E - Engineering

• Control Software & Automation
• HMI & Visualization
• Commissioning & Startup

About the Project

Reditech was hired to automate two essential stages in the automotive production process:

• Leak Test – where each vehicle is submerged in a water tank and pressurized with air.
• Curing Oven – where the final layer of paint is dried under strictly controlled temperature and humidity.

Both systems are part of a state-of-the-art factory in Brazil, designed to strengthen a global network of flexible and efficient production.

Challenge

The client needed a system capable of:

• fully controlling the leak test cycle
• operating conveyors, doors, pumps, tank levels, and dryers
• ensuring safety during submersion and pressurization
• controlling the curing oven according to the requirements of each model
• combining burner and water spray to create the ideal climate
• integrating with the rest of the production line
• being fully tested and commissioned within a tight deadline

Our Contribution:

Control & Automation Software:

• Complete programming of the leak test line
• Conveyor, door, pump, tank level, and dryer control
• Process logic for immersion, pressurization, and safety interlocks
• Curing oven automation
• Burner and water spray control for temperature and humidity
• Configurable curing cycles by vehicle model

HMI & Visualization:

• Development of visualization on multiple HMIs
• Intuitive screens for operators
• Real-time monitoring and alarm management

Commissioning & Startup:

• Testing, adjustments, and validation of both systems
• Local startup and integration with the production line

Results:

• Safe and fully automated leak testing
• Perfect curing conditions for consistent paint quality
• Intuitive interfaces for efficient operation
• Systems validated and operating on schedule
• The entire factory was ready for production in just 19 months

REDI Pillars in this Project:

E – Engineering
Process logic, automation design, safety integration