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AACD (Automatic Average Current Density)

The AACD (Automatic Average Current Density) is an automatic rectifier voltage controller that is used to control the DC output of an existing or new rectifier. Automatic voltage control brings uniform paint film thickness to e-coat processes in which groups of various sized parts enter the tank at different times. This uniformity improves quality and reduces part rejection. By using the AACD , undercoating is reduced or eliminated and overcoating is corrected. Note too, that by correcting for overcoating, the AACD will reduce paint and energy consumption! With a short-term ROI (typically 1 – 6 months, part / loading pattern dependent), the AACD offers tremendous customer benefits when used in a continuous conveyor or batch e-coat process.

The AACD can be retrofitted to any rectifier, as long as there is a method of electronic voltage adjustment, a means to attach the NEMA2-enclosed AACD unit near or to the rectifier, an external single phase power source, as well as signal wiring internal to the rectifier.

When ordered in conjunction with a new Controlled Power Company rectifier, the AACD electronics and “HMI/OIT” (human-machine interface / operator interface terminal) are physically integrated into the rectifier, thus eliminating the need for an external enclosure, external single phase power, and the running of any external signal wires.

Watch an animated video of the AACD in action!

Animated Demo(25MEG) Quick Time Movie (mp4)

(If necessary, click here for the free download of the Quick Time player.)

The video illustrates a continuous conveyor e-coat process, and simulates voltage and paint film thickness both with and without invoking the AACD . Black bar graphs represent the AACD as “off” ... blue bar graphs represent the AACD as “on”. The film thickness graph represents actual data, but has been expanded to clarify the results.

Click Here to watch our demonstration video on YouTube

Features & Benefits
Technical Specs

General Specifications

Guide Specifications

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Features & Benefits

  • Narrows paint film deviation between various sized parts
  • Reduces / eliminates undercoating and overcoating
  • If overcoating, reduces excess paint and energy consumption
  • Multiple recipe control when different film thicknesses are required for various part runs
  • Compatible with both continuous conveyor and batch processes
  • Digital monitoring of rectifier, including voltage and current trending
  • Multi-zone compatible
  • Multiple PLC platforms available
  • Compatible with various substrates
  • Retrofittable to most e-coat rectifiers
  • ROI typically between 1 – 6 months (part type, size, and loading pattern dependent)
  • Optional bath temperature voltage compensation

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Technical Specs

  • Input Power Source: Single phase 120 VAC, 60Hz; or 220 VAC, 50Hz
  • Enclosure: All steel, NEMA 2 rated
  • Mounting: Secures to rectifier cabinet or any vertical surface
  • Weight: 60 lbs.
  • Dimensions: 16”W x 8”D x 20”H

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  • Electrocoating
  • Any DC Painting Application

  • How much can I save with the AACD?

  • We have seen savings of up to $50,000 per year and in one case even a $1,000,000 per year. (Note that savings depend upon system configuration and volume of parts.)

  • Can the end user program the AACD?

  • Yes, the AACD can be programmed by the end user via a touch screen display. A technician from the factory is not required.

  • What improvements are achieved by using the AACD?

  • Paint Savings: Film builds are reduced to about +/- 0.1 mil or +/- 2.5 microns. Energy Savings: The ability to control the rectifier voltage and eliminate overcoating result in less energy consumption during the e-coat process. Labor Savings: Automatic voltage control eliminates the need to manually adjust the voltage during the e-coat processes. Quality Improvements: Rework costs are drastically reduced, if not eliminated.

  • What tolerances on film build can I expect to achieve with the AACD?

  • There are many factors to consider. However, if groups of parts are loaded fairly consistently, then the AACD can achieve film build tolerances to within 0.1 mil or 2.5 microns.

  • Does the AACD require a part detection system?

  • No. The AACD uses proprietary software to set voltage levels based upon current levels in the paint tank.

  • What is required for AACD Installation?

  • Typically the following (4) criteria are required: Hardwired 120V or 220V single phase source, 5A. Approximately 15 signal wires (16 awg or 18 awg), 1 must be shielded (rectifier and configuration dependent). Conduit for signal wires running from the AACD enclosure to inside the rectifier. A Controlled Power Company technician to perform the internal wiring of the rectifier and the initial setup of the system.