Design Principles:
Utilize reliable production technology and equipment, along with modern management to replace traditional, outdated painting processes, equipment, and management. Comply with requirements for painting technology, paint quality, environment, hygiene, and production guidelines; equipment is reliable, advanced, aesthetically pleasing, economically operational, user-friendly, and easy to handle.
Painting workshop layout principles:
The manual and non-manual operation areas are relatively separated.
2. Clean and non-clean areas are separated relative to each other.
Minimize the transportation volume.
4. Minimize noise pollution.
Process Design:
Based on the absorption and digestion of advanced domestic and international coating technologies and mature experiences, ensure the practicality, reliability, and advancement of this process design.
All equipment design and manufacturing strictly comply with national standards regarding environmental protection, hygiene, and safety. Noise reduction measures are implemented for each piece of equipment, ensuring that noise levels in the workshop are kept 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 domestic renowned products, ensuring reliable quality and guaranteeing the equipment's performance and service life.
Fully consider the interconnection between systems and implement protective measures for equipment failures to prevent accidents.
(6) The paint spray chamber employs a dry spray booth with top air supply and bottom exhaust.
Equipment specifications and structural design
1. Operating Principle:
During painting, the external air is filtered through the primary filter mesh via the intake vent and then delivered to the roof by the blower (heating system activated in winter). This allows the gas to enter the static pressure room, uniformly filling the paint room and forming an air curtain around the workpiece. At this point, the empty room air speed in the paint room exceeds 0.23 m/s, ensuring that paint mist during application does not linger in the operator's breathing zone but quickly descends. Subsequently, the air flow is directed through the exhaust fan to the exhaust duct, passing through the waste gas treatment system and exiting through the environmental protection box, thus ensuring the discharged gas meets the GB16297-1996 standard.
2. Main structure and components of the equipment
Structural Composition: Comprises the chamber 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. The cabinet is mainly composed of the frame, wall panels, workpiece access doors, and safety doors. The cabinet meets the national or relevant industry standards in terms of strength, stability, thermal insulation, sealing, impact resistance, and seismic resistance.
⑴ Skeleton
The chamber frame is made by bending and welding square steel tubes and galvanized steel plates.
⑵ Wall Panels
The room wall panels are made of composite thermal insulation boards, with both inner and outer plates being made of color steel plates, filled with 58mm thick polyurethane insulation material. Total thickness is 75mm. All wall panels are of assembled 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 use explosion-proof Philips high-efficiency sources, ensuring safety, energy-saving, and easy maintenance. The ballasts are designed specifically for spray rooms by our company, ensuring an illumination intensity of approximately 700Lux.
Each side of the waist features a two-layer lighting arrangement.
2.3 Air Filtration System
Air filtration is a two-stage process, including preliminary filtration (inlet air filtration) and high-efficiency filtration (top filtration). The preliminary filtration is set at the inlet, featuring a mesh structure, which effectively filters particles larger than 15μm.
Primary technical specifications of the initial-effect filter cotton are:
Initial Resistance 24 Pa
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 then tightly clamped 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 supply air velocity and an increase in pressure difference, to prevent mismatched supply and exhaust air that could lead to excessive indoor-outdoor pressure differences affecting the painting effect. Its main technical specifications are:
Model: 600
Initial Resistance 19 Pa
Final Resistance: 230 Pa
Average Capture Rate: 98%
Dust Holding Capacity: 419g/m²
Thickness: 25mm
Flame Retardant Ability - Meets F5 Standard
2.4 Air Supply System: Mainly composed of an air supply fan, fan base, and steel frame. The fan bases are internally filled with sound-absorbing material to reduce noise and vibration.
Based on the workpiece characteristics, the empty-load wind speed inside the paint room is above 0.23 m/s, calculations show that...
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 groups of supply systems, and 8 units of YDW type centrifugal fans are configured.
Fan parameters are as follows:
Model: YDW
Airflow: 15,000 m³/h
RPM: 950 rpm
Pressure: 801 Pa
Power: 5.5 kW
Quantity: 8 units
2.5. Exhaust System: Composed mainly of exhaust fans, ducts, and profiles. During painting, to discharge the filtered air at a high altitude, two sets of exhaust systems are configured, each with a flow rate 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 treated gases emitted to high altitudes, in compliance with the national standard GB16297-1996.
Fan exhaust ducting
