Challenge details:

In an automotive paint shop, the viscosity of paint is measured manually using a Ford cup at predetermined intervals. This process does not account for real-time variations in paint viscocity caused by changes in atmospheric temperature and humidity, which affects the overall paint finish quality.

The paint shop process involves several key steps: charging paint and compatible thinner, adjusting the paint to the desired application viscosity, and maintaining continuous stirring and circulation to ensure uniformity. Critical process parameters include:

• Viscosity: Metallic 15-17 sec; Solid/Surfacer/Clear 26-30 sec
• Paint Temperature: 25 ± 2 °C
• Supply Line Pressure: 5-7 Kg/cm²
• Return Line Flow: 3-5 GPM
• Supply Filter Pressure Differential (∆P): Max 2 Kg
• Electrical Resistivity: 1000 ± 500 µS
• Pump Strokes: 9-12 per minute

A real-time paint viscosity measurement and automatic control system is required for an automotive paint shop to maintain the quality of painting operations.