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Catalytic Convertor

Catalytic converters largely neutralize carbon monoxide, nitrous oxides, hydrocarbon, and particulate matter from automobile exhaust.


Substrate Coating, Drying, & Calcining System

Project Videos

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Discover our turnkey Catalytic Converter Substrate Coating Solutions

Cybernetik’s Substrate Coating System for Catalytic Converters enables data traceability, high productivity, customized design, and safety for heavy duty trucks, passenger cars, and motorcycles.
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The future
of automation is here.

Capacity

Customizable

Market

Automobile

Applications

Catalytic converters installed in:

  • Heavy duty trucks
  • Passenger cars
  • Motorcycles

Highlights

  • Total traceability i.e. every operation on each part is inspected and the data noted down for real time supervision and control.
  • Online tracking & traceability via SCADA systems, inkjet printers, and barcode readers.
  • Recipe based management.
  • Calciner treatment at 6500C.
  • Tray dryer with upto 1200C temperature. 
  • Fast and accurate solution with robotic pick & place based on 2D vision.
  • Error-proofing through inline poka yoke complete with weighing conveyors, colour sensors, and dimension measurement mechanisms.
  • Sub systems:
    • Washcoat automation:
      • Premix tank
      • Brewing tank
      • Activation tank
    • Coating automation:
      • Passenger car standalone coating system
      • Motorcycle coating System
      • Heavy duty coating system 
    • Substrate handling & thermal processing automation: 
      • Dryer
      • Calciner
      • Robotic pick & place 
    • Quality Checks Automation:
      • Track & trace: Height sensor, pad printer, laser printer, barcode scanner.
      • Quality checks: Back pressure checking stations, weighing stations.

Heavy Duty Coating System

Project Video

Capacity

  • Customizable
  • Substrate size: 
    • Diameter: 75-450 mm
    • Height: 100-400 mm

Industry

Automobile

Applications

DPF and SCR catalytic converters installed in heavy duty trucks.

Highlights

  • Automatic and semi-automatic operation.
  • Process:
    • Pre weighing the substrate on the coating station before it is coated. 
    • Coating of one substrate at a time:
      • Is performed by a vacuum based substrate coating system (coater) which moves slurry from bottom to top of the substrate (converter) after dipping the latter to the prescribed depth in a recirculating slurry tank. 
      • Vacuum turbine blower generates a vacuum. 
      • Slurry viscosity and homogeneity maintained by agitator and continuous slurry recirculation between coating station and batch tank. 
      • Recipe based suction time and pressure. 
      • Accurate dip height and required isolation for vacuum suction via servo linear actuator driven top hood and bottom slurry cup. 
      • Batch tank has high and low level sensors, and interfaces with the external slurry feeding system. 
    • Air stripping:
      • Achieves required weight gain of substrate as per recipe.
      • Passes compressed air from compressed air buffer tank through substrate. 
    • Post weighing checks if the substrate has gained the required weight. 

Motorcycle Coating System

Project Video

Capacity

  • Customizable
  • Substrate size: 30-52 mm

Industry

Automobile

Applications

Motorcycle catalytic converters

Highlights

  • Integrated and flexible system for coating metallic substrates.
  • Intelligent mechanism with Total Recipe Management via IoT or SCADA systems. 
  • HMI for parameter setting and alarms. 
  • Digital bench weigh scales interfaced with PLC. 
  • Two (2) compliant grippers on each station of the rotary indexer. 
  • Process stations:
    • Loading station: Conveyor with pneumatic loader moves substrate to pneumatic gripper on the rotary indexer. Gripper holds the substrate’s external cylindrical surface. 
    • Weighing station records uncoated weight.
    • Coating station vacuum raises slurry through the substrate’s honeycomb mesh after gripping it in top and bottom seal plates. 
    • Dripping station collects excess coating in the bottom slurry tank. 
    • Air stripping station removes excess coating using a digitally controlled air blast. Substrate is vertically inverted for a second blast. 
    • Weighing station records coated weight. 
    • Drying station passes substrate on a wire mesh conveyor with hot air circulation. 
    • Reject station rejects substrates with incorrect weight gain.

Passenger Car Standalone Coating System

Project Video

Capacity

Customizable

Industry

Automobile

Applications

Passenger car catalytic converters

Highlights

  • Fully / semi automatic standalone set up for coating and air stripping metallic and ceramic substrates.
  • Recipe-based system with SCADA / IoT.
  • User-friendly HMI for easy operation and troubleshooting.
  • Flexibility:
    • Adjustable dipping height.
    • Simple and rapid fixture changing.
  • Material saving with slurry recirculation.
  • Process:
    • Pre weighing before coating on the pre-weighing station of the coater. 
    • Coating of two parts simultaneously:
      • Is performed by a vacuum based substrate coating system (coater) which moves slurry from bottom to top of the substrate (converter) after substrate is dipped in the recirculating slurry tank to the prescribed depth. 
      • Vacuum turbine blower generates a vacuum. 
      • Slurry viscosity and homogeneity maintained by agitator and continuous slurry recirculation between coating station and batch tank. 
      • Recipe based suction time and pressure. 
      • Batch tank has high and low level sensors, and interfaces with the external slurry feeding system. 
    • Air purging removes excess slurry from the substrate via required number of passes.
    • Offloading on the unload slide after purging. 
    • Post weighing after coating on the post-weigh station of the coater. 
    • Pre weighing before air stripping.
    • Air stripping:
      • Achieves required weight gain of substrate as per recipe.
      • Passes compressed air from compressed air buffer tank through substrate. 
    • Post weighing checks if the substrate has gained the required weight.

Calciner

Capacity

Customizable

Industry

Automobile

Applications

Catalytic converters installed in:

  • Heavy duty Trucks
  • Passenger cars
  • Motorcycles

Highlights

  • Improves catalyst coating’s strength via heat treatment. 
  • Holds coated part at pre-set temperature for pre-set duration. For e.g. at 600° C for 5 min.
  • Gradual heating and cooling prevents ceramic cracking.
  • Mesh belt conveyor moves parts continuously.
  • RTDs monitor temperature.
  • Pressure sensor checks air flow continuity.

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