Design Principles:
Utilize reliable production technologies and equipment, as well as modern management to replace traditional, outdated painting processes, equipment, and management.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 in operation, easy to use, and convenient.
Painting workshop layout principles:
The manual and non-manual operation areas are relatively separated.
2. Clean and non-clean areas are separated relatively.
Minimize the transportation volume as much as possible.
4. Minimize noise pollution.
Process Design:
Based on the absorption and digestion of advanced and mature coating technologies and experiences from both domestic and international markets, ensure that the design of this process 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 implemented for each piece of equipment, ensuring noise levels in the workshop are 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 renowned domestic products, ensuring reliable quality and guaranteeing the equipment's performance and lifespan.
Thoroughly consider the interconnectivity between systems and implement protective measures for equipment failures to prevent accidents.
(6) The spray booth utilizes a dry spray booth with top air supply and bottom exhaust.
Equipment specifications and structural design
1. Principle of Operation:
During painting, the external air is filtered through the primary filter via the intake vent and then blown to the roof by the fan (heating system activated in winter). This allows the gas to enter the static pressure room, uniformly filling the paint room and forming a wind curtain around the workpiece. At this point, the air speed inside the paint room is above 0.23 m/s, ensuring that the 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 into the exhaust gas treatment system, passing through the environmental protection box and discharged to meet the GB16297-1996 standard.
2. Main structure and components of the equipment
Structural Composition: Consists of several components including 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.
2.1 Body: Composed mainly of the frame, wall panels, workpiece entry 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.
⑴ Skeleton
The chamber frame is constructed from square steel tubes and galvanized steel plate bent and welded together.
⑵ Wall Panel
The chamber wall panels are made of composite thermal insulation boards, with both inner and outer plates 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 waist sides of the room. The top side units are mounted at a 45-degree angle, while the waist side units 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 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 initial efficiency filter cotton are:
Initial Resistance 24 Pa
Final Resistance 250 Pa
Average Capture Rate (Calculation Method) 86%
Dust Retention Capacity: 620g/㎡
Thickness: 20mm
High-efficiency filtration material is selected, with 600G precision-grade filter cotton laid flat on the galvanized mesh at the bottom of the static pressure chamber. It is securely fastened with a round steel frame, achieving secondary air filtration and ensuring more even airflow into the operation area, thereby guaranteeing uniform air volume and cleanliness. The filter cotton features a multi-layer structure, with an oil-impregnated intermediate layer that possesses 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 replacement when the filter cotton becomes severely clogged, causing a significant decrease in supply air velocity and an increase in pressure differential, to avoid mismatched supply and exhaust air that could lead to excessive indoor-outdoor pressure differentials affecting the painting process. Its main technical specifications are:
Model: 600
Original Resistance 19 Pa
Ultimate 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 composed 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 air velocity inside the paint room should be 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 supply 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
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, etc. 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 room 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
