Design principles:

Replace traditional and outdated painting processes, equipment, and management with reliable production technology, equipment, and modern management. Meet the requirements of painting process, paint quality, environment, hygiene, and production guidelines; The equipment is reliable, advanced, aesthetically pleasing, economically efficient, easy to operate, and user-friendly.

Principles for Layout of Painting Workshop:

1. Separate manual and non manual operations relatively;

2. Clean and non clean areas are relatively separated;

3. Minimize transportation volume as much as possible;

4. Minimize noise pollution as much as possible.

Process design:

On the basis of absorbing and digesting advanced painting technologies and mature experience at home and abroad, ensure that this process design is practical, reliable, and advanced;

Equipment design and manufacturing are strictly carried out in accordance with relevant national standards and regulations on environmental protection, health, and safety; Each device adopts noise reduction measures to control the noise in the workshop below 85 decibels;

The equipment meets the requirements for product use, operates reliably, is easy to operate, and is easy to maintain;

The selected accessories, materials, and electrical components are all domestically renowned products with reliable quality, ensuring the performance and service life of the equipment;

(5) Fully consider the interlocking between systems and take protective measures in case of equipment failures to avoid equipment accidents;

(6) The paint booth adopts a dry paint booth with upper air supply and lower air exhaust.

Equipment description and structural design

1. Working principle:

When painting, the external air is filtered through the primary filter through the air inlet and then sent to the roof by the air supply fan (the heating system is turned on in winter). This way, the gas enters the static pressure chamber and evenly fills the paint room through the filter cotton, forming an air curtain around the workpiece. At this time, the empty air speed in the paint room reaches 0.23m/s or above. The paint mist during painting will not stay at the operator's breathing zone, but will quickly decrease with the airflow. Then, under the action of the exhaust fan, the airflow flows through the exhaust gas treatment system to the exhaust duct and is discharged through the environmental protection box. This way, the discharged gas meets the standard of GB16297-1996.

2. The main structure and components of the equipment

Structural composition: including the room body, lighting system, air filtration system, air supply system, heating system, exhaust system, paint mist and exhaust gas treatment system, electronic control system, safety system, and other parts.

2.1. Room body: mainly composed of skeleton, wall panels, workpiece entry and exit doors, and safety doors. The strength, stability, insulation, sealing, impact resistance, and seismic resistance of the indoor structure meet the requirements of national or relevant industry standards.

⑴ Skeleton

The indoor framework is made of square steel pipes and galvanized steel plates bent and welded together.

⑵ Wall panels

The wall panels of the room are made of composite insulation boards, and both the inner and outer panels are made of color steel plates, with a 58mm thick polymer insulation material in the middle. The total thickness is 75mm. All wall panels adopt an assembled structure for easy assembly and disassembly. The color is white.

Lighting system: Install explosion-proof lighting fixtures on the top and waist sides of the room. The top side light group is installed at a 45 degree angle, and the waist side light group is installed inside the wall panel. The lamp tube adopts explosion-proof Philips high-efficiency light source, which is safe, energy-saving and easy to maintain. The ballast adopts the spray room special ballast designed by our company, ensuring a light intensity of about 700Lux.

Two layers of lighting are arranged on each side of the waist.

2.3 Air filtration system

Air filtration is a secondary filtration, including primary filtration (inlet air filtration) and high-efficiency filtration (top filtration). The initial filtration is set at the air inlet and adopts a mesh structure, which can effectively filter dust particles larger than 15 μ m.

The main technical indicators of primary filter cotton are:

Original resistance 24Pa

Final resistance 250Pa

Average capture rate (calculation method) 86%

Dust holding capacity 620g/㎡

Thickness 20mm

The high-efficiency filtering material is made of 600G precision grade filter cotton, which is laid flat on the galvanized mesh at the bottom of the static pressure chamber. It is compressed with a round steel frame to achieve further filtration of the air and more uniform airflow into the operating room, thereby ensuring uniform air volume and air cleanliness. The filter cotton has a multi-layer structure, and the adhesion force of the oily interlayer in the middle can ensure that the air cleanliness reaches a dust content of no more than 1.5mg/m3, a dust particle number of no more than 200/cm3, and a large dust particle size of no more than 5 µ m. A pressure difference gauge is installed on the top and bottom of the filter cotton. When the filter cotton is severely blocked and the air supply speed is significantly reduced and the pressure difference increases, an alarm prompt is given to replace it, to avoid the mismatch between air supply and exhaust, which may cause excessive indoor and outdoor pressure difference and affect the painting effect. Its main technical indicators are:

Model 600

Original resistance 19Pa

Final resistance 230Pa

Average capture rate of 98%

Dust holding capacity 419g/m2

Thickness 25mm

Flame retardant ability meets F5 level standard

2.4. Air supply system: mainly composed of air supply fan, fan base, and steel frame. The fan base is filled with sound-absorbing materials to reduce noise and vibration.

According to the characteristics of the workpiece, the no-load wind speed in the paint room is above 0.23m/s. After calculation,

Q1=3600FV=3600×（14×10）×0.23=115920m3/h

Considering wind resistance and interference coefficient, a supply air volume of 120000m3/h is taken, and a total of 4 sets of supply air systems are configured, with a total of 8 YDW centrifugal fans.

The fan parameters are as follows:

Model: YDW

Airflow: 15000m3/h

Speed: 950r/min

Pressure: 801pa

Power: 5.5kw

Quantity: 8 units

2.5. Exhaust system: mainly composed of exhaust fans, ducts, and profiles. When painting, in order to discharge the filtered air at high altitude, two sets of exhaust systems are configured, each with an exhaust volume of 35201m3/h, to maintain a slight positive pressure state of the chamber during painting and ensure the quality of spraying. Each group is equipped with one centrifugal fan, model 4-82.

2.6 Paint mist and exhaust gas treatment system: Dry treatment is adopted, and the treated gas is sent to high altitude for emission, in accordance with the provisions of the national standard GB16297-1996.

Fan exhaust duct division