High-speed rotation atomization is the supreme discipline in surface technology: It combines particularly fine atomization with very high transfer efficiency and high working speed. The technology is primarily used in series production, for example for automotive and plastic components, in wood and furniture coating or glass coating. Despite these convincing advantages, high-speed rotation atomizers have often been limited to high-end applications that require special skills in system planning, set-up and productive use.
With the TF Bell 2 system, WAGNER makes the high-speed rotation process easily accessible beyond high-end applications. Due to the reduced effort required for setting, operating, monitoring and maintaining the coating system, the solution is not only aimed at experienced users, but also at companies working with high-speed rotation atomizers for the first time. Together with the existing high-speed rotation atomizers (TF Bell 1 and ECH variants), WAGNER now offers a comprehensive bell portfolio that also enables special applications, e.g. 2K coatings with integrated mixer or with external charging for water-based coatings.
TF Bell 2: Efficient atomization with innovative air deflector ring
The TF Bell 2 works with very low air and material consumption. Depending on the material, flow rate and workpiece geometry, it achieves a transfer efficiency of up to 90%. Newly developed air deflector rings with slot-shaped openings distribute the air and thus the material with particularly fine atomization and very evenly on the workpiece. The TF Bell 2 therefore achieves excellent coating results for a wide range of materials and workpieces. The bell cup size and serration can be specifically adapted to the workpiece shape, size and coating material. The spray jet width can be precisely adjusted and covers a range from 80 to 800 millimeters.
Integrated high voltage and a wide range of applications
The TF Bell 2 has an integrated high-voltage cascade with an output of 8 watts, making it suitable for all common solvent applications as well as for water-based paint applications with smaller paint kitchens (up to approx. 60 liters). For applications with higher power requirements, such as water-based paint applications with larger paint kitchens or larger systems, e.g. in wheel coating, an external cascade can be used as an alternative.
There are different configuration options available depending on the production environment: The TF RobotBell 2 variant is suitable for robot applications, while the TF Bell 2S is suitable for linear axes, reciprocators and installations without movement technology. Thanks to the high modularity, configurations without high voltage are also possible, e.g. for highly viscous materials. An adapter can be used to quickly convert from the bell to an airspray gun without the need to change any hoses. This makes the system suitable for automated series processes as well as for customer-specific application scenarios.
Fast color changes and service-friendly design
A modular, expandable valve block allows a second color to be added. After flushing the first color circuit, the next color is immediately available so that color changes are possible within a few seconds. Robust valves ensure a long service life. The innovative quick-change system with strain relief makes it easier to replace hoses and cables. The removable three-part air deflector ring can be cleaned particularly efficiently and thus enables years of reliable work. In addition, the one-piece bell plate prevents paint deposits inside the bell and thus also contributes to trouble-free coating.
WACON Spray: Intuitive control and flexible system architecture
Whether beginner or professional: With WACON Spray, the TF Bell 2 is quickly ready for use and easy to operate - without prior programming. All relevant bell parameters (including turbine speed, bearing air, high voltage, shaping airs) are controlled centrally via a 7-inch-touchscreen. Parameter settings can be saved as recipes and called up quickly when required.
The WACON Spray control concept is designed as a modular system and can be flexibly adapted to different production environments. It consists of several components that can be individually combined and flexibly assembled.
The stand-alone WACON Spray device has touchscreen operation and is suitable for 19-inch rack or desktop installation. WACON Extension is an extension box without a HMI. Up to two WAMOD plug-in modules can be installed in both housings. These modules regulate the high voltage, turbine speed and volume flow of atomizing air. The range of functions extends from basic to advanced features for high-end users, while only the components that are actually needed are installed. Subsequent adaptations are possible at any time - with minimal installation effort thanks to communication via the WAGNER bus. WACON Spray offers numerous interfaces for integration into external control systems, including digital and analog inputs and outputs or Profinet fieldbus. The modular design allows different operating modes. With the help of additional function modules, more complex systems can also be implemented in which up to four bells can be controlled simultaneously.
Stand-alone function modules for PLC connection
The stand-alone WACAS function modules are available as an alternative variant. They can be connected directly to higher-level control systems (e.g. PLC or robot control). The electrical connection is made conveniently via modern fieldbuses, minimizing the cabling effort. Their compact design makes them ideal for mounting in robot arms or in control cabinets with limited space.
Volume flow-based air control for maximum process reliability
WACON Spray uses innovative volumetric flow control instead of conventional pressure control to adjust the shaping airs. Being no longer dependent on hose lengths or diameters, recipes can be transferred between different systems or remain unchanged when the system is converted – a major time saving and a big step towards superior process stability.
Conclusion
The TF Bell 2 system combines highly efficient high-speed rotation atomization with an intelligent, modular control system. The system delivers excellent surface quality, reduces material and air consumption and simplifies operation, service and integration into existing systems. At the same time, it meets the latest and highest safety standards with global certification. This makes it a future-proof solution that allows companies to design their coating systems to achieve highly efficient and outstanding results for years to come.
