Paint spraying and drying integrated room is also called paint spraying and baking room, which is mainly used for painting and baking equipment on metal or non-metal (plastic, wood) surfaces, so as to form a protective layer or decorative layer on the surface. The equipment has the advantages of high brightness, fresh air, fast air purification, good paint mist treatment effect, hot air supply in winter, etc. during painting, the equipment has the functions of constant temperature timing, fast temperature and constant temperature speed, good sealing effect of heating system, and high exhaust gas purification efficiency.
The paint spraying and drying integrated room is widely used for the surface paint spraying and baking construction of workpieces in the industries of ship pipe parts, wind power blades, towers (towers), wind power gearboxes, wind power bearings, wind power hubs, chemical equipment, petroleum equipment, aerospace, printing machinery, automobile, machinery, hardware, FRP products, etc.
|Working principle of painting
During painting, the external air enters the painting room after passing through the medium and low efficiency filter cotton, enters the dynamic and static pressure chamber, and then enters the painting room. The air flow forms an air curtain around the workpiece to be painted. The air in the room is of full pressure type, and the wind speed can reach above. The paint mist generated during painting rapidly drops with the air flow, shrinks toward the exhaust outlet under the action of the exhaust fan, enters the organic solvent adsorption box after being filtered by the paint mist filter material, and then is discharged at high altitude, The discharged gas complies with GB16297-1996 integrated emission standard of air pollutants. When painting, the air cleanliness in the room is more than 98%, and the incoming air has a certain pressure, which can form a constant airflow around the workpiece to remove excessive paint, so as to ensure the quality of painting to the greatest extent.
In the painting and drying integrated room, natural gas is heated and the circulation mode of upper air supply and lower air return is adopted to realize drying. The heated air enters the drying chamber through the circulating fan and pipe to heat the workpiece. The air after heat exchange is collected by the return air pipe, and then returns to the heating chamber with the supplementary fresh air to form an internal circulation. Through continuous circulation, the surface of the workpiece rises to the specified temperature. When the set value is reached, the heater stops working; The fan continues to work. When the indoor temperature drops to the set value, the heater automatically works to raise the temperature to the set value.
When baking paint, the air in the room is in full drop circulation at the wind speed of 0.3 M / s, which makes the temperature of all points in the room the same, and overcomes the disadvantage that the drying temperature is affected by the distance. Therefore, the paint of the whole workpiece is dried at the same speed, so that the surface can be smooth as a mirror without polishing. In order to ensure safety, the drying room needs to remove part of the hot air containing the concentration of solvent vapor, and at the same time, it needs to inhale part of fresh air to supplement, and is equipped with a multi probe combustible gas concentration detection device to monitor the concentration at any time, so as to ensure that the combustible gas concentration cannot exceed 25% of its lower explosive limit.
Painting and drying integrated room structure
It has two functions of painting and baking. When painting, it needs to have the functions of ventilation, air purification, paint mist treatment and hot air supply in winter; The drying shall have the functions of temperature rise, constant temperature and timing, and waste gas treatment. It is mainly composed of the spray booth body, air supply system, exhaust system, air purification system, paint mist treatment system, waste gas treatment system, hot air circulation heating system, lighting system, safety detection and alarm system, electric control system and three-dimensional lifting operation trolley.
|Indoor main materials
|Static pressure chamber
|foot level grill
Paint drying integrated room main material: column 200 × two hundred × 5 square steel pipe, inner and outer wall plates are δ 0.6mm thick galvanized and plastic sprayed color steel plate, filled with sandwich insulation layer rock wool in the middle, 100mm thick, so that the temperature of the outer wall plate is not higher than 5 ° C of the room temperature, and the average sound insulation is not less than 21.5r (DB), which is beautiful, sealed and has good thermal insulation effect, strong impact resistance and long service life
Fresh air enters the static pressure chamber and passes through the high-efficiency air filter cotton. The air flow direction to the operation room is more stable to avoid turbulence. The high-efficiency filter cotton adopts the "Filtrair" product imported from the Netherlands, with a filtration level of F5 and an average weight counting efficiency of 98%; It is equipped with a section steel framework and a C-shaped steel structure of the top net. After special rust prevention treatment, it has good rigidity, no rust, and it is easy to replace the top cotton.
The international new roller shutter door is selected, which has good heat preservation effect and strong bending resistance to prevent condensate; The surface of the profile is multi-layer baking paint or film layer, which has excellent scratch resistance, corrosion resistance, non corruption, wear resistance, knock resistance and impact resistance; During startup and operation, it is fast and noiseless (the speed can reach about 0.1m/s and the noise is less than 58db)
An outward opening safety door is set longitudinally in the room, and an anti riot emergency light is installed to facilitate personnel access and evacuation in case of emergency. The size of the safety door can be customized. The safety door is equipped with a mechanical pressure lock and an automatic door closer. When the pressure in the room exceeds 100Pa, it can automatically open the pedestrian door outward to relieve the pressure and play the role of explosion relief.
The pit inside the track of part of the painting and drying integrated room is the operation area for the operators during the bottom painting. Lighting is set on both sides of the passage to facilitate the bottom painting of the workpiece. The grating is laid on the upper part of the pit outside the two tracks according to the floor height, and the paint mist filter glass fiber cotton is arranged in the middle.
40x3mm flat steel and Ø 8 round steel are welded, (its bearing capacity is not less than 500kg / m2). The spacing between loaded flat steel is 30mm, the spacing between cross bars is 150mm, the area of each piece is about 1m2, and the weight is ≤ 25kg / m2, which is convenient for disassembly and cleaning.
The control wind speed of the painting and drying integrated room must comply with gb14444-2006 & lt; The control wind speed required by the safety technical regulations of paint booth in the safety regulations of painting operation. The principle of micro positive pressure should be considered in the air supply volume of the paint booth, that is, the exhaust volume is slightly less than 3 ~ 5% of the air supply volume, so that the external dust will not enter the operation area through the door crack of the room. The modular design concept organically combines the air supply and heating system into a set of modular system, and skillfully organizes the air flow in it. The framework of the module system is welded with industrial profiles and the surface is paved δ 100mm rock wool color steel sandwich panel, and access doors are set in each functional area.
|Air inlet section
Metal mesh is installed at the air inlet to prevent birds and debris from being sucked in. The air inlet is arranged indoors. The exhaust outlet is arranged at a high altitude to ensure that the exhaust gas will not be sucked in again. Air volume regulating valve is set to regulate the air inlet to ensure that it matches the exhaust air volume. The air valve conversion section is to realize the conversion of spraying and baking paint. It is composed of air valve and automatic air valve controller. The automatic air valve controller is Swiss bellmo product, which is sensitive and accurate
The forced draft fan unit adopts a coarse filter device, and the coarse filter material adopts vnf-290 (G3), a series of synthetic fiber filter material produced by the Dutch "Filtrair" company, which has the characteristics of high dust capacity and low pressure drop. It is economical and practical, and can resist the influence of chemical solvents, acid smoke and other chemicals. It can be reused after dust collection or cleaning, and has a long service life.
The fan adopts double suction explosion-proof centrifugal fan with good performance, high efficiency, beautiful appearance, compact structure, stable operation and convenient installation; The frame is welded with channel steel and angle steel to ensure its bearing capacity; Air supply pipes are all made of δ 1.2mm high-quality galvanized steel plate undercut production, and the pipeline is formed without deformation; A damping or elastic reducer is installed at the bottom of the fan, and a fan noise reduction room is set to ensure that the system noise is controlled below 75dBA
In order to ensure the adhesion between the paint film and the workpiece substrate in winter, the ambient temperature is usually required to be ≥ 15 ゜ C. The increased heating device ensures the spraying effect of low temperature operation in winter. It is integrated into the air supply system. Combined with the requirements of heating power value in winter, the burner adopts btg28p two-stage fire gas burner of Italian "Baltur" company, which is safe and energy-saving
The selection of exhaust fan in the painting and drying integrated room is mainly determined by the two parameters of fan air volume and fan pressure head. The base adopts channel steel and angle steel industrial profiles welded into a frame, and the exhaust pipe adopts δ 1.2mm high-quality galvanized steel plate undercut production, without welding, to ensure that the pipeline is formed without deformation; A damping or elastic reducer is installed at the bottom of the fan, and a fan noise reduction room is designed to ensure that the system noise is controlled below 75dBA; The size of the exhaust chimney is determined by the air flow velocity and the concentration of harmful substances discharged. The wind resistant structure is used for reinforcement in the installation.
The painting system of the painting and drying integrated room is composed of high-pressure airless painting pump, pneumatic mixer, paint filter and pipeline. It is installed in the paint pump room (paint supply room). The painting pump system is connected to the painting room by pipeline.
Paint supply room
One (5.5m) is installed under the platform of the air supply system × 2m × 3m（L × W × H) The paint supply room is equipped with an exhaust fan with an exhaust volume of not less than 10 times / min, and explosion-proof exhaust fan and lighting are used. Lay ground wires in the paint supply room to prevent fire caused by static electricity; In order to facilitate the painting operation, compressed air quick connectors are set on both sides of the paint booth
American Graco manual high-pressure airless spray gun is adopted, with ergonomic design and strong comfort; Oval insulated handle, high safety; The structure design is compact and reasonable, with mobile hose, flexible operation even in narrow space, and high spraying quality; The spray gun filter is easy to take out and easy to repair, reducing the maintenance time due to nozzle blockage.
With the rising labor cost and the gradual disappearance of the population dividend, it has become an inevitable trend for robots to replace people. The robot is used to replace the spray painting workers for spray painting, which can avoid the heavy labor of the operators in the harsh working environment, and can ensure the stable surface quality of the workpiece and high production efficiency.
The heat sources of the painting and drying integrated room mainly include natural gas, electricity, natural gas radiation and steam. Taking natural gas as an example, the heating system is mainly composed of natural gas burner, stainless steel heat exchanger (liner), hot air circulation pipeline, temperature control system, safety detection system and other parts
Air heat exchanger
Insulation chamber body
Temperature control system
According to the requirements of heating power value in winter, btg28p two-stage fire gas burner of Italian "Baltur" company is selected as the burner, which is safe and energy-saving
The inner tank of heat exchanger adopts δ 4mm stainless steel is made by argon arc welding. The two process heat exchange design of the whole machine has reasonable structure, large heat exchange area and high heat exchange efficiency. At the same time, it is equipped with a wind pressure switch to effectively monitor the operation of the system. When it is found that there is no circulating air in the system, immediately cut off the burner and stop heating. So as to ensure the safe and reliable operation of the equipment
The hot blast stove adopts profile steel as the framework and is surrounded by δ 100mm thick rock wool insulation board mask, and an access door is set at one side
A platinum thermistor temperature sensor is set in the paint booth, and the collected signal is sent to the temperature controller of the control cabinet. The temperature controller automatically controls the operation of the burner according to the set temperature value, and the temperature can be set as required. Ensure that the temperature in the room meets the requirements of painting tasks.
The air purification of the spray painting and drying integrated room adopts two-stage filtration: the primary effect of air inlet is 1-2-stage filtration and sub high efficiency filtration (top filtration). The sub high efficiency filtration material is composed of air inlet filter, top filter material, top cotton support net, connecting plate, etc. the sub high efficiency filtration material is set at the bottom of the static chamber and is supported by the top cotton support net. The top cotton support net is a high-quality C-shaped steel structure. After special rust prevention treatment, it has good rigidity, no rust, and it is easy to replace the top cotton;
Primary filter material
Sub high efficiency filter material
The synthetic fiber filter material product vnf-290 (G3) and the bag filter of the filter section of the air supply system can increase the cotton area of the air inlet by 3-4 times with the cloth bag structure. The adoption of this filter form can reduce the wind resistance, increase the dust capacity and reduce the replacement times
The Dutch "arresters" synthetic fiber filter material cc-600g (F5) is selected as the sub high efficiency filter material, which can filter out all particles that can damage the paint quality, and the dust content is 100% removed to ensure that the air flow passing through the paint booth is evenly diffused and forms a laminar flow state, which conforms to the fire classification standards of European din53438-f1 and American ul900-class1.
Paint mist treatment system
Dry paint mist filter is used to set three exhaust ditches on the ground of the paint booth, namely, left, middle and right. Baffle plate and paint mist filter device are installed in the air ditch to absorb the paint mist. The paint mist filter device is composed of a filter fiber support net and a filter fiber cotton, and the baffle filter fiber cotton is placed on the support net. When replacing, remove the upper floor grid, take out the flat filter cotton and support net, and then replace the vertical filter cotton. The saturated filter bottom cotton is sent to the incinerator for incineration to prevent environmental pollution. The flat filter cotton can absorb a large amount of paint mist, and the efficiency can reach more than 98%; After spraying for a period of time, when the adsorption of the tiled filter cotton reaches saturation so that the air flow cannot pass through, the two layers of tiled filter cotton form a baffle plate. The spray mist passes through the air flow, about 70% of the paint mist settles on the tiled filter cotton through the baffle, the remaining paint mist settles at the bottom of the air ditch after passing through the baffle channel with the air flow, and about less than 2% of the paint mist is further adsorbed by the vertical filter cotton, and finally the standard air flow is discharged from the exhaust duct.
During painting, the exhaust gas shall be treated to make the treated exhaust gas meet the integrated emission standard of air pollutants (gb16297-195). There are two treatment methods commonly used in the spray painting and drying integrated room of our company: activated carbon system + RCO catalytic combustion and molecular sieve zeolite runner adsorption + catalytic combustion.
Activated carbon adsorption + RCO catalytic combustion
The organic waste gas can be adsorbed by using the adsorption characteristics of activated carbon micropores, and the waste gas with low concentration, low temperature and hydrocarbon can be treated. The solvent can be recovered and reused, and the purification efficiency is as high as 90-95%. Activated carbon is a non-polar adsorbent with hydrophobic and organophilic properties. It can adsorb most organic gases, such as benzene, aldehydes and ketones, alcohols, hydrocarbons, etc. and malodorous substances. After adsorption saturation, it can be desorbed and regenerated with hot air and put into use again.
Molecular sieve zeolite runner adsorption + catalytic combustion
The zeolite runner concentration area can be divided into treatment area, regeneration area and cooling area. After collection and pretreatment, VOC organic waste gas enters the zeolite molecular sieve runner system. Through the continuous process of adsorption desorption concentration of zeolite molecular sieve runner, large air volume and low concentration organic waste gas is concentrated into small air volume and high concentration waste gas, and then enters the regenerative oxidation furnace for combustion purification, And effectively utilize the surplus heat released by the combustion of organic matter.
All light boxes adopt δ 1.2 the galvanized plate is made and sprayed with white paint, which is beautiful and elegant, and can prevent rust; The lamp tube adopts explosion-proof Philips high-efficiency light source, which is safe, energy-saving and easy to maintain. The ballast adopts the special electronic ballast for the spray booth, which ensures that the light intensity of each spray booth is ≥ 80olux and meets the spraying operation of each end face of the workpiece. The light box is connected with the wall panel with small angle iron, and a detachable frame is installed on the light box to facilitate maintenance.
Safety alarm system
The differential pressure detection alarm adopts the sound and light alarm mode, and is interlocked with the air supply and exhaust system to cut off the fan operation and remind the operator to replace the filter material; The combustible gas detection and alarm instrument has a central control system and multiple detection channels, which can connect multiple probes. The probes are placed on each indoor working section to monitor the indoor combustible gas concentration at any time and send out alarm signals.
3D operation platform
The lifting is stable, the transportation is reliable, and the structure is reasonable. The operating staff only need to press the six buttons of lifting, lowering, entering, retreating, front and rear to realize the horizontal, vertical, front and rear movement of the working platform. In order to ensure safety, iron chain guard rails are arranged on both sides of the extended platform; The limit switch in the room is of safe voltage, and the pull tube, junction box and motor are of explosion-proof type, thus ensuring the safety of the three-dimensional trolley
Electric control system
The components of the electronic control system of the spray painting and drying integrated room are well-known brands such as Omron, Siemens and Schneider. The main circuit has protection functions such as overcurrent, overload, short circuit and lack of power, ensuring high reliability of the electrical control system and low failure rate. The circuit design is reasonable, with functions such as short-circuit protection, overload protection and reliable grounding protection system. PLC programming can control the whole equipment; The power distribution control cabinet in the system has a plastic sprayed surface and is beautiful
|Section steel framework
|Square tube F200x200x5
|δ75mm Rock wool color steel sandwich board
|Static pressure chamber
|Square tube F80x80x4+50x50xØ3
|Partition wall of static pressure chamber
|δ50mm EPS color steel sandwich panel
|40×3 Flat iron
|Air supply system
|Forced draft fan
|Air inlet duct
|Air inlet equalizer
|Air regulating valve
|Air valve body 1500x800
|Air valve actuator
|Fresh air outlet coarse efficiency bag filter
|Coarse filter material:VNF-290（G3）
|Fan soft connection
|Fire resistant canvas
|Air supply noise reduction room
|Skeleton 80x80x3+ δ 100 rock wool
|Air valve actuator
|T1.2mm galvanized steel plate
|Φ1050×25m(exhaust outlet elevation)
|Fan soft connection
|Fire resistant canvas
|skeleton 50x50x3+δ50mmEPS Color steel sandwich panel
|Natural gas burner
|Inner gallbladder SUS304 t=4mm
|Air filtration system
|Sub high efficiency filtration in static chamber
|Paint mist filtration system
|Baffle dry paint mist filter glass fiber
|Glass fiber filter felt (model PA-50)
|Exhaust gas treatment system
|Activated carbon adsorption box
|Skeleton 50x50x3 square steel + EPS 50mm sandwich color steel plate
|Activated carbon adsorption cotton
|Honeycomb activated carbon
|Safety detection system
|Differential pressure detection
|Combustible gas detection
|RB-KX(with audible and visual alarm function)
|electric control system
|1. Possess chain control function; 2, with short-circuit and overload protection function; 3. Manual + automatic control function; 4. Fault audible and visual alarm function
|Flameproof lighting lamp box
|2X40W / group, illuminance ≥ 700lux, embedded in the room, the inner surface and the inner wall of the room are basically flat, and two rows are arranged on the top and both sides; Total lighting power: 7.20kw
|Explosion proof three-dimensional operation platform
|It is composed of frame, telescopic workbench, walking mechanism, lifting mechanism and electrical control system.
|Meet the operation requirements within the full length of the workpiece ② the maximum vertical movement height of the workbench: 5000mm. ③ Front and rear telescopic movement distance of worktop: ≤ 2000mm.
|Fire extinguishing system
|Manual dry powder fire extinguisher
Note: all equipment dimensions are for reference and can be designed and manufactured according to the customer's product dimensions.
If you want to customize it, you can click this text