The Electro Coating Simulation was so far mainly performed by ”computer fluid dynamic (CFD) simulation” with a so-called two-phase description.

Based on our experience the CFD method is not very efficient because of a long simulation run time. Likewise other constraints, such as the thickness of the wall film, the spatial movements through the dip tank, the free surfaces and especially the time–dependent description of the diving procedure can only be taken into account insufficiently. Although almost any detailed description of the time–dependent diving process of objects with a flow simulation (CFD) is theoretically possible to calculate, in practice however, the largest source of deficiency is the proper description of the correct boundary conditions.

The approach of ALSIM is a revolution in efficiency.

The following listing describes the workflow of ALSIM. A triangulated boundary representation of the surface and the diving curve of the bath are sufficiently to start the computation of the simulation. No other boundary conditions are necessary. This is the only way to provide a simulation tool which computation is time efficient and therefore applicable in the design phase in the automotive industry.

WORKFLOW:

• Clean the Mesh (with Software MERGE)
• Import Mesh
• Import Flow Path of Paintshop
• Simulate Dip Paint Process
• Interface to CAD

INPUT:

• STL
• Angle
• Options

OUTPUT:

• Air Bubbles
• Puddles
• Surfaces
• Interface
• Html Lists
• Excel Tables