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Utilize reliable production technologies and equipment, along with modern management, to replace the traditional, outdated painting processes, equipment, and management.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 schedules; equipment is reliable, advanced, aesthetically pleasing, economically operational, easy to handle, and user-friendly.
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.
3. Minimize the volume of shipping.
4. Minimize noise pollution.
Process Design:
Based on the absorption and digestion of advanced domestic and international coating technologies and mature experiences, ensure that this process design is practical, reliable, and advanced.
Equipment design and manufacturing strictly comply with national standards regarding environmental protection, hygiene, and safety. Noise reduction measures are implemented for all equipment, ensuring that the noise level in the workshop is kept below 85 decibels.
The equipment meets the product's usage requirements, operates reliably, is easy to operate, and convenient for maintenance and upkeep.
The accessories, materials, and electrical components selected are all renowned domestic products, ensuring reliable quality and guaranteed performance and lifespan of the equipment.
Carefully consider the interconnectivity between systems and implement protective measures against equipment failures to prevent accidents.
(6) The painting room is a dry paint booth with top air supply and bottom exhaust.
Equipment Description and Structural Design
1. Operating Principle:
During painting, the external air is filtered through the primary filter net and then sent to the ceiling by the fan (heating system activated in winter), allowing the gas to uniformly fill the paint room through the static pressure chamber and form an air curtain around the workpiece. At this point, the wind speed in the paint room is above 0.23 m/s, preventing paint mist from staying in the operator's breathing zone and allowing it to quickly descend. Subsequently, the air flow is directed through the exhaust fan and into the exhaust gas treatment system, flowing out through the environmental protection box, ensuring the discharged gas meets the GB16297-1996 standard.
2. Main structure and components of the equipment
Structure Composition: Comprises 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 others.
2.1 Body: Composed mainly of the frame, wall panels, access doors for workpieces, and safety doors. The body meets the national or relevant industry standards in terms of strength, stability, thermal insulation, sealing, impact resistance, and seismic resistance.
⑴ Frame
The cabinet frame is made from rectangular steel tubes and galvanized steel plate that are bent and welded together.
⑵ Panel
The room wall panels are made of composite thermal insulation boards, with both the inner and outer plates made of color steel. The middle is filled with 58mm thick polyurethane insulation material. Total thickness is 75mm. All wall panels are assembled in a modular structure, making them easy to install and dismantle. 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 both safety and energy-saving with easy maintenance. The ballasts are designed specifically for spray rooms by our company, guaranteeing an illumination intensity of approximately 700Lux.
Each side of the waist features two layers of lighting arrangement.
2.3 Air Filtration System
Air filtration is of two stages, including preliminary filtration (inlet air filtration) and high-efficiency filtration (top filtration). The preliminary filtration is set at the inlet, utilizing a mesh structure, which effectively filters particles larger than 15μm.
The primary technical specifications of the initial-effect filtration cotton are:
Raw 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 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 becomes severely clogged, causing a significant decrease in airspeed and an increase in pressure differential, which avoids mismatched supply and exhaust air, leading to excessive indoor-outdoor pressure differential and affecting the paint spraying 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: Mainly composed of an air supply fan, fan base, and H-shaped steel frame. The fan bases are internally filled with sound-absorbing material to reduce noise and vibration.
Based on the workpiece characteristics, the empty speed of the paint room is above 0.23 m/s, according to calculation,
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, consisting 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: Comprised 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 treated gases released into the air at high altitudes, in compliance with the national standard GB16297-1996.
Fan exhaust ducting
