自動式粉末噴涂生產(chǎn)線設(shè)備工藝流程及系統(tǒng)詳解
一、完整工藝流程
1、 Complete process flow
自動化粉末噴涂生產(chǎn)線包含以下標(biāo)準(zhǔn)工藝流程：上件工序→前處理工序（噴拋丸除銹/自噴式）→烘干工序→靜電粉末噴涂系統(tǒng)→固化處理→下件工序。在前處理階段，必須對工件進(jìn)行全面的表面預(yù)處理，包括但不限于脫脂除油、防銹處理、氯硅烷轉(zhuǎn)化處理以及多道水洗等工序。對于特殊要求的工件，還需增加機(jī)械打磨和噴砂處理等工藝，以顯著提升涂層結(jié)合強(qiáng)度。只有經(jīng)過規(guī)范前處理的工件，才能確保獲得均勻的膜厚分布和優(yōu)異的涂層附著力。噴涂完成后，必須在規(guī)定時間內(nèi)將工件送入固化爐進(jìn)行烘烤，使粉末涂層在受熱條件下按照不同工藝要求形成完整的高性能涂層。目前行業(yè)普遍采用的固化方式主要包括熱風(fēng)循環(huán)烘烤和輻射加熱烘烤兩大類型。
The automated powder coating production line includes the following standard process flow: upper part process → pre-treatment process (spray shot blasting rust removal/self spraying) → drying process → electrostatic powder coating system → solidification treatment → lower part process. In the pre-processing stage, the workpiece must undergo comprehensive surface pretreatment, including but not limited to degreasing and degreasing, rust prevention treatment, chlorosilane conversion treatment, and multiple water washing processes. For workpieces with special requirements, it is necessary to add processes such as mechanical polishing and sandblasting to significantly improve the bonding strength of the coating. Only workpieces that have undergone standardized pre-treatment can ensure uniform film thickness distribution and excellent coating adhesion. After the spraying is completed, the workpiece must be sent to the curing furnace for baking within the specified time, so that the powder coating can form a complete high-performance coating according to different process requirements under heating conditions. The commonly used curing methods in the industry currently include two types: hot air circulation baking and radiation heating baking.
二、靜電粉末噴涂系統(tǒng)構(gòu)成
2、 Composition of electrostatic powder spraying system
完整的靜電粉末噴涂系統(tǒng)主要由以下幾個核心部件組成：專業(yè)噴粉房、高效供粉設(shè)備、一套或多套靜電噴槍及智能控制系統(tǒng)、高壓靜電發(fā)生器以及先進(jìn)的粉末回收處理裝置。噴粉房采用優(yōu)質(zhì)不銹鋼板材制造，具有優(yōu)異的耐用性和防腐性能；其內(nèi)部氣流分布基于流體力學(xué)原理進(jìn)行優(yōu)化設(shè)計，既能有效防止粉末外溢，又能在噴涂區(qū)域形成穩(wěn)定的氣流場，最大限度地降低排風(fēng)氣流對噴涂過程的干擾。
The complete electrostatic powder spraying system mainly consists of the following core components: a professional powder spraying room, efficient powder supply equipment, one or more sets of electrostatic spray guns and intelligent control systems, high-voltage electrostatic generators, and advanced powder recycling and processing devices. The powder spraying room is made of high-quality stainless steel plates, which have excellent durability and anti-corrosion performance; The internal airflow distribution is optimized based on fluid mechanics principles, which can effectively prevent powder overflow and form a stable airflow field in the spraying area, minimizing the interference of exhaust airflow on the spraying process.
三、供粉系統(tǒng)工作原理
3、 Working principle of powder supply system
在供粉系統(tǒng)中，粉末通過壓縮空氣的作用保持流化狀態(tài)，隨后利用虹吸原理被流動氣流攜帶，形成均勻的粉氣混合物。該混合物經(jīng)過文丘里管或HDLV粉泵、輸粉管道，最終輸送至噴槍。系統(tǒng)可精確調(diào)節(jié)輸氣量和霧化氣壓參數(shù)，靈活控制出粉量和粉末霧化狀態(tài)，從而實現(xiàn)不同涂層厚度的精確控制，滿足各類產(chǎn)品的差異化需求。高性能供粉設(shè)備具備強(qiáng)大的輸送能力，即使噴槍的輸粉管長達(dá)50英尺，仍能提供充足的壓力和流量保證穩(wěn)定噴涂。
In the powder supply system, the powder is maintained in a fluidized state by the action of compressed air, and then carried by the flowing airflow using the siphon principle to form a uniform powder air mixture. The mixture is transported through a Venturi tube or HDLV powder pump, powder conveying pipeline, and finally delivered to the spray gun. The system can accurately adjust the parameters of gas transmission and atomization pressure, flexibly control the powder output and powder atomization state, thereby achieving precise control of different coating thicknesses and meeting the differentiated needs of various products. High performance powder supply equipment has strong conveying capacity, even if the powder delivery pipe of the spray gun is up to 50 feet long, it can still provide sufficient pressure and flow to ensure stable spraying.
四、靜電噴槍技術(shù)特點
4、 Technical characteristics of electrostatic spray gun
專業(yè)靜電噴槍的結(jié)構(gòu)設(shè)計必須滿足粉末充電的嚴(yán)格要求，其功能性設(shè)計需適應(yīng)各種噴涂作業(yè)方式和不同形狀工件的噴涂需求。與傳統(tǒng)的液體噴涂技術(shù)相比，靜電粉末噴涂形成的涂層在機(jī)械強(qiáng)度、附著力、耐腐蝕性、耐老化性等方面具有顯著優(yōu)勢，在同等效果下更具成本效益。
The structural design of professional electrostatic spray guns must meet the strict requirements of powder charging, and their functional design needs to adapt to various spraying operation methods and the spraying needs of different shaped workpieces. Compared with traditional liquid spraying techniques, coatings formed by electrostatic powder spraying have significant advantages in mechanical strength, adhesion, corrosion resistance, aging resistance, etc., and are more cost-effective under the same effect.
五、固化室結(jié)構(gòu)設(shè)計
5、 Structural design of solidification chamber
粉末固化室在結(jié)構(gòu)上主要分為直通式固化室和橋式（或π型）固化室兩種類型。為有效減少熱量散失對車間環(huán)境的污染及能源浪費，高溫粉末固化室通常采用橋式結(jié)構(gòu)設(shè)計；而脫水烘干室則可根據(jù)實際情況選擇直通式或橋式結(jié)構(gòu)。采用直通式設(shè)計的烘干室必須在進(jìn)出口處設(shè)置高效風(fēng)幕或自動門系統(tǒng)，以最大限度減少熱量損失。這種科學(xué)的結(jié)構(gòu)設(shè)計不僅能提升能源利用率，還能顯著改善車間工作環(huán)境。
The powder solidification chamber is mainly divided into two types in structure: straight through solidification chamber and bridge (or π - type) solidification chamber. To effectively reduce the pollution and energy waste caused by heat loss in the workshop environment, the high-temperature powder solidification chamber is usually designed with a bridge structure; The dehydration and drying chamber can choose a straight through or bridge structure according to the actual situation. Drying rooms with a straight through design must be equipped with efficient air curtains or automatic door systems at the inlet and outlet to minimize heat loss. This scientific structural design not only improves energy efficiency, but also significantly improves the working environment in the workshop.
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