Design Principles:
Utilize reliable production technologies and equipment, along with modern management, to replace traditional, outdated painting processes, equipment, and management. Meet requirements for painting processes, paint quality, environment, hygiene, and production schedules; equipment is reliable, advanced, aesthetically pleasing, cost-effective, easy to operate, and convenient.
Principles for Paint Shop Layout
The manual and non-manual operation areas are relatively separated.
2. Clean and non-clean areas are relatively separated.
Minimize the volume of shipment.
4. Minimize noise pollution.
Process Design:
Based on absorbing and digesting advanced domestic and international coating technologies and mature experiences, ensure that this process design is practical, reliable, and cutting-edge.
Equipment design and manufacturing are strictly carried out in accordance with national standards related to environmental protection, hygiene, and safety. Noise reduction measures are taken for all equipment, ensuring 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 and service.
The selected accessories, materials, and electrical components are all domestic renowned products, ensuring reliable quality and guaranteeing the equipment's performance and service life.
Thoroughly consider the interconnectivity between systems and implement protective measures against equipment failures to prevent accidents.
(6) The paint booth utilizes a dry spray booth with top air supply and bottom exhaust.
Equipment specifications and structural design
1. Principle of Operation:
During the painting process, the external air is filtered through the primary filter net via the intake vent and then sent to the ceiling by the blower (heating system is activated in winter). This allows the gas to enter the static pressure room, evenly filling the paint room with the help of the filter cotton, creating a wind screen around the workpiece. At this point, the empty air velocity in the paint room exceeds 0.23 m/s; the paint mist generated during painting does not linger in the operator's breathing zone but swiftly descends with the air current. Subsequently, the air current is directed through the exhaust gas treatment system to the exhaust duct by the exhaust fan and emitted through the environmental protection box, ensuring that the emitted 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 other components.
2.1 Body: Comprised mainly of frames, wall panels, access doors, and safety doors, etc. The body meets the national or relevant industry standards for strength, stability, insulation, sealing, shock resistance, and seismic resistance.
⑴ Frame
The housing frame is made by bending and welding square steel tubes and galvanized steel plates.
⑵ Panel
The room panels are made of composite thermal insulation boards, with both inner and outer plates being color steel plates, filled with 58mm thick polyurethane thermal insulation material. Total thickness is 75mm. All panels are assembled in a modular structure for easy installation and dismantling. The color is white.
Lighting System: Explosion-proof lighting units are installed at the top and side sections of the room. The top side units are mounted at a 45º angle, while the side units 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 our company-designed spray room-specific ballasts, ensuring 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 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.
The primary technical specifications of the preliminary 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 materials are selected, with 600G precision-grade filter cotton laid flat on the galvanized mesh at the bottom of the static pressure chamber. It is then secured with a round steel frame to achieve secondary air filtration and ensure more uniform airflow into the operation area, thereby guaranteeing consistent air volume and cleanliness. The filter cotton features 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 particles/cm3, and large dust particles ≯5µm. Differential pressure gauges are set on the top and bottom of the filter cotton. An alarm will prompt for replacement when the filter cotton becomes severely clogged, causing a significant decrease in airspeed and an increase in pressure differential, to prevent mismatched air supply and exhaust, which could lead to excessive indoor-outdoor pressure differential and affect 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 Retardancy Compliant with F5 rating
2.4 Air Supply System: Mainly consists of an air supply fan, fan base, and steel frame. The fan 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 air resistance and interference coefficients, a total air supply rate of 120,000 m³/h is selected, with a total of 4 air supply systems, equipped with 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: Mainly composed of exhaust fans, ducts, and profiles. During painting, to discharge the filtered air at a high altitude, two sets of exhaust systems are installed, each with an exhaust 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 emitted to high altitudes, in compliance with the national standard GB16297-1996.
Fan exhaust ducting
