Well-equipped for use in snow and ice

World market leader Kässbohrer automates production of its PistenBully with painting robot from Dürr

Temperatures below freezing, sharp ice crystals, strong UV radiation: When used on slopes and cross-country skiing trails, the surfaces of cabs of vehicles for slope and trail preparation are subjected to the most extreme conditions. PistenBullys of Kässbohrer are recently painted by a robot from Dürr.

For the internationally leading manufacturer of specialist vehicles for slope preparation, automating the process means greater efficiency in production. The reason for this is that painting only takes half the time, as the robot applies paint much faster than a person can by hand. This reduces the exposure of employees to paint and solvents.

“The most the robot needs to paint a cab is an hour. Compared to previous painting by hand, this saves us so much time that we’ve been able to significantly increase our output to 600 cabs per year”, says Uwe Thierer, Plant Manager at Kässbohrer Geländefahrzeug AG’s Laupheim site (Germany).

Compared to previous painting by hand, this saves us so much time that we’ve been able to significantly increase our output to 600 cabs per year.

Uwe Thierer, Plant Manager at Kässbohrer Geländefahrzeug AG’s Laupheim site (Germany)

Reproducible quality

Apart from the speed, the robot’s uniform and reproducible quality ensures a high efficiency gain in the process. The paint layers are applied in a combination booth. First, the EcoRP L033 applies two primer layers as a bonding agent and corrosion protection wet-in-wet without drying in-between. The color changing and dosing technology integrated in the front robot arm ensures minimal paint losses when changing color as well as short rinsing times with minimal solvent consumption. This is followed by the intermediate drying stage before the third painting stage, the base coat as color application.

Dürr’s scope of delivery also includes the skid conveyor technology with turntable and tilt function. This ensures reproducible cab adjustment and correct positioning of the cab for the painting process. The robot paints the cab body fully and by applying two primer layers also looks after the corrosion protection. Five pressure pots for main color, hardener, and thinner are provided for the paint supply.

In the snow as on the beach

Kässbohrer Geländefahrzeug AG is a leading supplier of all-terrain vehicles for the environment, nature and recreation. The product range comprises four PistenBully models for ski slope and trail preparation, BeachTech machines for beach cleaning and various special vehicles for work and transport operations in normally impassable terrain - since 2014 with PowerBully for high payloads too.

With a market share of over 60 percent PistenBully is world leader in ski slope and trail preparation as well as in the design of amusement parks. Even the business area BeachTech advanced to number one on the world market.

(Source: Kässbohrer Geländefahrzeug AG)

The EcoRP L033 painting robot from Dürr coats the metal frames of the PistenBully from the outside and inside.

The robot applies the base coat.

PistenBully in action: Ice crystals and UV radiation can no longer harm the painted cab. (c) Kässbohrer Geländefahrzeug AG