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Utilize reliable production technologies and equipment, along with modern management, to replace traditional, outdated painting processes, equipment, and management.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 guidelines; equipment is reliable, advanced, aesthetically pleasing, economically operated, 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 shipping volume.
Minimize noise pollution.
Process Design:
Based on the absorption and digestion of advanced domestic and international coating technologies and mature experiences, this process design ensures practicality, reliability, and advancement.
The equipment design and manufacturing strictly comply with national standards regarding environmental protection, hygiene, and safety. Noise reduction measures are implemented for all equipment, ensuring the workshop noise 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 domestic renowned products, ensuring reliable quality and performance, as well as the lifespan of the equipment.
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 Description and Structural Design
1. Working Principle:
During painting, the external air is filtered through the primary filter mesh at the intake and then blown to the roof by the blower (heating system activated in winter). This allows the gas to enter the static pressure room, evenly filling the paint room with filtered cotton, creating a wind curtain around the workpiece. At this point, the empty room air speed in the paint room is above 0.23 m/s, ensuring that paint mist during spraying 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 being discharged through the environmental protection box, thus meeting the GB16297-1996 standard.
2. Main Structure and Components of the Equipment
Structure Composition: Comprises the room body, lighting system, air filtration system, air distribution 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 frames, wall panels, access doors for workpieces, and safety doors. The body meets the national or relevant industry standards for strength, stability, thermal insulation, sealing, shock resistance, and seismic resistance.
Frame
The chamber frame is constructed from square steel tubes and galvanized steel plate bent and welded together.
⑵ Panel
The chamber wall panels are made of composite insulation boards, with both inner and outer panels made of color steel, filled with 58mm thick polyurethane insulation material. Total thickness is 75mm. All wall panels feature modular construction for easy assembly and disassembly. The color is white.
Lighting System: Explosion-proof lighting groups are installed on the top and side sections of the room body. 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 our company-designed spray room-specific ballasts, 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:
Original Resistance 24Pa
Final Resistance 250Pa
Average Capture Rate (Calculation Method) 86%
Dust Holding Capacity: 620g/㎡
Thickness: 20mm
High-efficiency filtering materials are selected, with 600G precision-grade filter cotton flatly laid on the galvanized wire mesh at the bottom of the static pressure chamber. It is then tightly secured with a round steel frame to achieve secondary air filtration and ensure more uniform air flow into the workspace, 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 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 when the filter cotton is severely clogged, causing a significant decrease in airflow speed and an increase in pressure differential, prompting a replacement. This prevents mismatched air supply and exhaust, which can lead to excessive indoor-outdoor pressure differentials 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 - Meets F5 rating standard
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 empty wind speed in 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 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: 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 installed, each with a capacity of 35,201 m³/h, to maintain a slightly positive pressure state within the chamber 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 atmosphere at high altitudes, in compliance with the national standard GB16297-1996.
Ductwork for exhaust fans
