more coating schemes may be applicable as a coating scheme for the objects belonging to a particular object group. Object Group Coating scheme 1 Coating scheme 2 Coating scheme 3 Group 1 Applicable Applicable Applicable Group 2 Applicable Applicable NA Group 3 Applicable NA NA Group4 NA Applicable Applicable Group 5 NA NA Applicable Group 6 NA Applicable Applicable Group 7 NA NA Applicable Table 6 The QPwd values (and optionally Qloss values) for different coatings for a particular object group and for a particular coating scheme may be stored in memory and be retrievable by the CPU 102. Table 7 below shows example QPwd values for different powder coatings Coating QPwd QLoss g/m² Coating 1 110 5% Coating 2 123 8% Coating 3 125 4% Coating 4 134 9% 14567648-1
Coating 5 155 3% Table 7 Determining an environmental emissions parameter may comprise the CPU 102 determining, at step S410, the environmental emissions parameter using the energy usage performance parameter (Ereq,tot) determined at step S406, and the quantity of the specific coating (Qpowder) determined at step S408. Thus, the step S308 of determining an environmental emissions parameter may comprise the CPU 102 determining, at step S410, the environmental emissions parameter using the energy usage performance parameter (Ereq,tot) determined at step S406, and the quantity of coating 1 (Qpowder1) determined at step S408. At step S410, the CPU 102 may compute the quantity of environmental emissions (e.g. CO2 emissions) due to the fuel (energy source) of the oven (CEfuel) as described above in connection with step S404. At step S410, the CPU 102 may further compute the quantity of environmental emissions (e.g. CO2 emissions) due to the powder quantity requirement (CEpowder) using the quantity of the specific powder (Qpowder) determined at step S408. In particular, the CPU 102 may compute the quantity of environmental emissions due to the powder quantity requirement (CEpowder) using: CEpowder=Qpowder/EFpowder Whereby an emissions factor (EFpowder) defines the energy required to produce the specific coating. The emissions factor EFpowder of powder coatings is available in EPD (environmental product declaration) databases, other databases, or can be specifically measured. Thus, at step S410 the CPU 102 may compute an environmental emissions parameter (CEtotal) which indicates the total environmental emissions due to both the environmental emissions of the fuel (energy source) of the oven (CEfuel), and the environmental emissions of the powder quantity requirement (CEpowder). In particular, the CPU 102 may compute the environmental emissions parameter (CEtotal) using: CEtotal= CEfuel + CEpowder 14567648-1
The object parameter(s) used in the determination at step S406 may be the same or different to the object parameter(s) used in the determination at step S408. Similarly, the coating parameter(s) used in the determination at step S406 may be the same or different to the coating parameter(s) used in the determination at step S408. At step S308, multiple performance parameters associated with applying the first powder coating (coating 1) to the object may be determined. In embodiments where multiple performance parameters are determined at step S308, the determination of the multiple performance parameters may use the same, or different object parameter(s). In embodiments where multiple performance parameters are determined at step S308, the determination of the multiple performance parameters may use the same, or different oven parameter(s). In embodiments where multiple performance parameters are determined at step S308, the determination of the multiple performance parameters may use the same, or different coating parameter(s). The evaluation of the first powder coating (coating 1) may optionally further comprise the CPU 102 determining, at step S310, how much powder of coating 1 is needed to coat the specific object using: one or more of the object parameter(s) obtained at step S302, and one or more of the coating parameter(s) of coating 1 obtained at step S306. It will be appreciated that in embodiments whereby step S408 is performed at step S308, it is not necessary to determine the quantity of the coating 1 again at step S310. As noted above, a coating-dependent oven parameter is computed using one or more oven parameters and one or more coating parameters (and optionally one or more object parameters). The energy usage performance parameter may be computed by the CPU 102 at step S402 and/or step S406 by determining a coating-dependent oven parameter using one or more oven parameters and one or more coating parameters (and optionally one or more object parameters). To determine the energy usage performance parameter, the CPU 102 may use the coating-dependent oven parameter with or without one or more oven parameters and/or one or more coating parameters and/or one or more object parameters. 14567648-1
At step S316, the CPU 102 obtains one or more parameters of a second coating (coating 2) that is to be evaluated as a candidate for being used to coat the object. The coating parameter(s) of the second coating may include any of those described above in connection with step S306. The coating parameter(s) of the second coating may be obtained using any of the mechanisms described above in connection with step S306. At step S318, the CPU 102 determines at least one performance parameter associated with applying the second powder coating (coating 2) to the object. The determination of each of the performance parameters is based on: (i) one or more of the object parameter(s) obtained at step S302, (ii) one or more of the oven parameter(s) obtained at step S304, and (iii) one or more of the coating parameter(s) of coating 2 obtained at step S316. The determination of any of the performance parameters described above with reference to step S308, may be performed at step S318 for the second powder coating (coating 2).That is, the same performance parameter(s) are determined for all of powder coatings being evaluated. In embodiments where multiple performance parameters are determined at step S318, the determination of the multiple performance parameters may use the same, or different object parameter(s). In embodiments where multiple performance parameters are determined at step S318, the determination of the multiple performance parameters may use the same, or different oven parameter(s). In embodiments where multiple performance parameters are determined at step S318, the determination of the multiple performance parameters may use the same, or different coating parameter(s). The determination of a performance parameter at step S308 for coating 1 may use the same or different object parameter(s) to the object parameter(s) used in the determination of the corresponding performance parameter at step S318 for coating 2. The determination of a performance parameter at step S308 for coating 1 may use the same or different oven parameter(s) to the oven parameter(s) used in the determination of the corresponding performance parameter at step S318 for coating 2. The determination of a performance parameter at step S308 for coating 1 may use the same or different coating parameter(s) to the coating parameter(s) used in the determination of the corresponding performance parameter at step S318 for coating 2. 14567648-1
The evaluation of the second powder coating (coating 2) may optionally further comprise the CPU 102 determining, at step S320, how much powder of coating 2 is needed to coat the specific object using: one or more of the object parameter(s) obtained at step S302, and one or more of the coating parameter(s) of coating 2 obtained at step S316. It will be appreciated that in embodiments whereby step S408 is performed at step S318 (for coating 2), it is not necessary to determine the quantity of the coating 2 again at step S320. At step S324, the CPU 102 provides an evaluation output based on the performance parameter(s) of each of the plurality of powder coatings. The CPU 102 may output the evaluation output to a user of the computing device 100 via the output device 108. For example, the CPU 102 may transmit the evaluation output to a display of the computing device 100. At step S324, the CPU 102 may select a single powder coating from the plurality of powder coatings that is to be used to coat the object based on the performance parameter(s) of each of the plurality of powder coatings, and provide this selected single powder coating in the evaluation output. In an example whereby a first environmental emissions performance parameter is determined at step S308 for coating 1, and a second environmental emissions performance parameter is determined at step S318 for coating 2 (which is higher than the first environmental emissions performance parameter indicating that more environmental emissions will be produced when using coating 2), at step S324 the CPU 102 may select coating 1 and provide coating 1 in the evaluation output. In embodiments whereby the quantity of the selected powder coating has been determined (e.g. at step S310/S320), the quantity of the selected powder coating may also be included in the evaluation output. Alternatively, at step S324, the CPU 102 may assign a ranking value to each of the plurality of powder coatings being evaluated based on the performance parameter(s) of each of the plurality of powder coatings. The evaluation output may comprise the plurality of powder coatings (e.g. identified by their unique identifier) and the ranking values associated with each of the plurality of powder coatings. For example, when the evaluation output is transmitted to a display of the computing device 100, the evaluation 14567648-1
output may comprise a list of the plurality of powder coatings with an indication of the ranking value assigned to each of the plurality of powder coatings. The plurality of powder coatings may be arranged in the list in an order dependent on their ranking values. In an example whereby a first environmental emissions performance parameter is determined at step S308 for coating 1, and a second environmental emissions performance parameter is determined at step S318 for coating 2 (which is higher than the first environmental emissions performance parameter indicating that more environmental emissions will be produced when using coating 2), at step S324 the CPU 102 may output a list comprising the unique identifier of coating 1 and the unique identifier of coating 2 in the evaluation output, with coating 1 having a higher ranking value than coating 2. The list may be ordered so that coating 1 appears at the top of the list above coating 2. In embodiments whereby a single performance parameter is used to evaluate the plurality of powder coatings, this single performance parameter is used by the CPU 102 at step 324 to either select a single powder coating or to assign a ranking value to each of the plurality of powder coatings. For example, if an energy usage performance parameter is used to evaluate the plurality of powder coatings, the CPU 102 may select a single powder coating having the lowest energy usage or provide the list of powder coatings in an order (ascending or descending) dependent on the energy usage values. In embodiments whereby a multiple performance parameters are used to evaluate the plurality of powder coatings the CPU 102 may compute an overall performance parameter Poverall of each of the plurality of powder coatings. The CPU 102 may use the overall performance parameter Poverall to select a single powder coating from the plurality of powder coatings that is to be used to coat the object based on the overall performance parameter Poverall of each of the plurality of powder coatings, Alternatively, the CPU 102 may assign the ranking value referred to above based on the overall performance parameter Poverall of each of the plurality of powder coatings. Persons skilled in the art could employ various methods to determine the overall performance parameter Poverall. As a mere example, the CPU 102 may use a weighted, 14567648-1
scaled sum of the performance parameters to compute an overall performance parameter Poverall: Poverall = Σi(wi * Pi) whereby: wi is weighting parameters and Σi (wi) = 1. Pi are scaled individual performance parameters where the scaling to be performed is to a common scale. Taking an example combine an energy usage performance parameter in kWh/y and a productivity performance parameter in tons of material coated per year T/y the CPU 102 would apply scaling of both to e.g. a scale between 0 and 100: - a scaling of the energy usage performance parameter: Penergy, scaled = [(Penergy, max - Penergy)/Penergy, max]*100 and if Penergy, scaled > 100: Penergy, scaled = 100 if Penergy, scaled < 0 : Penergy, scaled = 0 whereby: Penergy, max is the maximum allowed energy value, Penergy is the computed energy consumption and Penergy, scaled is the scaled performance indicator for energy consumption - a scaling of the productivity performance parameter Ppro, scaled = [(Ppro, max - Ppro)/Ppro, max]*100 and if Ppro, scaled > 100: Ppro, scaled = 100 if Ppro, scaled < 0 : Ppro, scaled = 0 Whereby: Ppro, max is the maximum allowed productivity value, Ppro is the computed productivity value, and Ppro, scaled is the scaled productivity performance parameter 14567648-1
The weighting parameters could e.g. be set to wenergy = 0.4 and wpro = 0.6, to put more weight on optimizing productivity than on energy consumption. In case both are equally important a weight of 0.5 would be set for both. The weighting parameters may be predetermined or user selected. The maximum energy and productivity values may be predetermined or user selected. In embodiments whereby the required quantity of each of the powder coatings to coat the object has been determined (e.g. at step S310/S320), the quantity of each of the powder coatings may also be included in the evaluation output. Referring back to Figure 2, once the computer implemented powder coating evaluation method of Figure 3 has been performed at step S202, the method 200 further comprises a step S204 of a user selecting a powder coating to apply to the object based on the evaluation output. That is, the user sources and/or supplies the powder coating from one or more location(s) to the oven, ready to be applied to the object. In implementations whereby a single powder coating is included in the evaluation output, step S204 comprises the user selecting the powder coating included in the evaluation output. In implementations whereby the evaluation output comprises the plurality of powder coatings and a ranking value associated with each of the plurality of powder coatings, step S204 may comprise the user selecting the powder coating from the plurality of powder coatings based on the ranking values (e.g. the powder coating that has the highest ranking value). For example, coating the object with the powder coating with the highest ranking value may result in the lowest energy usage. At step S206, the method 200 further comprises applying the selected powder coating to the object. That is, step S206 comprises operating the oven such that the selected powder coating is applied to the object thereby forming a coating film and thereby forming a coating on the object. Thus, at step S206 the object is coated with the selected powder coating. Figure 5 illustrates a computer implemented powder coating evaluation method that is performed at step S202 to evaluate multiple powder coating systems as candidates for being used to coat an object. 14567648-1
At step S502, the CPU 102 obtains one or more object parameters of an object that is to be coated with the powder coatings of a powder coating system. Step S502 may correspond to step S302 described above with the difference being that the object is to be coated with a powder coating system rather than a single powder coating. At step S504, the CPU 102 obtains one or more parameters of an oven that is to be used to apply the powder coating system to the object. Step S504 may correspond to step S304 described above with the difference being that the oven is to be used to apply a powder coating system to the object rather than used to apply a single powder coating to the object. A unique identifier of each of the plurality of powder coating systems to be evaluated is accessible to the CPU 102. For example, the unique identifier of each of the plurality of powder coating system to be evaluated may be stored in memory 104. A user may select the plurality of powder coating system to be evaluated using the input device 106. That is, a user may select the plurality of powder coating systems to be evaluated from a list of powder coating systems (which comprises the plurality of powder coating systems and additional powder coating systems) using the input device 106. The unique identifier of each of the plurality of powder coating systems may for example be a coating system name, and/or a numerical or alphanumerical code. As a simple example, Figure 5 illustrates the steps performed by the CPU 102 when two powder coating systems (coating system A and coating system B) are evaluated. As a mere example, powder coating system A comprises two powder coatings (powder coatings 1 and 2), and powder coating system B also comprises two powder coatings (powder coating 3 and 4). It will be appreciated that any number of powder coating systems may be evaluated using the computer implemented powder coating system evaluation method of Figure 5. Whilst the example coating systems referred to in Figure 5 comprise two powder coatings, this is an example and a coating system may define more than two powder coatings. Furthermore, whilst the example coating systems referred to in Figure 5 comprise different powder coatings to each other, there may be some overlap in the powder 14567648-1
coatings of the coating systems evaluated using the computer implemented powder coating evaluation method of Figure 5. In the computer implemented powder coating evaluation method of Figure 5, the CPU 102 determines a powder coating system performance parameter of each powder coating system being evaluated. The CPU 102 determines a powder coating system performance parameter of each powder coating system based on at least one performance parameter of each of the plurality of powder coatings of the powder coating system. At step S506, the CPU 102 obtains one or more parameters of the first powder coating (coating 1) of coating system A. At step S508, the CPU 102 determines at least one performance parameter associated with applying the powder coating 1 to the object. The determination of each of the performance parameters is based on: (i) one or more of the object parameter(s) obtained at step S502, (ii) one or more of the oven parameter(s) obtained at step S504, and (iii) one or more of the coating parameter(s) of powder coating 1 obtained at step S506. The performance parameter(s) determined at step S508 relate to the performance of the process of applying the powder coating 1 to the object. Various performance parameters may be determined by the CPU 102 at step S508 in accordance with the methods described herein. In particular, one or more of an energy usage performance parameter, a productivity performance parameter, and environmental emissions performance parameter may be determined at step S508. At step S510, the CPU 102 obtains one or more parameters of the powder coating 2 of coating system A. At step S512, the CPU 102 determines at least one performance parameter associated with applying powder coating 2 to the object. The determination of each of the performance parameters is based on: (i) one or more of the object parameter(s) obtained at step S502, (ii) one or more of the oven parameter(s) obtained at step S504, and (iii) one or more of the coating parameter(s) of powder coating 2 obtained at step S510. The 14567648-1
performance parameter(s) determined at step S512 relate to the performance of the process of applying the powder coating 2 to the object. The same performance parameter(s) are determined for all of the powder coatings of a coating system, and for all of the coating systems being evaluated. At step S514, the CPU 102 determines a powder coating system performance parameter of coating system A using the performance parameter(s) determined at step S508 and the performance parameter(s) determined at step S512. In embodiments whereby a single performance parameter is determined for each of the plurality of powder coatings of a particular powder coating system, the CPU 102 combines the performance parameter determined for each of the plurality of powder coatings to determine the powder coating system performance parameter of the particular powder coating system. Thus at step S514, the CPU 102 may combine a performance parameter determined at step S508 for powder coating 1 with a performance parameter determined at step S512 for the powder coating 2 to determine the powder coating system performance parameter of the powder coating system A. In embodiments whereby multiple performance parameters are determined for each of the plurality of powder coatings of a particular powder coating system, the CPU 102 may compute an overall performance parameter Poverall of each of the plurality of powder coatings, and then combines the overall performance parameter Poverall determined for each of the plurality of powder coatings to determine the powder coating system performance parameter of the particular powder coating system. Thus at step S514, the CPU 102 may combine multiple performance parameters determined at step S508 for the powder coating 1 to compute an overall performance parameter Poverall1 for the powder coating 1 using any of the methods described herein, and combine multiple performance parameters determined at step S512 for the powder coating 2 to compute an overall performance parameter Poverall2 for the powder coating 2 using any of the methods described herein. At step S514, the CPU 102 may then combine the overall performance parameters Poverall1 and Poverall2 to determine the powder coating system performance parameter of powder coating system A. 14567648-1
At step S516, the CPU 102 obtains one or more parameters of powder coating 3 of coating system B. At step S518, the CPU 102 determines CPU 102 determines at least one performance parameter associated with applying the powder coating 3 to the object. The determination of each of the performance parameters is based on: (i) one or more of the object parameter(s) obtained at step S502, (ii) one or more of the oven parameter(s) obtained at step S504, and (iii) one or more of the coating parameter(s) of powder coating 3 obtained at step S516. The performance parameter(s) determined at step S518 relate to the performance of the process of applying the powder coating 3 to the object. As noted above, the same performance parameter(s) are determined for all of the powder coatings of a coating system, and for all of the coating systems being evaluated. At step S520, the CPU 102 obtains one or more parameters of the powder coating 4 of coating system B. At step S522, the CPU 102 determines at least one performance parameter associated with applying powder coating 4 to the object. The determination of each of the performance parameters is based on: (i) one or more of the object parameter(s) obtained at step S502, (ii) one or more of the oven parameter(s) obtained at step S504, and (iii) one or more of the coating parameter(s) of powder coating 4 obtained at step S520. The performance parameter(s) determined at step S522 relate to the performance of the process of applying the powder coating 4 to the object. At step S524, the CPU 102 determines a powder coating system performance parameter of coating system B using the performance parameter(s) determined at step S518 and the performance parameter(s) determined at step S522. At step S524, the CPU 102 may combine a performance parameter determined at step S518 for powder coating 3 with a performance parameter determined at step S522 for the powder coating 4 to determine the powder coating system performance parameter of the powder coating system B. 14567648-1
At step S524, the CPU 102 may combine multiple performance parameters determined at step S518 for the powder coating 3 to compute an overall performance parameter Poverall3 for the powder coating 3 using any of the methods described herein, and combine multiple performance parameters determined at step S522 for the powder coating 4 to compute an overall performance parameter Poverall4 for the powder coating 4 using any of the methods described herein. At step S524, the CPU 102 may then combine the overall performance parameters Poverall3 and Poverall4 to determine the powder coating system performance parameter of powder coating system B. At step S526, the CPU 102 provides an evaluation output based on the performance parameter(s) of each of the plurality of powder coating systems. The CPU 102 may output the evaluation output to a user of the computing device 100 via the output device 108. For example, the CPU 102 may transmit the evaluation output to a display of the computing device 100. At step S526, the CPU 102 may select a single powder coating system from the plurality of powder coating systems that is to be used to coat the object based on the powder coating system performance parameter of each of the plurality of powder coating systems, and provide this selected single powder coating system in the evaluation output. In an example whereby a first environmental emissions powder coating system performance parameter is determined at step S514 for coating system A, and a second environmental emissions powder coating system performance parameter is determined at step S524 for coating system B (which is higher than the first environmental emissions powder coating system performance parameter indicating that more environmental emissions will be produced when using coating system B), at step S526 the CPU 102 may select coating system A and provide coating system A in the evaluation output. The required quantity of the powder coatings of the selected coating system may be determined using methods described herein and included in the evaluation output. Alternatively, at step S526, the CPU 102 may assign a ranking value to each of the plurality of powder coating systems being evaluated based on the powder coating system performance parameter of each of the plurality of powder coating systems. The evaluation output may comprise the plurality of powder coating systems (e.g. identified by their unique identifier) and the ranking values associated with each of the plurality of 14567648-1
powder coating systems. For example, when the evaluation output is transmitted to a display of the computing device 100, the evaluation output may comprise a list of the plurality of powder coating systems with an indication of the ranking value assigned to each of the plurality of powder coating systems. The plurality of powder coatings may be arranged in the list in an order dependent on their ranking values. In an example whereby a first environmental emissions powder coating system performance parameter is determined at step S514 for coating system A, and a second environmental emissions powder coating system performance parameter is determined at step S524 for coating system B (which is higher than the first environmental emissions powder coating system performance parameter indicating that more environmental emissions will be produced when using coating system B), at step S526 the CPU 102 may output a list comprising the unique identifier of coating system A and the unique identifier of coating system B in the evaluation output, with coating system A having a higher ranking value than coating system B. The list may be ordered so that coating system A appears at the top of the list above coating system B. The required quantity of the powder coatings of each of the plurality of coating systems may be determined using methods described herein and included in the evaluation output. Referring back to Figure 2, once the computer implemented powder coating evaluation method of Figure 5 has been performed at step S202, the method 200 further comprises a step S204 of a user selecting a powder coating system to apply to the object based on the evaluation output. That is, the user sources and/or supplies the powder coatings of the powder coating system from one or more location(s) to the oven, ready to be applied to the object. In implementations whereby a single powder coating system is included in the evaluation output, step S204 comprises the user selecting the powder coating system included in the evaluation output. In implementations whereby the evaluation output comprises the plurality of powder coating systems and a ranking value associated with each of the plurality of powder coating systems, step S204 may comprise the user selecting the powder coating system from the plurality of powder coating systems based on the ranking values (e.g. the powder coating system that has the highest ranking value). For example, coating the object with the powder coating system with the highest ranking value may result in the lowest energy usage. 14567648-1
At step S206, the method 200 further comprises applying the powder coatings of the selected powder coating system to the object. That is, step S206 comprises operating the oven such that the powder coatings of the selected powder coating system are applied to the object (in an order defined by selected powder coating system) thereby forming a coating film (of multiple layers) and thereby forming a coating on the object. Thus, at step S206 the object is coated with the powder coatings of the selected powder coating system. Configuring an oven for use in applying a powder coating to an object Figure 6 illustrates a method 600 of configuring an oven for use in applying a powder coating to an object As shown in Figure 6, at step S602 the method 600 comprises performing a computer implemented coating-dependent oven parameter determination method. The computer implemented coating-dependent oven parameter determination method may be performed by the computing device 100. In particular, the computer implemented coating-dependent oven parameter determination method performed at step S602 may be performed by the CPU 102. Figure 7 illustrates a computer implemented coating-dependent oven parameter determination method that is performed at step S602. At step S702, the CPU 102 receives a user selection of a powder coating. The user may select a powder coating using the input device 106. For example the user may select the powder coating from a plurality of powder coatings displayed to the user via a display. At step S704, the CPU 102 obtains one or more parameters of an object that is to be coated with the selected powder coating, examples of the object parameter(s) have been described herein. At step S706, the CPU 102 obtains one or more parameters of an oven that is to be used to apply the powder coating to the object, examples of the oven parameter(s) have been described herein. 14567648-1
At step S708, the CPU 102 obtains one or more parameters of the selected powder coating. Examples of the coating parameter(s) have been described herein. At step S710, the CPU 102 identifies one or more coating-dependent oven parameter to optimize at least one performance parameter. Examples of coating-dependent oven parameter(s) have been described herein. The performance parameter(s) may be any of those described herein. For example, the performance parameter(s) to be optimized may comprise one or more of: an energy usage performance parameter, a productivity performance parameter, and environmental emissions performance parameter. We refer to optimizing the energy usage performance parameter as minimizing the energy usage performance parameter i.e. determining the coating-dependent oven parameter(s) that minimize the energy usage performance parameter when applying the selected powder coating to the object. We refer to optimizing the productivity performance parameter as maximizing the productivity performance parameter i.e. determining the coating-dependent oven parameter(s) that maximize the productivity performance parameter when applying the selected powder coating to the object. We refer to optimizing the environmental emissions performance parameter as minimizing the environmental emissions performance parameter i.e. determining the coating-dependent oven parameter(s) that minimize the environmental emissions performance parameter when applying the selected powder coating to the object. In implementations where multiple performance parameters are to be optimized, the CPU 102 may compute an overall performance parameter Poverall using the coating- dependent oven parameter(s) and optimizing the overall performance parameter Poverall may comprise minimizing or maximizing the overall performance parameter Poverall. The performance parameter(s) to be optimized may be predetermined. Alternatively, the CPU 102 may receive a user selection of the performance parameter(s). The user may select the performance parameter(s) using the input device 106. 14567648-1
For each of the coating-dependent oven parameter(s) a range of values for the coating- dependent oven parameter is accessible to the CPU 102 e.g. stored in memory 104 or a remote storage location. In an example where line speed is used as coating-dependent oven parameter, a range of values from a minimum line speed value Line speedmin to a maximum line speed value Line speedmax would be accessible to the CPU 102. In an example where air temperature (Tair) of the air enclosed with the oven is used as coating-dependent oven parameter, a range of values from a minimum air temperature Tair, min to a maximum air temperature Tair, max would be accessible to the CPU 102. In an example whereby the CPU 102 is configured to identify a single coating-dependent oven parameter (e.g. line speed or air temperature (Tair) of the air enclosed with the oven) which will optimize at least one performance parameter, the CPU 102 would be configured with access to the allowed range of values for the coating-dependent oven parameter. In this example, at step S710 the CPU 102 is configured to vary the value of the coating- dependent oven parameter within the allowed range and compute the performance parameter for each of the values of the coating-dependent oven parameter using (i) the coating-dependent oven parameter (ii) one or more object parameter (which may be the same or different to the object parameter(s) used to compute the coating-dependent oven parameter), (iii) one or more oven parameter (which may be the same or different to the oven parameter(s) used to compute the coating-dependent oven parameter), and (iv) one or more coating parameter (which may be the same or different to the coating parameter(s) used to compute the coating-dependent oven parameter). In this example, at step S710 the CPU 102 is configured to identify the coating- dependent oven parameter value which optimizes the performance parameter(s), and the performance parameter(s) derived using the coating-dependent oven parameter value. For example, at step S710 the CPU 102 may vary line speed values (line speedi) in the allowed range, determine the corresponding energy usage performance parameter values Ereg,i, and identify the minimal energy usage performance parameter value in the set {Ereg,i} together with the optimal line speed value. 14567648-1
In an example whereby the CPU 102 is configured to identify multiple coating-dependent oven parameters (e.g. line speed and air temperature (Tair) of the air enclosed with the oven) which will optimize at least one performance parameter, the CPU 102 would be configured with access to the allowed range of values for each the coating-dependent oven parameters, a functional dependency between the multiple coating-dependent oven parameters. The functional dependency may be stored in memory 104 or a remote storage location. In an example whereby the CPU 102 is configured to identify multiple coating-dependent oven parameters (e.g. line speed and air temperature (Tair) of the air enclosed with the oven) which will optimize at least one performance parameter, the CPU 102 would be configured with access to the allowed range of values for each the coating-dependent oven parameters, a functional dependency between the multiple coating-dependent oven parameters. The functional dependency may be stored in memory 104 or a remote storage location. For example whereby the CPU 102 is configured to determine the line speed and air temperature which will optimize an energy usage performance parameter, the CPU 102 would be configured with access to a functional dependency between the line speed and air temperature i.e.: Tair = f(line speed) In this example, at step S710 the CPU 102 is configured to vary the values of the coating- dependent oven parameter within the allowed ranges and according to the functional dependency between them, and compute the performance parameter for the values of the coating-dependent oven parameters using (i) the coating-dependent oven parameters (ii) one or more object parameter (which may be the same or different to the object parameter(s) used to compute the coating-dependent oven parameters), (iii) one or more oven parameter (which may be the same or different to the oven parameter(s) used to compute the coating-dependent oven parameters), and (iv) one or more coating parameters (which may be the same or different to the coating parameter(s) used to compute the coating-dependent oven parameters). In this example, at step S710 the CPU 102 is configured to identify the coating- dependent oven parameter values which optimizes the performance parameter(s), the 14567648-1
performance parameter(s) derived using the coating-dependent oven parameter values. For example, at step S710 the CPU 102 may vary the air temperature and line speed values in the allowed ranges and according to the functional dependency between them, and determine the corresponding energy usage performance parameter values Ereg,i, and identify the minimal energy usage performance parameter in the set {Ereg,i} together with the optimal air temperature Tair and line speed value. At step S712, the CPU 102 outputs the one or more coating-dependent oven parameter values which optimizes the performance parameter(s). The CPU 102 may additionally output the values of the performance parameter(s) associated with the one or more coating-dependent oven parameter values which optimizes the performance parameter(s). The CPU 102 may provide this output to a user of the computing device 100 via the output device 108. For example, the CPU 102 may transmit the one or more coating- dependent oven parameters (and optionally the performance parameter(s) associated with the one or more coating-dependent oven parameter values) to a display of the computing device 100. Referring back to Figure 6, once the computer implemented coating-dependent oven parameter determination method of Figure 7 has been performed at step S602, the method 600 further comprises a step S604 of a user configuring the oven using the one or more coating-dependent oven parameters which optimizes the performance parameter(s). For example, step S604 may comprise the user configuring the oven by controlling a line speed, an air temperature (Tair) of the air enclosed with the oven, and/or one or more settings of a spray gun of the oven. Figure 8 illustrates a method 800 of configuring an oven for use in applying a powder coating to an object. As shown in Figure 8, at step S802 the method 800 comprises performing a computer implemented oven parameter evaluation method. The computer implemented oven parameter evaluation method may be performed by the computing device 100. In 14567648-1
particular, the computer implemented oven parameter evaluation method performed at step S802 may be performed by the CPU 102. Figure 9 illustrates a computer implemented coating-dependent oven parameter evaluation method that is performed at step S802. At step S902, the CPU 102 receives a user selection of a powder coating. The user may select a powder coating using the input device 106. For example the user may select the powder coating from a plurality of powder coatings displayed to the user via a display. At step S903, the CPU 102 obtains a set of parameters. As part of step S903, at step S904, the CPU 102 obtains one or more parameters of an object that is to be coated with the selected powder coating, examples of the object parameter(s) have been described herein. As part of step S903, at step S906, the CPU 102 obtains one or more parameters of an oven that is to be used to apply the powder coating to the object, examples of the oven parameter(s) have been described herein. As part of step S903, at step S908, the CPU 102 obtains one or more parameters of the selected powder coating. Examples of the coating parameter(s) have been described herein. Thus the set of parameters obtained at step S903 comprises the at least one object parameter obtained at step S904, the at least one oven parameter obtained at step S906, and the at least one coating parameter obtained at step S908. At step S910, the CPU 102 receives a user selection of at least one coating-dependent oven parameter. Examples of coating-dependent oven parameter(s) have been described herein. The user may select a powder coating using the input device 106. At step S912, the CPU 102 determines at least one performance parameter using the set of parameters obtained at step S903 and the at least one user selected coating- dependent oven parameter. In particular, at step S910 the CPU 102 determines the at least one performance parameter using (i) the at least one coating-dependent oven parameter (ii) the object parameter(s), (iii) the oven parameter(s), and (iv) the coating parameter(s). The performance parameter(s) may be any of those described herein. For example, the performance parameter(s) may comprise one or more of: an energy usage performance parameter, a productivity performance parameter, and environmental emissions 14567648-1
performance parameter. At step S912, the CPU 102 may determine the at least one performance parameter according to any of the methods described herein. At step S914, the CPU 102 outputs the at least one performance parameter. The CPU 102 may additionally output the at least one coating-dependent oven parameter in association with the at least one performance parameter e.g. indicating that the performance parameter will be achieved if the oven is configured with the at least one coating-dependent oven parameter. The CPU 102 may provide this output to a user of the computing device 100 via the output device 108. For example, the CPU 102 may transmit the at least one performance parameter (and optionally the at least one coating-dependent oven parameter) to a display of the computing device 100. As shown in Figure 9, the computer implemented oven parameter evaluation method may loop back to step S910 where the CPU 102 receives a further user selection of at least one coating-dependent oven parameter. Thus, step S912 may be performed again such that the CPU 102 determines at least one performance parameter using the set of parameters obtained at step S903 and the at least one further user selected coating- dependent oven parameter. Taking the example whereby the coating-dependent oven parameter is a line speed, the computer implemented coating-dependent oven parameter evaluation method enables a user to select different values of the line speed (at each time step S910 is performed) and to be presented with at least one performance parameter associated with using the different values of the line speed. Referring back to Figure 8, once the computer implemented coating-dependent oven parameter evaluation method of Figure 9 has been performed at step S802, the method 800 further comprises a step S804 of a user configuring the oven using coating- dependent oven parameters selected by the user at step S910. In particular, the computer implemented coating-dependent oven parameter evaluation method performed at step S802 enables a user to determine values of the at least one coating- dependent oven parameter which optimize the performance parameter(s). 14567648-1
Step S804 may comprise the user configuring the oven by controlling a line speed, an air temperature (Tair) of the air enclosed with the oven, and/or one or more settings of a spray gun of the oven. When referring herein to the CPU 102 determining a parameter (e.g. a performance parameter and/or or a coating-dependent oven parameter) this refers to the CPU 102 determining a value of the parameter. Similarly, when referring herein to the CPU 102 receiving a user selection of parameter (e.g. a performance parameter and/or or a coating-dependent oven parameter) this refers to the CPU 102 receiving a user selection of a value of the parameter. When referring herein to the CPU 102 outputting a parameter (e.g. a performance parameter and/or or a coating-dependent oven parameter) this refers to the CPU 102 outputting a value of the parameter. Other aspects of the present disclosure can be defined by the following clauses. A1. A method of configuring an oven for use in applying a powder coating to an object, the method comprising: performing a computer implemented coating-dependent oven parameter determination method comprising: receiving a user selection of a powder coating; obtaining at least one oven parameter associated with the oven; obtaining at least one coating parameter associated with the powder coating; obtaining at least one object parameter associated with the object; identifying at least one coating-dependent oven parameter that optimizes at least one performance parameter that is determined using (i) the at least one coating-dependent oven parameter (ii) one or more of the at least one object parameter, (iii) one or more of the at least one oven parameter, and (iv) one or more of the at least one coating parameter; and outputting the at least one coating-dependent oven parameter; wherein the method further comprises: 14567648-1
configuring the oven using the at least one coating dependent oven parameter. A2. The method of clause A1, wherein the at least one object parameter comprises one or any combination of: a type of material of the object, a material thickness of the object, an object type of the object, a surface area of the object to be coated, a target thickness of the powder coating at one or more surface areas of the object, a mass of the object, a coating scheme for the object, and a surface preparation of the object. A3. The method of clause A1 or A2, wherein the at least one oven parameter comprises one or any combination of: a heating mechanism type of the oven, a design type of the oven, an energy source of the oven, a material of the oven, one or more dimensions of the oven, a heat transfer type of the oven, one or more settings of a component of the oven, a material of a component of the oven, and a mass of a component of the oven. A4. The method of any of clauses A1-A3, wherein the at least one coating parameter comprises one or any combination of: a temperature to be used in the oven when applying the powder coating, a coating thickness of the powder coating, a specific gravity of the powder coating, and a particle size distribution of the powder coating. A5. The method of any of clauses A1-A4, wherein the at least one coating-dependent oven parameter comprises one or any combination of: a temperature of air enclosed with the oven, a line speed of the oven, one or more settings of a component of the oven. A6. The method of any of clauses A1-A5, wherein the computer implemented coating-dependent oven parameter determination method further comprises: receiving a user selection of the at least one performance parameter. A7. The method of any of clauses A1-A6, wherein the computer implemented coating-dependent oven parameter determination method further comprises: determining each of the at least one performance parameter based on: (i) the at least one coating-dependent oven parameter (ii) one or more of the at least one object parameter, (iii) one or more of the at least one oven parameter, and (iv) one or more of the at least one coating parameter. 14567648-1
A8. The method of any of clauses A1-A7, wherein the computer implemented coating-dependent oven parameter determination method further comprises: outputting the at least one performance parameter that is optimized using the at least one coating-dependent oven parameter. A9. The method of any of clauses A1-A8, wherein the at least one performance parameter comprises an energy usage performance parameter indicating the energy required to apply the powder coating to the object when using the at least one coating- dependent oven parameter. A10. The method of clause A9, wherein determining the energy usage performance parameter comprises: determining an energy required to heat the oven using: one or more of the at least one oven parameter, and one or more of the at least one coating parameter; determining an energy required to heat the object using: one or more of the at least one object parameter, one or more of the at least one oven parameter, and one or more of the at least one coating parameter; determining energy losses due to heat loss of air used for heating the object using: one or more of the at least one oven parameter, and one or more of the at least one coating parameter; and determining the energy usage performance parameter by summing the energy required to heat the oven, the energy required to heat the object; and the energy losses. A11. The method of any of clauses A1-A10, wherein the at least one performance parameter comprises an environmental emissions performance parameter indicating the environmental emissions that will result from the use of the at least one coating- dependent oven parameter when applying the powder coating to the object. A12. The method of clause A11, wherein determining the environmental emissions performance parameter comprises: determining an energy usage performance parameter indicating the energy required to apply the powder coating to the object based on: (i) one or more of the at least one object parameter, (ii) one or more of the at least one oven parameter, and (iii) one or more of the at least one coating parameter; and 14567648-1
converting the energy usage performance parameter into the environmental emissions performance parameter. A13. The method of clause A11, wherein the determining the environmental emissions performance parameter comprises: determining an energy usage performance parameter indicating the energy required to apply the powder coating to the object based on: (i) one or more of the at least one object parameter, (ii) one or more of the at least one oven parameter, and (iii) one or more of the at least one coating parameter; determining a quantity of the powder coating required to coat the object based on one or more of the at least one object parameter, and one or more of the at least one coating parameter; and determining the environmental emissions performance parameter using the energy usage performance parameter and the quantity of the powder coating. A14. The method of any of clauses A1-A13, wherein the at least one performance parameter comprises a productivity performance parameter indicating the productivity of the oven that will result from the use of the at least one coating-dependent oven parameter when applying the powder coating to the object. A15. The method of clause A14, wherein the computer implemented coating- dependent oven parameter determination method comprises determining the productivity performance parameter using a coating process speed and conversion factor which converts the coating process speed into the productivity performance parameter. A16. The method of clause A15, wherein the computer implemented coating- dependent oven parameter determination method comprises determining the coating process speed using: one or more of the at least one object parameter, one or more of the at least one oven parameter, and one or more of the at least one coating parameter. A17. The method of any of clauses A1-A16, wherein said identifying identifies a single coating-dependent oven parameter that optimizes the at least one performance parameter, the computer implemented coating-dependent oven parameter determination method comprises: 14567648-1
varying a value of the coating-dependent oven parameter within a range and determining the performance parameter for each of the values of the coating-dependent oven parameter. A18. The method of any of clauses A1-A16, wherein said identifying identifies a multiple coating-dependent oven parameters that optimize the at least one performance parameter, the computer implemented coating-dependent oven parameter determination method comprises: varying a value of each of the multiple coating-dependent oven parameters within a range associated with the coating-dependent oven parameter, and according to a functional dependency between the multiple coating-dependent oven parameters; and determining the performance parameter for each of the values of the multiple coating-dependent oven parameters A19. A non-transitory computer-readable storage medium comprising instructions which, when executed by a processor of a computing device, cause the processor to perform the computer implemented coating-dependent oven parameter determination method of any of clauses A1-A18. A20. A computing device comprising a processor configured to perform the computer implemented coating-dependent oven parameter determination method of any of any of clauses A1-A18. B1. A method of configuring an oven for use in applying a powder coating to an object, the method comprising: performing a computer implemented oven parameter evaluation method comprising: receiving a user selection of a powder coating; obtaining a set of parameters, the set of parameters comprising: at least one object parameter associated with the object, at least one oven parameter associated with the oven, at least one coating parameter associated with the powder coating; receiving a user selection of at least one coating-dependent oven parameter; 14567648-1
determining at least one performance parameter associated with applying the powder coating to the object using the set of parameters and the at least one coating-dependent oven parameter; and outputting the at least one performance parameter; wherein the method further comprises: configuring the oven using the at least one coating-dependent oven parameter. B2. The method of clause B1, wherein the at least one object parameter comprises one or any combination of: a type of material of the object, a material thickness of the object, an object type of the object, a surface area of the object to be coated, a target thickness of the powder coating at one or more surface areas of the object, a mass of the object, a coating scheme for the object, and a surface preparation of the object. B3. The method of clause B1 or B2, wherein the at least one oven parameter comprises one or any combination of: a heating mechanism type of the oven, a design type of the oven, an energy source of the oven, a material of the oven, one or more dimensions of the oven, a heat transfer type of the oven, one or more settings of a component of the oven, a material of a component of the oven, and a mass of a component of the oven. B4. The method of any clauses B1-B3, wherein the at least one coating parameter comprises one or any combination of: a temperature to be used in an oven when applying the powder coating, a coating thickness of the powder coating, a specific gravity of the powder coating, and a particle size distribution of the powder coating. B5. The method of any clauses B1-B4, wherein the at least one coating-dependent oven parameter comprises one or any combination of: a temperature of air enclosed with the oven, a line speed of the oven, one or more settings of a component of the oven. B6. The method of any clauses B1-B5, wherein the at least one performance parameter comprises an energy usage performance parameter indicating the energy required to apply the powder coating to the object when using the at least one coating- dependent oven parameter. 14567648-1
B7. The method of clause B6, wherein determining the energy usage performance parameter comprises: determining an energy required to heat the oven using: one or more of the at least one oven parameter, and one or more of the at least one coating parameter; determining an energy required to heat the object using: one or more of the at least one object parameter, one or more of the at least one oven parameter, and one or more of the at least one coating parameter; determining energy losses due to heat loss of air used for heating the object using: one or more of the at least one oven parameter, and one or more of the at least one coating parameter; and determining the energy usage performance parameter by summing the energy required to heat the oven, the energy required to heat the object; and the energy losses. B8. The method of any clauses B1-B7, wherein the at least one performance parameter comprises an environmental emissions performance parameter indicating the environmental emissions that will result from the use of the at least one coating- dependent oven parameter when applying the powder coating to the object. B9. The method of clause B8, wherein determining the environmental emissions performance parameter comprises: determining an energy usage performance parameter indicating the energy required to apply the powder coating to the object based on: (i) one or more of the at least one object parameter, (ii) one or more of the at least one oven parameter, and (iii) one or more of the at least one coating parameter; and converting the energy usage performance parameter into the environmental emissions performance parameter. B10. The method of clause B8, wherein the determining the environmental emissions performance parameter comprises: determining an energy usage performance parameter indicating the energy required to apply the powder coating to the object based on: (i) one or more of the at least one object parameter, (ii) one or more of the at least one oven parameter, and (iii) one or more of the at least one coating parameter; 14567648-1
determining a quantity of the powder coating required to coat the object based on one or more of the at least one object parameter, and one or more of the at least one coating parameter; and determining the environmental emissions performance parameter using the energy usage performance parameter and the quantity of the powder coating. B11. The method of any clauses B1-B10, wherein the at least one performance parameter comprises a productivity performance parameter indicating the productivity of the oven that will result from the use of the at least one coating-dependent oven parameter when applying the powder coating to the object. B12. The method of clause B11, wherein the computer implemented oven parameter evaluation method comprises determining the productivity performance parameter using a coating process speed and conversion factor which converts the coating process speed into the productivity performance parameter. B13. The method of clause B12, wherein the computer implemented oven parameter evaluation method comprises determining the coating process speed using: one or more of the at least one object parameter, one or more of the at least one oven parameter, and one or more of the at least one coating parameter. B14. The method of any clauses B1-B13, wherein the computer implemented oven parameter evaluation method further comprises outputting the at least one coating- dependent oven parameter in association with the at least one performance parameter. B15. A non-transitory computer-readable storage medium comprising instructions which, when executed by a processor of a computing device, cause the processor to perform the computer implemented oven parameter evaluation method of any clauses B1-B14. B16. A computing device comprising a processor configured to perform the computer implemented oven parameter evaluation method of any of clauses B1 to B14. While the present disclosure has been particularly shown and described with reference to preferred embodiments, it will be understood to those skilled in the art that various 14567648-1
changes in form and detail may be made without departing from the scope of the present disclosure as defined by the appendant claims. 14567648-1
Claims
4. The method of any preceding claim, wherein the at least one coating parameter comprises one or any combination of: a temperature to be used in an oven when applying the powder coating, a coating thickness of the powder coating, a specific gravity of the powder coating, and a particle size distribution of the powder coating. 5. The method of any preceding claim, wherein determining one or more the at least one performance parameter comprises: determining at least one coating-dependent oven parameter using (i) one or more of the at least one oven parameter and (ii) one or more of the at least one coating parameter; and determining the performance parameter is further based on the at least one coating-dependent oven parameter. 6. The method of claim 5, wherein the at least one coating-dependent oven parameter comprises one or any combination of: a temperature of air enclosed with the oven, a line speed of the oven, and one or more settings of a component of the oven. 7. The method of claim 5 or 6, wherein the determining the at least one coating- dependent oven parameter is further based on one or more of the at least one object parameter. 8. The method of any preceding claim, wherein the at least one performance parameter comprises an energy usage performance parameter indicating the energy required to apply the powder coating to the object. 9. The method of claim 8, wherein the determining the energy usage performance parameter comprises: determining an energy required to heat the oven using: one or more of the at least one oven parameter, and one or more of the at least one coating parameter; determining an energy required to heat the object using: one or more of the at least one object parameter, one or more of the at least one oven parameter, and one or more of the at least one coating parameter; determining energy losses due to heat loss of air used for heating the object using: one or more of the at least one oven parameter, and one or more of the at least one coating parameter; and 14567648-1
determining the energy usage performance parameter by summing the energy required to heat the oven, the energy required to heat the object; and the energy losses. 10. The method of any preceding claim, wherein the at least one performance parameter comprises a productivity performance parameter indicating the productivity of the oven when applying the powder coating to the object. 11. The method of claim 10, wherein the computer implemented powder coating evaluation method comprises determining the productivity performance parameter using a coating process speed and conversion factor which converts the coating process speed into the productivity performance parameter. 12. The method of claim 11, wherein the method comprises determining the coating process speed using: one or more of the at least one object parameter, one or more of the at least one oven parameter, and one or more of the at least one coating parameter. 13. The method of any preceding claim, wherein the at least one performance parameter comprises an environmental emissions performance parameter indicating the environmental emissions that will result from applying the powder coating to the object. 14. The method of claim 13, wherein the determining the environmental emissions performance parameter comprises: determining an energy usage performance parameter indicating the energy required to apply the powder coating to the object based on: (i) one or more of the at least one object parameter, (ii) one or more of the at least one oven parameter, and (iii) one or more of the at least one coating parameter; and converting the energy usage performance parameter into the environmental emissions performance parameter 15. The method of claim 13, wherein the determining the environmental emissions performance parameter comprises: determining an energy usage performance parameter indicating the energy required to apply the powder coating to the object based on: (i) one or more of the at least one object parameter, (ii) one or more of the at least one oven parameter, and (iii) one or more of the at least one coating parameter; 14567648-1
determining a quantity of the powder coating required to coat the object based on one or more of the at least one object parameter, and one or more of the at least one coating parameter; and determining the environmental emissions performance parameter using the energy usage performance parameter and the quantity of the powder coating. 16. The method of claim 15, further comprising including the quantity of the powder coating of one or more of the plurality of powder coatings in the evaluation output. 17. The method of any of claims 1 to 14, wherein the computer implemented powder coating evaluation method further comprises, for each of the plurality of powder coatings: determining a quantity of the powder coating required to coat the object based on one or more of the at least one object parameter and one or more of the at least one coating parameter; and including the quantity of the powder coating of one or more of the plurality of powder coatings in the evaluation output. 18. The method of claim 17, wherein the determining a quantity of the powder coating required to coat the object is further based on: a powder coating loss parameter indicating an amount of the powder coating that becomes surplus during applying the powder coating to the object that cannot be captured from within the oven and reused in applying the powder coating to the object. 19. The method of any preceding claim, wherein the computer implemented powder coating evaluation method further comprises: selecting a powder coating from the plurality of powder coatings based on the at least one performance parameter of each of the plurality of powder coatings, wherein the evaluation output comprises the selected powder coating. 20. The method of any of claims 1 to 18, wherein the computer implemented powder coating evaluation method further comprises: assigning a ranking value to each of the plurality of powder coatings based on the at least one performance parameter of each of the plurality of powder coatings; wherein the evaluation output comprises the plurality of powder coatings and the ranking values associated with each of the plurality of powder coatings. 14567648-1
21. A non-transitory computer-readable storage medium comprising instructions which, when executed by a processor of a computing device, cause the processor to perform the computer implemented powder coating evaluation method of any preceding claim. 22. A computing device comprising a processor configured to perform the computer implemented powder coating evaluation method of any of claims 1 to 20. 23. A method of applying a powder coating system to an object, the method comprising: performing a computer implemented powder coating system evaluation method comprising: obtaining at least one object parameter associated with the object; obtaining at least one oven parameter associated with an oven to be used to apply the powder coating to an object; for each of a plurality of powder coating systems: for each of a plurality of powder coatings of the powder coating system: obtaining at least one coating parameter associated with the powder coating; determining at least one performance parameter associated with applying the powder coating to the object, wherein determining each of the at least one performance parameter is based on: (i) one or more of the at least one object parameter, (ii) one or more of the at least one oven parameter, and (iii) one or more of the at least one coating parameter; determining a powder coating system performance parameter of the powder coating system based on the at least one performance parameter of each of the plurality of powder coatings of the powder coating system; providing an evaluation output based on the powder coating system performance parameter of each of the plurality of powder coating systems; wherein the method further comprises: selecting a powder coating system based on the evaluation output; and 14567648-1
applying the plurality of powder coatings of the selected powder coating system to the object. 24. A non-transitory computer-readable storage medium comprising instructions which, when executed by a processor of a computing device, cause the processor to perform the computer implemented powder coating system evaluation method of claim 23. 25. A computing device comprising a processor configured to perform the computer implemented powder coating system evaluation method of claim 23. 26. A method of configuring an oven for use in applying a powder coating to an object, the method comprising: performing a computer implemented coating-dependent oven parameter determination method comprising: receiving a user selection of a powder coating; obtaining at least one oven parameter associated with the oven; obtaining at least one coating parameter associated with the powder coating; obtaining at least one object parameter associated with the object; identifying at least one coating-dependent oven parameter that optimizes at least one performance parameter that is determined using (i) the at least one coating-dependent oven parameter (ii) one or more of the at least one object parameter, (iii) one or more of the at least one oven parameter, and (iv) one or more of the at least one coating parameter; and outputting the at least one coating-dependent oven parameter; wherein the method further comprises: configuring the oven using the at least one coating dependent oven parameter. 27. The method of claim 26, wherein the at least one object parameter comprises one or any combination of: a type of material of the object, a material thickness of the object, an object type of the object, a surface area of the object to be coated, a target thickness of the powder coating at one or more surface areas of the object, a mass of the object, a coating scheme for the object, and a surface preparation of the object. 14567648-1
28. The method of claim 26 or 27, wherein the at least one oven parameter comprises one or any combination of: a heating mechanism type of the oven, a design type of the oven, an energy source of the oven, a material of the oven, one or more dimensions of the oven, a heat transfer type of the oven, one or more settings of a component of the oven, a material of a component of the oven, and a mass of a component of the oven. 29. The method of any of claims 26-28, wherein the at least one coating parameter comprises one or any combination of: a temperature to be used in the oven when applying the powder coating, a coating thickness of the powder coating, a specific gravity of the powder coating, and a particle size distribution of the powder coating. 30. The method of any of claims 26-29, wherein the at least one coating-dependent oven parameter comprises one or any combination of: a temperature of air enclosed with the oven, a line speed of the oven, one or more settings of a component of the oven. 31. The method of any of claims 26-30, wherein the computer implemented coating- dependent oven parameter determination method further comprises: receiving a user selection of the at least one performance parameter. 32. The method of any of claims 26-31, wherein the computer implemented coating- dependent oven parameter determination method further comprises: determining each of the at least one performance parameter based on: (i) the at least one coating-dependent oven parameter (ii) one or more of the at least one object parameter, (iii) one or more of the at least one oven parameter, and (iv) one or more of the at least one coating parameter. 33. The method of any of claims 26-32, wherein the computer implemented coating- dependent oven parameter determination method further comprises: outputting the at least one performance parameter that is optimized using the at least one coating-dependent oven parameter. 34. The method of any of claims 26-33, wherein the at least one performance parameter comprises an energy usage performance parameter indicating the energy required to apply the powder coating to the object when using the at least one coating- dependent oven parameter. 14567648-1
35. The method of claim 34, wherein determining the energy usage performance parameter comprises: determining an energy required to heat the oven using: one or more of the at least one oven parameter, and one or more of the at least one coating parameter; determining an energy required to heat the object using: one or more of the at least one object parameter, one or more of the at least one oven parameter, and one or more of the at least one coating parameter; determining energy losses due to heat loss of air used for heating the object using: one or more of the at least one oven parameter, and one or more of the at least one coating parameter; and determining the energy usage performance parameter by summing the energy required to heat the oven, the energy required to heat the object; and the energy losses. 36. The method of any of claims 26-35, wherein the at least one performance parameter comprises an environmental emissions performance parameter indicating the environmental emissions that will result from the use of the at least one coating- dependent oven parameter when applying the powder coating to the object. 37. The method of claim 36, wherein determining the environmental emissions performance parameter comprises: determining an energy usage performance parameter indicating the energy required to apply the powder coating to the object based on: (i) one or more of the at least one object parameter, (ii) one or more of the at least one oven parameter, and (iii) one or more of the at least one coating parameter; and converting the energy usage performance parameter into the environmental emissions performance parameter. 38. The method of claim 36, wherein the determining the environmental emissions performance parameter comprises: determining an energy usage performance parameter indicating the energy required to apply the powder coating to the object based on: (i) one or more of the at least one object parameter, (ii) one or more of the at least one oven parameter, and (iii) one or more of the at least one coating parameter; 14567648-1
determining a quantity of the powder coating required to coat the object based on one or more of the at least one object parameter, and one or more of the at least one coating parameter; and determining the environmental emissions performance parameter using the energy usage performance parameter and the quantity of the powder coating. 39. The method of any of claims 26-38, wherein the at least one performance parameter comprises a productivity performance parameter indicating the productivity of the oven that will result from the use of the at least one coating-dependent oven parameter when applying the powder coating to the object. 40. The method of claim 39, wherein the computer implemented coating-dependent oven parameter determination method comprises determining the productivity performance parameter using a coating process speed and conversion factor which converts the coating process speed into the productivity performance parameter. 41. The method of claim 40, wherein the computer implemented coating-dependent oven parameter determination method comprises determining the coating process speed using: one or more of the at least one object parameter, one or more of the at least one oven parameter, and one or more of the at least one coating parameter. 42. The method of any of claims 26-41, wherein said identifying identifies a single coating-dependent oven parameter that optimizes the at least one performance parameter, the computer implemented coating-dependent oven parameter determination method comprises: varying a value of the coating-dependent oven parameter within a range and determining the performance parameter for each of the values of the coating-dependent oven parameter. 43. The method of any of claims 26-41, wherein said identifying identifies a multiple coating-dependent oven parameters that optimize the at least one performance parameter, the computer implemented coating-dependent oven parameter determination method comprises: 14567648-1
varying a value of each of the multiple coating-dependent oven parameters within a range associated with the coating-dependent oven parameter, and according to a functional dependency between the multiple coating-dependent oven parameters; and determining the performance parameter for each of the values of the multiple coating-dependent oven parameters 44. A non-transitory computer-readable storage medium comprising instructions which, when executed by a processor of a computing device, cause the processor to perform the computer implemented coating-dependent oven parameter determination method of any of claims 26-43. 45. A computing device comprising a processor configured to perform the computer implemented coating-dependent oven parameter determination method of any of any of claims 26-43. 46. A method of configuring an oven for use in applying a powder coating to an object, the method comprising: performing a computer implemented oven parameter evaluation method comprising: receiving a user selection of a powder coating; obtaining a set of parameters, the set of parameters comprising: at least one object parameter associated with the object, at least one oven parameter associated with the oven, at least one coating parameter associated with the powder coating; receiving a user selection of at least one coating-dependent oven parameter; determining at least one performance parameter associated with applying the powder coating to the object using the set of parameters and the at least one coating-dependent oven parameter; and outputting the at least one performance parameter; wherein the method further comprises: configuring the oven using the at least one coating-dependent oven parameter. 14567648-1
47. The method of claim 46, wherein the at least one object parameter comprises one or any combination of: a type of material of the object, a material thickness of the object, an object type of the object, a surface area of the object to be coated, a target thickness of the powder coating at one or more surface areas of the object, a mass of the object, a coating scheme for the object, and a surface preparation of the object. 48. The method of claim 46 or 47, wherein the at least one oven parameter comprises one or any combination of: a heating mechanism type of the oven, a design type of the oven, an energy source of the oven, a material of the oven, one or more dimensions of the oven, a heat transfer type of the oven, one or more settings of a component of the oven, a material of a component of the oven, and a mass of a component of the oven. 49. The method of any claims 46-48, wherein the at least one coating parameter comprises one or any combination of: a temperature to be used in an oven when applying the powder coating, a coating thickness of the powder coating, a specific gravity of the powder coating, and a particle size distribution of the powder coating. 50. The method of any claims 46-49, wherein the at least one coating-dependent oven parameter comprises one or any combination of: a temperature of air enclosed with the oven, a line speed of the oven, one or more settings of a component of the oven. 51. The method of any claims 46-50, wherein the at least one performance parameter comprises an energy usage performance parameter indicating the energy required to apply the powder coating to the object when using the at least one coating-dependent oven parameter. 52. The method of claim 51, wherein determining the energy usage performance parameter comprises: determining an energy required to heat the oven using: one or more of the at least one oven parameter, and one or more of the at least one coating parameter; determining an energy required to heat the object using: one or more of the at least one object parameter, one or more of the at least one oven parameter, and one or more of the at least one coating parameter; 14567648-1
determining energy losses due to heat loss of air used for heating the object using: one or more of the at least one oven parameter, and one or more of the at least one coating parameter; and determining the energy usage performance parameter by summing the energy required to heat the oven, the energy required to heat the object; and the energy losses. 53. The method of any claims 46-52, wherein the at least one performance parameter comprises an environmental emissions performance parameter indicating the environmental emissions that will result from the use of the at least one coating- dependent oven parameter when applying the powder coating to the object. 54. The method of claim 53, wherein determining the environmental emissions performance parameter comprises: determining an energy usage performance parameter indicating the energy required to apply the powder coating to the object based on: (i) one or more of the at least one object parameter, (ii) one or more of the at least one oven parameter, and (iii) one or more of the at least one coating parameter; and converting the energy usage performance parameter into the environmental emissions performance parameter. 55. The method of claim 53, wherein the determining the environmental emissions performance parameter comprises: determining an energy usage performance parameter indicating the energy required to apply the powder coating to the object based on: (i) one or more of the at least one object parameter, (ii) one or more of the at least one oven parameter, and (iii) one or more of the at least one coating parameter; determining a quantity of the powder coating required to coat the object based on one or more of the at least one object parameter, and one or more of the at least one coating parameter; and determining the environmental emissions performance parameter using the energy usage performance parameter and the quantity of the powder coating. 56. The method of any claims 46-55, wherein the at least one performance parameter comprises a productivity performance parameter indicating the productivity of the oven 14567648-1
that will result from the use of the at least one coating-dependent oven parameter when applying the powder coating to the object. 57. The method of claim 56, wherein the computer implemented oven parameter evaluation method comprises determining the productivity performance parameter using a coating process speed and conversion factor which converts the coating process speed into the productivity performance parameter. 58. The method of claim 57, wherein the computer implemented oven parameter evaluation method comprises determining the coating process speed using: one or more of the at least one object parameter, one or more of the at least one oven parameter, and one or more of the at least one coating parameter. 59. The method of any claims 46-58, wherein the computer implemented oven parameter evaluation method further comprises outputting the at least one coating- dependent oven parameter in association with the at least one performance parameter. 60. A non-transitory computer-readable storage medium comprising instructions which, when executed by a processor of a computing device, cause the processor to perform the computer implemented oven parameter evaluation method of any claims 46- 59. 61. A computing device comprising a processor configured to perform the computer implemented oven parameter evaluation method of any of claims 46-59. 14567648-1
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GBGB2403042.1A GB202403042D0 (en) | 2024-03-01 | 2024-03-01 | Powder coating composition selection and application |
| GB2403042.1 | 2024-03-01 |
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| WO2025181363A1 true WO2025181363A1 (en) | 2025-09-04 |
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| WO2012110451A1 (en) | 2011-02-14 | 2012-08-23 | Jotun Powder Coatings (N) As | Powder coating |
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-
2024
- 2024-03-01 GB GBGB2403042.1A patent/GB202403042D0/en not_active Ceased
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- 2025-02-28 WO PCT/EP2025/055576 patent/WO2025181363A1/en active Pending
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| WO2012110451A1 (en) | 2011-02-14 | 2012-08-23 | Jotun Powder Coatings (N) As | Powder coating |
| WO2015063024A1 (en) | 2013-10-30 | 2015-05-07 | Akzo Nobel Coatings International B.V. | Powder coating composition |
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| GB202403042D0 (en) | 2024-04-17 |
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