In the paint shop, the bodies of the Macan and Panamera go through six phases. First, the body is cleaned, degreased and immersed in a zinc phosphate solution, which ensures optimum adhesion of the subsequent corrosion protection. This is applied in the cathodic dip coating process. After the subsequent seam sealing in the PVC line, three different layers of paint are applied: filler, top coat and clear coat. The elastic filler protects the top coat (also known as the base coat) from damage and improves the structure and subsequent brilliance. Colour then comes into play: the top coat is applied in the colour desired by the customer. After intermediate drying, a clear coat seals the previously applied layers of paint. Finally, all car bodies are checked by employees in the LED light tunnel. The automatic defect detection (AFE) supports this process. Two robots scan the entire outer skin of the car body with a light strip pattern in 70 seconds. In doing so, they take around 100,000 photos in which they recognise even the smallest imperfections based on reflections. In a further 30 seconds, five image processing computers analyse the results. In this way, the workers are shown the position and type of the detected anomalies on a 3D visualisation of the bodywork within a very short time.
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