Automated Brake Disc Coating Solution Unveiled

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Prima Additive and Comau, two leading Italian companies, have introduced a fully automated brake disc coating solution designed to meet the stringent Euro 7 emissions standards. This innovative system uses high-speed laser cladding technology to coat brake discs with durable metal layers, significantly reducing particle emissions by up to 80%. The solution, showcased at Stellantis Factory Booster Day, is set to be installed at Stellantis’ production facility by the end of 2024, offering a cost-effective way for automotive manufacturers to comply with upcoming environmental regulations.

Key Highlights:

• Automated brake disc coating system: Developed by Prima Additive and Comau, this robotic solution efficiently coats brake discs with durable materials.
• Emission reduction: The laser cladding process reduces brake disc particle emissions by up to 80%, supporting compliance with the Euro 7 standard.
• High-speed process: The system ensures minimal cycle times, optimizing productivity while maintaining high precision.
• Compliance with Euro 7 standards: This technology helps automotive OEMs meet the Euro 7 requirement for a 27% reduction in brake emissions by 2026.
• Versatile and flexible: The system can handle various brake disc sizes, from cars to trucks, ensuring adaptability for different production needs.
• Modular design: Its modular setup allows for easy integration and scalability, making it suitable for evolving automotive manufacturing demands.

The Euro 7 standard, which mandates a 27% reduction in brake disc emissions by 2026, has posed significant challenges for the automotive industry. However, the collaborative efforts of Prima Additive and Comau offer a practical solution. By using laser cladding, their system creates a hard coating on brake discs made from resilient steel and composite materials. This not only improves the discs’ lifespan but also minimizes pollution, aligning with the increasing focus on sustainability in the automotive sector.

The system leverages Comau’s advanced robotic arms, fully integrated with Siemens SINUMERIK Run MyRobot software, ensuring direct control and eliminating the need for additional controllers. This integration enables high precision and flexibility, allowing manufacturers to handle a wide range of brake disc sizes and production scenarios. Additionally, the modularity of the system facilitates easy adjustments for future production needs, ensuring long-term adaptability.

The solution’s energy efficiency and reduced footprint make it an environmentally friendly option for automakers. By minimizing the space and resources required, the system further contributes to cost savings and sustainability efforts.

According to Paolo Calefati, CEO of Prima Additive, “Our collaboration with Comau joins two companies with deep expertise in their respective fields to develop a truly cutting-edge industrial solution in automation and advanced laser systems for material processing.”

Pietro Gorlier, CEO of Comau, added, “In working together to safely automate high-speed laser cladding, Comau and Prima Additive are helping meet a growing demand in Europe and beyond for flexible, turn-key solutions that will help reduce particle emission pollution in response to recent regulations.”

The first of these robotic Rapid Coating Process cells is scheduled for deployment at Stellantis’ Septfonds plant in France by late 2024. This will make Stellantis one of the pioneering automakers to implement a fully automated system for hard coating brake discs, complying with the Euro 7 policy standards.