RFID stands for \"Radio-Frequency Identification<\/a>\", i.e. identification using radio waves. Many industries are already using the technology, which transmits information wirelessly, to make their processes more efficient. RFID is used to identify containers in port terminals, control ticketless entrances in parking garages and automate checkout processes in retail. In simple terms, the wireless data exchange of an RFID system works by something sending and something receiving. The transmitter is a RFID transponder<\/a>which consists of a microchip and an antenna. The receiver is the RFID reader<\/a>which reads the data from the chip and forwards it to a computer system. D\u00fcrr recognized the advantages that the technology offers in a paint shop, both for high system availability and for more efficient maintenance. As there was no RFID system available for this environment, D\u00fcrr developed a tailor-made solution based on the technology from Kathrein Solutions GmbH.<\/p>\n New geometry for interference-free data exchange<\/strong><\/p>\n The metal often used in paint booths shields the radio signals. Conventional RFID chips, which achieve long ranges in many applications, do not work there. Accordingly, the engineers at D\u00fcrr and Kathrein Solutions jointly developed a transponder with individual antenna geometry for each component of the atomizer. The chips and ranges of the antennas are designed in such a way that the radio waves penetrate all materials. Inside the cabin Low-range antennas<\/a> with the lowest possible susceptibility to interference, outside Wide-range antennas<\/a>. They supply the passive transponders with energy.<\/p>\n <\/p>\n Read and write function on a transponder<\/strong><\/p>\n The transponders can both read and write operating data. This makes it possible to store extensive information chains\u2014such as the number of operating cycles or rotational speeds\u2014directly on the components. The storage capacity of the NXP UCODE DNA chips is sufficient for large data volumes of up to 3 KB, and AES 128-bit (Advanced Encryption Standard) enables encryption of sensitive data in accordance with ISO\/IEC 29167-10.\n\nThe newly developed infrastructure also connects a PC to a central database that manages all RFID data for one or more painting lines. The maintenance workstation is connected to this system as well. Since all information is stored both in the database and directly on the atomizers, a seamless system is created with data access on both levels. The operator can therefore view the current status of the atomizer and its components both at the maintenance workstation and directly on the line.<\/p>\n Avoid typical mistakes in the paint booth<\/strong><\/p>\n After manual installation, it could always happen that a bell cup was installed in the wrong paint booth or for the wrong painting process. This worsened the painting result and, in practice, could possibly only become apparent after several incorrectly coated car bodies and cause considerable reworking. Such typical errors are avoided in the new line at Audi, as the RFID readers automatically identify each component using a unique identification number. In the event of incorrect replacement or missing parts, the system warns the operator via a pop-up window before the painting process is even started.<\/p>\n Demand-driven maintenance saves costs<\/strong><\/p>\n The RFID maintenance station shows the technician all the specifications of a component and its maintenance history. The exact history enables needs-based maintenance that makes optimum use of the service life of components. This saves maintenance costs, as only parts that are actually worn out are replaced. System availability is also significantly increased as the operating personnel can plan all maintenance measures in advance. Detailed tutorials support high maintenance quality. Clearly prepared videos guide even semi-skilled personnel step-by-step through the processes, starting with the right tools and the required auxiliary materials through to the necessary steps for individual assembly elements or entire atomizers. The workstation contains all the necessary tools and a printer. This can be used to print labels with information such as operating hours and the date of the last repair, so that the worker in the production plant immediately recognizes that a component is a serviced, freshly reconditioned atomizer.<\/p>\n More sustainable and efficient painting<\/strong><\/p>\n Audi has placed great emphasis on sustainable and at the same time highly productive equipment for the new top coat line. The redesign of one line, i.e. half of the top coat capacity, improves the environmental balance of the entire Ingolstadt plant. The application technology with the economical EcoBell4 with 4-main needle technology, which significantly reduces overall paint consumption, contributes to this. The amount of paint saved can be used to produce an additional 12,500 car bodies. The digitalization of the atomizer contributes to system availability. This is because it makes it possible to use the newly developed RFID system to optimize processes in the paint shop, reduce errors and increase efficiency.<\/p>\n <\/p>\n![\"\"](\"https:\/\/www.kathrein-solutions.com\/wp-content\/uploads\/2025\/08\/Duerr_Decklacklinie-Audi-Werk_Duerr-Reader-600x401.jpg\")
\nIllustration: The new topcoat line at the Audi plant in Ingolstadt has 28 painting stations.<\/em>
\nrobots are equipped with RFID technology. This allows extensive<\/em>
\ninformation chains, for example on the number of operating cycles or speeds, directly<\/em>
\non the components.<\/em><\/p>\n