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Utilize reliable production technologies and equipment, along with modern management, to replace traditional, outdated painting processes, equipment, and management.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, environmental standards, hygiene, and production specifications; equipment is reliable, advanced, aesthetically pleasing, operates economically, is user-friendly, and easy to handle.
Painting workshop layout principles:
Manual and non-manual operation areas are relatively separated.
2. Clean and non-clean areas are separated relative to each other.
3. Minimize 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 that this process design is practical, reliable, and advanced.
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 all equipment, ensuring 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 is convenient for maintenance and care.
The accessories, materials, and electrical components selected are all renowned domestic 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) Dry paint booth with top air supply and bottom exhaust.
Equipment Description and Structural Design
1. Working Principle:
During painting, the external air is filtered through the primary filter mesh at 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 air speed in the paint room is above 0.23 m/s, ensuring that paint mist during application does not linger in the operator's breathing zone but rapidly descends. Subsequently, the air flow is directed through the exhaust fan to the exhaust duct, passing through the waste gas treatment system and being discharged through the environmental protection box, thus 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 other components.
2.1. Body: Composed mainly of the frame, wall panels, access doors, 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.
Frame
The chamber frame is made by bending and welding square steel tubes and galvanized steel plates.
⑵ Wall Panels
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 insulation material. Total thickness is 75mm. All 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 both safety and energy-saving with easy maintenance. The ballasts are designed specifically for our spray booth 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 of the secondary type, including pre-filtering (inlet air filtering) and high-efficiency filtering (top filtering). The pre-filter is located at the air intake, featuring a mesh structure, and effectively filters particles larger than 15μm.
The primary technical specifications of the preliminary 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 materials are selected, with 600G precision-grade filter cotton flatly laid on the galvanized mesh at the bottom of the static pressure chamber. The cotton is tightly secured with a round steel frame, ensuring a secondary air filtration and more uniform airflow distribution into the operation area, thereby guaranteeing consistent air volume and purity. The filter cotton features a multi-layer structure, with an intermediate oily interlayer that provides strong adhesion, ensuring air purity 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 prompts for replacement when the filter cotton becomes severely clogged, causing a significant decrease in airflow speed and an increase in pressure differential, to avoid mismatched supply and exhaust air, which can 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 Retardant Ability - Meets F5 rating standard
2.4 Air Supply System: Composed mainly 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 features, the empty speed in the paint room is above 0.23 m/s, calculated as follows,
Q1=3600FV=3600×（14×10）×0.23=115920m3/h
Considering aerodynamic resistance and interference coefficients, a total air volume of 120,000 m³/h is selected, with a total of 4 fan supply systems, equipped with 8 units of 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 high altitudes, two sets of exhaust systems are installed, each with an exhaust volume of 35,201 m³/h, to maintain a slightly positive pressure inside the room during painting, ensuring the quality of the coating. Each set is equipped with one centrifugal fan, model 4-82.
2.6 Paint Mist and Exhaust Gas Treatment System: Utilizes dry treatment, with treated gases emitted to high altitudes, in compliance with the national standard GB16297-1996.
Fan exhaust ducting
