Design Principles:
Utilize reliable production technologies and equipment, along with modern management, to replace the traditional, outdated painting processes, equipment, and management. Comply with requirements for painting processes, paint quality, environment, hygiene, and production standards; equipment is reliable, advanced, aesthetically pleasing, economically operated, user-friendly, and easy to handle.
Principles for the layout of the painting workshop:
The manual and non-manual operation areas are relatively separated.
2. Clean and non-clean areas are separated from each other.
Minimize transportation volume as much as possible.
Minimize noise pollution.
Process Design:
Based on the absorption and digestion of advanced coating technologies and mature experiences from both domestic and international sources, ensure that this process design is practical, reliable, and advanced.
All equipment design and manufacturing strictly comply with national standards for environmental protection, hygiene, and safety; noise reduction measures are taken for each piece of equipment, ensuring that the noise level in the workshop is below 85 decibels.
The equipment meets the product's usage requirements, operates reliably, is easy to operate, and convenient to maintain.
The selected accessories, materials, and electrical components are all renowned domestic products, ensuring reliable quality and guaranteeing the equipment's operational performance and lifespan.
Fully consider the interconnection between systems and implement protective measures in aspects such as equipment failures to prevent equipment accidents.
(6) A dry paint booth with top air supply and bottom exhaust.
Equipment Description and Structural Design
1. Principle of Operation:
During painting, external air is filtered through a primary filter by the intake vent and then blown to the ceiling by the blower (heating system activated in winter). The air then enters the static pressure room, evenly fills the paint room through the filter cotton, and forms an air curtain around the workpiece. At this point, the empty wind speed in the paint room is above 0.23m/s. The paint mist during spraying does not remain in the operator's breathing zone but rapidly descends with the air flow. Subsequently, the air flow is directed through the exhaust gas treatment system by the exhaust fan to the exhaust duct, and then discharged through the environmental protection box, ensuring that the discharged gas meets the standard of GB16297-1996.
2. Main structure and components of the equipment
Structure Composition: Comprises of the room body, lighting system, air filtration system, air supply system, heating system, exhaust system, paint mist and waste gas treatment system, electrical control system, and safety system, among other components.
2.1 Body: Composed mainly of the frame, wall panels, workpiece entrance and exit doors, and safety doors. The body meets the national or relevant industry standards for strength, stability, thermal insulation, sealing, shock resistance, and seismic resistance.
Frame
The chamber frame is made by bending and welding square steel tubes and galvanized steel plates.
⑵ Wall Panel
The room wall panels are made of composite thermal insulation boards, with both inner and outer panels being color steel plates, filled with 58mm thick polyurethane insulation material in between. The total thickness is 75mm. All wall panels are assembled in a modular structure for easy installation and disassembly. The color is white.
Lighting System: Explosion-proof lighting units are installed at the top and side sections of the room. The top section lights are mounted at a 45-degree angle, while the side section lights are installed within the wall panels. The tubes utilize explosion-proof Philips high-efficiency sources, ensuring safety, energy savings, and easy maintenance. The ballasts are designed specifically for spray rooms by our company, guaranteeing an illumination intensity of approximately 700 Lux.
Each side of the waist is equipped with two layers of lighting arrangement.
2.3 Air Filtration System
Air filtration is of secondary grade, including preliminary filtration (inlet air filtration) and high-efficiency filtration (top filtration). The preliminary filtration is set at the inlet, with a mesh structure, effectively filtering particles larger than 15μm.
The primary technical specifications of the initial-effect filter cotton are:
Raw Resistance 24Pa
Final Resistance 250 Pa
Average Capture Rate (Calculation Method) 86%
Dust Holding Capacity: 620g/㎡
Thickness: 20mm
High-efficiency filtration material is chosen, with 600G precision-grade filter cotton laid flat on the galvanized mesh at the bottom of the static pressure chamber. It is tightly secured with a round steel frame, achieving a secondary filtration of the air and ensuring a more uniform airflow into the operation area, thereby guaranteeing the uniformity of air volume and cleanliness. The filter cotton has a multi-layer structure, with an intermediate oil-impregnated layer that provides strong adhesion, ensuring air cleanliness with dust content ≯1.5mg/m3, dust particle count ≯200 per cm3, and large dust particles ≯5µm. Differential pressure gauges are set on the top and bottom of the filter cotton. An alarm is triggered to prompt a replacement when the filter cotton is severely clogged, causing a significant decrease in airspeed and an increase in pressure differential, to avoid mismatched supply and exhaust airflows that could lead to excessive indoor-outdoor pressure differentials affecting the painting effect. Its main technical specifications are:
Model: 600
Original Resistance 19 Pa
Final Resistance: 230 Pa
Average Capture Rate: 98%
Dust Holding Capacity: 419g/m²
Thickness: 25mm
Flame Retardant Ability: Meets F5 rating standard
2.4 Air Supply System: Comprised mainly of an air blower, blower base, and steel frame. The blower bases are filled with sound-absorbing material to reduce noise and vibration.
Based on the workpiece characteristics, the empty wind speed in the paint room is above 0.23 m/s, calculated as follows:
Q1=3600FV=3600×（14×10）×0.23=115920m3/h
Considering wind resistance and interference coefficients, a total air volume of 120,000 m³/h is selected, with a total of 4 air supply systems, equipping a total of 8 YDW type centrifugal fans.
Fan parameters are as follows:
Model: YDW
Airflow: 15,000 m³/h
Speed: 950 rpm
Pressure: 801 Pa
Power: 5.5 kW
Quantity: 8 units
2.5, Exhaust System: Composed mainly of exhaust fans, ducts, and profiles, etc. During painting, to discharge the filtered air at a high altitude, two sets of exhaust systems are configured, each with a capacity of 35,201 m³/h, to maintain the chamber in a slightly positive pressure state during painting, thereby ensuring the quality of the coating. Each set is equipped with one centrifugal fan, model 4-82.
2.6 Paint Mist and Waste Gas Treatment System: Utilizes dry treatment, with the treated gases emitted to high altitudes, in compliance with the national standard GB16297-1996.
Ductwork for exhaust fans
