1200T/month Powder Coating Production Line
1, Major Equipment Parameter
1,1 Design consideration (confirmed by the factory)
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Workpiece name |
Aluminium profile |
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Workpiece material |
Aluminium alloy |
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Workpiece parameters (one-piece) |
Maximum workpiece dimension: L7000mm×W100mm×H200mm |
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Standard workpiece dimension: L7000mm×W50mm×H100mm |
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Standard workpiece weight: 3.3Kg/piece; maximum workpiece weight: 30Kg/piece |
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Output |
monthly output:1000- 1200 tons/year |
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Equipment working system |
8h |
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Speed of conveying chain |
Normal speed of production chain:1.5- 2.0m/min (the running speed of chain 1.0-3.0m/min can be adjusted steplessly) |
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Type of spraying |
Powder coating |
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Way of conveying |
Suspension conveying (cross track) |
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Technical temperature |
200℃ (adjustable under 230℃) |
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Heating method |
Heated directly by fuel gas and heated air circulation |
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Fuel |
Natural gas |
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Factory size (minimum) |
60000mm×24000mm×13500mm(L×W×H) |
2, Main technical parameters and features
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No. |
Name |
Description |
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| 01 |
Suspension conveying chain |
Speed: the normal speed of production chain is 2000mm/min, and the running chain speed is 1000-3000 mm/min which is continuously adjustable |
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Chain pitch: T=400mm; cross track, single-point sling load: 30Kg |
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Hanging pitch: 200mm, 100mm, 66mm, 150mm and 133mm |
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Maximum gas consumption: the water vapour is about 500KG/H (temperature rise)=400 thousand kilocalories/h water heater |
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| 02 |
Powder spraying and recovery |
Powder spraying room and recovery system, 1 set in total |
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Cyclone secondary recovery, setting the ultimate filter (bag type) |
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Powder recovered by cyclone is pumped into the powder supply bucket and reused. . |
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| 03 |
Drying oven, curing oven heating energy |
Heating energy: natural gas |
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Maximum gas consumption: about 100M3/H (temperature rise) |
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Temperature rise time: ≤45 min |
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Exterior furnace wall temperature: ≤room temperature+15℃ (large area of surface) |
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| 04 |
Power |
Power supply: 3-phase 5-line, 380V, 50Hz |
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Single-phase voltage stability: 220V+10%; three-phase voltage stability: 380V+10% |
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Total power: about 161.0KW |
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| 05 |
Air compression |
Pressure: 7-8Kgf/cm2 |
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Maximum gas consumption: 12.5 M3/MIN |
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Clean and dry air: maximum short-time flow 12M3/min, oil content ≤0.01ppm |
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| 06 |
Water consumption |
industrial water |
P=1bar; Q≤4M3/h(maximum) |
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Pure water |
u≤10us/cm; Q<4.5M3/h (maximum) |
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| 07 |
Quality and requirements |
Cured films should be well-distributed and firm, it's not allowed to have chameleon phenomenon such as yellowing. |
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| 09 |
Output computation method |
For example: normal speed of production chain is v=1800mm/min, hanging pitch (mean value) is T=150mm. One-piece weight (mean value) is q=3.3kg/piece. Working time:22hrs/day, 30days/month Hourly output: Q(1500mm/min÷150mm/piece×60mi)×3.3kg/piece=1.98T/h. Monthly output: M =1.98T/h×22hrs/day×30days/month=1306.8T/monthThe resulted calculated above is just a theoretical value, and the output assessed may be different based on the mean value of all the enterprises.
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3, The major components of equipments
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No. |
Name |
Specification |
Quantity |
| 01 |
Feeding and blanking conveying system (platform) |
Feeding conveying system, 1 set
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1 type |
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Blanking conveying system, 1 set
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Auxiliary blanking conveyor
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| 02 |
Suspension conveying chain |
Chain and support frame
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1 set
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Actuating device
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3 sets
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Tensioning gear |
1 set
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Rotary hanger
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Umpty
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| 03 |
Cascade pretreatment and supporting system |
Tent and overhauling channel
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1 set
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Water pump and pipeline
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9 sets
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exhaust gas fan and pipeline
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1 set
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Reservoir (bottom water channel)
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1 set
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Sewage treatment system and waste gas treatment system
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No configuration |
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| 04 |
Moisture drying oven |
Furnace body
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1 set |
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Heating and heated air circulation device
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Fuel machine BG400, 1 set
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| 05 |
Automatic electrostatic powder spraying system |
Rolling shutter machine
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1 set |
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Cyclones
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Bag filter and filter bag
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Draught fan and in-and-out air hose, etc
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Powder spraying elevator (effective travel: 7600MM)
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| 06 |
Powder curing oven |
Oven body
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1 set |
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Heating and heated air circulation device
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Fuel machine BG550, 1sets
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| 07 |
Electronic control system
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Electrical cabinet, electric wire and trunking, etc
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3 sets
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| 08 |
Powder spraying gun
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Optional equipment |
Configured by client
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| 09 |
air compressor
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Optional equipment
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Configured by client
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It’s made up of synchronous aluminium products feeding belt conveying platform, synchronous aluminium products feeding belt conveying platform, support, driving system, inclined auxiliary blanking conveyor.
Auxiliary conveyor: the aluminium products should be suspended over the lines to the feeding conveying platform in case of crash between workpieces. The aluminium products coated should be dropped down smoothly and steadily in case of crash between workpieces, and the running speed is adjusted by frequency control so that it’s convenient to get synchronous with the chain.
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No
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Name
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Content
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Quantity |
| 01 |
Feeding conveying system |
Conveying platform: L5000*W100*H100, 4pcs
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1 set |
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Synchronous belt: Length: 10.4M*width 80 mm *thickness 6mm
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Main support: square tube 100*﹩2.5
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Motor: 1.5KW. gear motor
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Transmission mode: ￠35 round steel, long axis, chain wheel, chain and synchronous pulley
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Speed adjustment mode: frequency control
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| 02 |
Blanking conveying system |
Conveying platform: L5000*W100*H100 4pcs
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1 set |
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Synchronous belt: length: 10.4M*width 80 mm *thickness 6mm
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Main support: square tube 100*﹩2.5
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Motor: 1.5KW gear motor
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Transmission mode: ￠35 round steel, long axis, chain wheel, chain and synchronous pulley
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Speed adjustment mode: frequency control
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| 03 |
Auxiliary balnking conveyor |
Blanking conveyor: length 11.5 M*width 150 mm |
1 set |
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Transmission system: chain wheel, chain and 6 roller chain, 23.5m in total
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Loose piece: nylon L120*W100*﹩10 mm,234pcs
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Guide pillar: nylon ￠30*H100
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Motor: 0.37 KW gear motor, frequency control
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2.2 Suspension conveying system:
Suspension conveying system: is made up of actuating device, driving chain, cross chain, track, tensioning gear, once hanger, stand and automatic adding machine, etc.
To meet the demand of wearproof, manganese steel is used for the crooked part of track of chain with carburizing treatment that it is solid and wear-resisting. Double strand chain is used for the power transmission chain, and mechanical safety, mechanical adjustable clutch and variable frequency motor are set on the chain wheel.
2-3 sets of chain driving systems are used in the whole line to get driven synchronously so as to make the chain run smoothly. Self-compensating tensioning gear, synchronous frequency converter stepless speed regulating can be in reliable operation.
| 01 |
Total length of chain |
Length: about310m |
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| 02 |
Whole-line actuating device |
1.5KW * 3 sets |
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| 03 |
Tensioning gear |
1 set |
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| 04 |
Running speed |
Standard production speed 1.5m/min (chain running speed 1.0-2.0m/min, stepless and adjustable) |
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| 05 |
Track stand |
Square tube: 150*150*δ3.5 |
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| 06 |
Actuating device |
Body frame |
Square tube: 50X2mm |
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Motor/speed reducer |
Variable-frequency three-phase machine: 1.5KW-4P |
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Chain wheel |
Cast steel |
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Quantity |
3 sets |
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| 07 |
Type and specification of chain |
Type |
XF400.80 (cross track chain, cross section 115*47) |
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Pitch |
T=200*2 mm | ||
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Single-point sling load |
30KG | ||
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Method of lubrication |
1 set of automatic oiling machine |
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Type of tensioning |
1 set of heavy-punch tensioner |
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| 08 |
Hanger |
Once hanger (rotary hanger): 1200 pcs |
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2.3 Cascade pretreatment and supporting system:
Cascade pretreatment has advantages as follows:
1, Cascade pretreatment: made up of aqua storage tank, tent (workpiece channel enclosure), process clapboard, water circulation system (water pump, heater)
2, PP plate structure applied can be in a long service life, and has a strong resistance to corrosion that frequent maintenance is unnecessary.
3, Cascade formed by basin can shower the workpieces well-distributedly from top to the bottom, and the workpieces can be cleaned completely that the evenness of surface treatment to the products is very high.
4, It has the function of sediment and filtration of water tank. After the dirt is washed away from the surface of workpieces, it will not come back again. Thus, the cleanliness degree of workpiece surface is higher than immersion. Compared with immersion, the capacity of water channel is small, heat exhaustion is less and the floor area occupied by equipments is small.
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No. |
Name |
Technical specification |
| 01 |
Pretreatment process |
Processing stations: 9 |
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Order of processing: washing 1 |
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| 02 |
Boundary dimension |
Total length: 35.00m
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Boundary dimension of tent: L17500*W2200* H9580mm
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Bottom aqua storage tank: H950*W1500 mm*L.
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| 03 |
Installed power |
65KW |
| 04 |
Heating source |
Steam: 350 thousand kilocalories/h
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| 05 |
Water consumption |
Industrial water: 4M3/h
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Pure water: 4.5M3/h
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| 06 |
Wastewater discharge |
＜8M3/h |
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Remark: due to the different demand of pretreatment process, the mode of pretreatment should be confirmed by client |
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Instruction of pretreatment structure:
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No. |
Name |
Instruction |
| 01 |
Water storage tank |
Quantity: 9 sets |
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Tank material: &15mm PP plate |
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Bottom stand: steel channel 10#/A3 |
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Removable head: &10mm PP plate |
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| 02 |
Side plate and top plate of tent |
Side panels of the shed: multi-layer composite high-strength corrosion-resistant PVC soft curtain |
| Roof of the shed: 15.0mm PP board | ||
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Main framework of tent: flat tube 120*40*3.0mm/A3,120*80*3.0mm/A3, steel channel 8#/A3 |
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| 03 |
Processing clapboard and end plate (groove clapboard) |
Material of clapboard: &10mm PP plate |
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H1.8m dodge gate configured on the bottom of clapboard, the material is &10mm PP plate |
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Two-layer clapboard is loaded with soft rubber plate in the area of exits and entrances in case of bath solution overflow |
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Dodge gate loaded with soft rubber plate on the bottom of clapboard in case of bath solution channeling |
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| 04 |
Cascade basin |
Quantity: 36pcs |
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Material: &10mm PP plate |
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Removable-type design: the distance of cascade can be adjusted according to different workpieces |
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| 05 |
Bath solution circulating system |
Each processing station is equipped with a set of bath solution circulating system, 9 sets in total |
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Constitution of bath solution circulating system: circulating water pump, filter screen, pipeline and regulating valve, etc |
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Corrosion-resistant pump material: MHB4 alloy pump |
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Material of bath solution filter screen: nylon filter screen |
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Pipeline, valve material and supporting: PVC pipe and PVC valve |
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Line pressure detection and control: pressure gage 0-4kg/cm2 , Φ80mm |
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| 06 |
Water charging system |
Flowmeter is used for the pre-separation tank, degreasing tank and chromizing tank to control replenishing water regularly |
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Automatic water replenishing device is used for rinsing tank |
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Material of water replenishing pipeline and valve inside the equipments: PVC pipe and PVC valve |
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Automatic water replenishing valve: stainless steel ball float valve |
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Material: 316L stainless steel |
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| 07 |
Overflow system |
8# tank (washing) overflows to 7# tank, 7# tank (washing) overflows |
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6# tank (chromizing tank) overflows |
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5# tank (washing) overflows to 4# tank (washing), 4# tank (washing) overflows |
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3# tank (main degreasing) overflows, 2# tank (pre-degreasing) overflows |
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Tank overflow inside and outside and blow-off pipe: PVC pipeΦ60 |
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| 08 |
Sewerage system |
9sets in total |
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Blow-off pipe: 1 set in each tank, 9 sets in total |
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Material of blow-off pipe: PVC pipe Φ75 |
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Material of blow-down valve: PVC valve
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| 09 |
Exhaust draindown system |
Drought fan: 2 sets |
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Power: 3.0KW |
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Material of air hose: PVC |
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| 10 |
Groove face grating |
Removable grating is convenient for maintenance |
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Grating material: fiberglass |
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| 11 |
Platform and guardrail |
Total length: 36.0m |
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Top installation platfor and guardrail are convenient for adjusting cascade basin |
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Platform: 2m/A3 riffled steel plate. Guardrail: square tube 40*20/A3 |
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| 12 |
Maintenance ladder |
Quantity: 1 set |
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Material: square tube 80*40/A3, square tube 30*30/A3
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Equipments and configurations in the process section of pretreatment-water pump and supporting:
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Station |
Name |
Configuration of water basin and water pump |
Main pipeline |
Filter screen |
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| 1# |
Washing 1 |
Quantity of cascade basin: 2 pcs |
￠75 PVC pipe |
Standard chemical nylon filter screen |
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Equipped with circulating water pump: 1 set |
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Type of water pump: 65FCHB20S, metal antiseptic pump |
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Parameter of water pump: P=4kw, Q=30M3/h/, H=20M. |
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Water collection tank (circulating water tank): 1 set |
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| 2# |
Pre-degreasing |
Quantity of cascade basin: 6 pcs |
￠110 PVC pipe |
Standard chemical nylon filter screen |
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Equipped with circulating water pump: 1 set |
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Type of water pump: 100FCHB20S, metal antiseptic pump |
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Parameter of water pump: P=11kw, Q=100M3/h/, H=20M. |
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Water collection tank (circulating water tank): 1 set |
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| 3# |
Main degreasing |
Quantity of cascade basin: 8 pcs |
￠110 PVC pipe |
Standard chemical nylon filter screen |
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Equipped with circulating water pump: 1 set |
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Type of water pump: 100FCHB20S, metal antiseptic pump |
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Parameter of water pump: P=11kw, Q=100M3/h/, H=20M. |
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Water collection tank (circulating water tank): 1 set |
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| 4# |
Washing 2 |
Quantity of water basin: 2 pcs |
￠75 PVC pipe |
Standard chemical nylon filter screen |
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Equipped with circulating water pump: 1 set |
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Type of water pump: 65FCHB20S, metal antiseptic pump |
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Parameter of water pump: P=4kw, Q=30M3/h/, H=20M. |
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Water collection tank (circulating water tank): 1 set |
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| 5# |
Washing 3 |
Quantity of cascade basin: 2 pcs |
￠75 PVC pipe |
Standard chemical nylon filter screen |
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Equipped with circulating water pump: 1 set |
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Type of water pump: 65FCHB20S, metal antiseptic pump |
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Parameter of water pump: P=4kw, Q=30M3/h/, H=20M. |
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Water collection tank (circulating water tank): 1 set |
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| 6# |
Chromizing |
Quantity of cascade basin: 8 pcs |
￠100 PVC pipe |
Standard chemical nylon filter screen |
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Equipped with circulating water pump: 1 set |
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Type of water pump: 100FCHB20S, metal antiseptic pump |
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Parameter of water pump: P=11kw, Q=100M3/h/, H=20M. |
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Water collection tank (circulating water tank): 1 set |
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| 7# |
Washing 4 |
Quantity of cascade basin: 2 pcs |
￠75 PVC pipe |
Standard chemical nylon filter screen |
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Equipped with circulating water pump: 1 set |
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Type of water pump: 65FCHB20S, metal antiseptic pump |
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Parameter of water pump: P=4kw, Q=30M3/h/, H=20M. |
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Water collection tank (circulating water tank): 1 set |
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| 8# |
Washing 5 |
Quantity of cascade basin: 2 pcs |
￠75 PVC pipe |
Standard chemical nylon filter screen |
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Equipped with circulating water pump: 1 set |
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Type of water pump: 65FCHB20S, metal antiseptic pump |
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Parameter of water pump: P=4kw, Q=30M3/h/, H=20M. |
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Water collection tank (circulating water tank): 1 set |
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| 9# |
washing 6(Pure water washing) |
Quantity of cascade basin: 2 pcs |
￠75 PVC pipe |
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Equipped with circulating water pump: 1 set |
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Type of water pump: 80FCHB15S, metal antiseptic pump |
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Parameter of water pump: P=5.5kw, Q=40M3/h/,H=15M. |
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Water collection tank (circulating water tank): 1 set |
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Water pump manufacturer |
Jeika |
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Technical features and functions:
Moisture drying oven is used for drying the aluminium profile after pretreatment, which means the ways of updraught and down-shot heated air circulation are used to dry aluminium products. Besides, in design, the hot air forms a kind of strong convection current so that there is the air curtain formed inside the oven, the purpose of this is to reduce the overflow of heat. The frame structure has a good rigidity and little heat leakage that it’s energy-saving.
There is no guard railing on the top of oven, and it’s equipped with a ladder stand for the personnel, which makes it easy for maintenance.
Hot-air blower is imbedded on the top of oven, connected by bolts and screws, air-cooled, which is convenient for maintenance and replacement.
The cover of air flue is a removable grating plate with an access door set, which is convenient for clearing the oven inside.
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No. |
Name |
Technical specification |
| 01 |
Operating temperature |
80—90℃, maximum 100℃ |
| 02 |
Temperature rise time |
﹤45min |
| 03 |
Temperature difference between oven wall and room |
﹤15℃ |
| 04 |
Temperature difference in workpiece area |
﹤+5℃
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| 05 |
Time of drying |
8-10 min |
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Drying condition: for the first drying workpiece after dropping water (aluminium products) |
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| 06 |
Boundary dimension |
L9480*W2385*H9280 mm. |
| 07 |
Track length inside the oven |
About 19m |
| 08 |
Mode of temperature control |
Heated air circulation, automatic temperature control |
| 09 |
Energy |
directly heated by natural gas |
| 10 |
Installed power |
﹤13KW |
| 11 |
Exit&entrance of workpiece |
Size: W400*H8300mm |
| 12 |
Side frame inside the oven |
Galvanized bolts assembled and connected |
| 13 |
Outside surface of oven |
Stand square tube is coated with anti-corrosive primer+blue finishing coat, board surface: primary colour |
Structure specification:
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No. |
Name |
Instruction |
| 01 |
Side plate of oven |
Main body framework: flat tube 120*40*3.0mm/A3,120*40*3.0mm/A3 |
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Insulating layer: standard rock beam and laminboard, thickness: external &150mm (&0.8mm/A3 color coated sheet, inside &0.8mm/A3 zinc sheet). |
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Weight of rock wool: 100K |
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| 02 |
End plate of oven |
Main body framework: flat tube 120*40*3.0mm/A3,120*40*3.0mm/A3 |
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Insulating layer: standard rock beam and laminboard, thickness: external &150mm (&0.8mm/A3 color coated sheet, inside &0.8mm/A3 zinc sheet). |
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Weight of rock wool: 100K |
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| 03 |
Hot air duct of oven |
Main body framework: flat tube 70*70*2.0mm/A3,30*40*2.0mm/A3 |
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Inner plate: &1.0mm/A3 zinc sheet |
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| 04 |
Oven top |
Crossgirder of oven top: flat tube 200*100*4.0mm/A3, angle iron 40*40*4.0mm/A3 |
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Draught fan permanent seat: assembled by &6mm/A3 and 7# angle iron, convenient for maintenance. |
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Insulating layer: 150 mm100K rock wool board |
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Top pinch plate: inside &1.0mm/zinc sheet, external &1.0mm/A3. |
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| 05 |
Baseplate |
Bottom pinch plate: &1.0mm/A3 zinc sheet |
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Insulating layer: 50 mm100K rock wool board |
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Inner frame: angle iron 25*2.5 |
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| 06 |
Heating system |
Hearth: heat-resisting stainless sheet &2.5mm, flange connection, convenient for dismantlement |
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Hearth connecting flange: &8.0mm/Q235 heat-resisting steel plate |
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Burner: BG400 1 set |
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| 07 |
Hot-air blower |
Air-cooled vane draught fan, temperature resistance 250℃ |
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Motor: 3KW |
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Flow: ﹥12500M3/H |
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Full pressure: 230Pa |
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Quantity: 3 sets in total |
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| 08 |
Air outlet of oven bottom |
Hot galvanizing flat iron grating |
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Zinc plate, angle iron 25/A3 |
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| 09 |
Ladder |
Main body framework: square tube 80*40*2.5mm/A3 |
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Ladder stand guardrail: flat iron 40mm*&4.0mm |
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Ladder stand step: square tube 30*30*2.0mm/A3 |
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| 10 |
Guardrail of oven top |
Guardrail height: 1100 mm |
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Flat tube: 40*20*1.5mm/A3 |
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| 11 |
Chimney air hose |
&0.8mm galvanized sheet spiral duct |
| 12 |
Access door |
Quantity: 1 type
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Material: stand square tube 120*40*3.0mm/A3, insulating layer: 15 rock wool |
Feature description:
Rolling shutter powder spraying system is designated for the vertical powder spraying of aluminium profile, and the shape of conveying chain inside spraying room is V, where there is equipped with hanger reversing gear in the intermediate point. Workpiece can rotate for 180°intermediate point, and the spray guns on the elevator are arranged in V. Workpieces are moved to the elevator where spray guns are equipped through conveying chain. Spray guns can spray powder to workpieces from one side, and when the workpieces move to the middle part of V track through reversing gears, it rotates for 180°. Thus, two sides of workpieces can be sprayed in the single powder spraying room. Two sets of powder spraying rooms are arranged side by side, and there is a set of hanger rotation device installed between two spraying rooms, one is used to spray the front side, rotating for 180° before going to the other spraying room. The other one is used to spray the reverse side so as that both sides can be sprayed.
The air in the spraying area can be discharged from the vertical joints of air draft barrel of spraying room. Air draft barrel of powder spraying room is joined with cyclone recovery system. Floating powder in the spraying area can be recycled by cyclone recovery system. And the superfine powder can be recycled by the filter recovery system. The automatic roller shutters can be retractable while changing colors fast in the powder spraying room. Besides, the problem of cross color can also be avoided effectively. Base plate is installed on the bottom of powder spraying room to collect the powder poured out in case of waste and pollution.
Rolling shutter device:
Core tube air draft system is connected with cyclone separator, and the design of rolling shutter is used that it’s convenient to change colors. Besides, with the electrodynamic automatic rolling shutter, and the part of core tube that is equipped with a trolley to clear up powder, it will be fast to clean the powder in the V hole of core tube.
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No.
|
Name
|
Instruction
|
| 01 |
Boundary dimension |
L4300×W2300×H9600mm |
| 02 |
Air draft core tube |
Material: steel plate 3/A3 roller
|
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Coating: epoxy paint inside, antirust paint outside+blue finishing paint
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| 03 |
Main body side stand
|
Square tube 120×3mm
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| 04 |
Top and bottom stand
|
Square tube 60×2mm, square tube 120×80×3mm/A3
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| 05 |
Passageway and guardrail |
Botton of passageway: zinc-coated grating, bottom stand: square tube 60×2mm/A3 |
|
Guardrail: square tube 40×20×1.5mm/A3
|
||
| 06 |
Rolling shutters rollers |
Length: L2200MM*2 sets
|
|
Material: galvanized tube
|
||
|
Rolling shutters rollers driving motor: 0.37KW
|
||
| 07 |
Coretube powder-cleaning trolley |
1 set |
| 08 |
Roller shutters curtain PU |
2 rolls |
| 09 |
Pressing plate |
2 sets |
| 10 |
Joint air hose |
2mm /A3 roller, 1 batch
|
Cyclone configuration:
This is used for recycling the dust in the air of powder spraying room, and the recovery rate is 95—98﹪. It’s connected to the core tube of spraying room in the entrance, and the exit is connected to the entrance of filter. Dust collected can be recycled through peristaltic valve and pumped into sifter and powder barrel.
|
No. |
Name |
Instruction |
| 01 |
Boundary dimension |
Main body: 2500×2500×11600mm |
|
Barrel body Ø1530×7600mm |
||
| 02 |
Exhaust tube |
Connected to the air hose of spraying room: steel plate 2mm/A3 roller+screw-thread galvanized air hose |
|
Connected to the air hose of filter: galvanized sheet: 1.0mm, spiral tube |
||
| 03 |
Cyclone body |
Material: 3mm/A3 steel plate, roller |
|
Mode of surface treatment: epoxy paint inside, antirust paint outside+blue finishing coat |
||
| 04 |
Main body stand |
Main body stand: square tube 120×80×2.5mm |
|
Side stand: square tube 80×40×2.5mm |
||
|
Fixed platform of cyclone barrel body: square tube 60×60×2.5mm |
||
| 05 |
Maintenance platform blanking plate |
Checkered plate 2mm/A3 |
| 06 |
Guardrail |
Guardrail height: 1100 mm
|
|
Square tube: 40×20×1.5mm/A3
|
||
| 07 |
Ladder |
Quantity: 1 piece
|
|
Step material: square tube 30×1.5mm/A3
|
||
| 08 |
Peristaltic powder conveying tube |
2 sets
|
|
Type and brand: DN80,
|
||
|
Powder conveying tube: chequered tube L=5
|
||
|
Control mode: PLC automatic control
|
Filter element dust collection device:
A combined polyester fiber filter bag is adopted, the recovery rate of dust is over 99.99%, and the exhaust emission is less than 0.04MG/M3. A removable inspection door is set on the top of filter for the convenience of maintenance and inspection. An automatic power-driven blow-off valve is set on the botton to release the power of work.
|
No. |
Name |
Instruction |
| 01 |
Boundary dimension |
Main body of filter: L2060×L2060×H6600mm |
|
Installation platform support of draught fan: L2060×1800×5400mm |
||
|
Main material of supports: square tube 120×80×2.5mm/A3 |
||
| 02 |
Main body |
External cover plate: 3m/A3 plate |
|
Main material of inner frame: square tube 80*40*3.5 and square tube 40×40×2.5mm/A3 |
||
| 03 |
Exhaust fan |
Centrifugal fan |
|
Power: 55KW |
||
|
Blast capacity: 26000M3/H |
||
| 04 |
Joint air hose |
Screw-thread zinc pipe: ∮0.8mm/ zinc sheet |
|
Air hose flange: steel plate 6/A3 |
||
| 05 |
Air pocket pipe |
Seamless steel tube: Φ219mm |
|
Steel channel 10# |
||
| 06 |
Electromagnetic valve |
Pulse mode: G1.5” |
|
Quantity: 25pcs |
||
| 07 |
Back flushing pipe |
Quantity: 25pcs |
|
Material: zinc pipe installed and welded
|
||
| 08 |
Filter bag |
Specification: standard polyester filter bag φ230×3000 mm
|
|
Quantity: 100pcs
|
||
|
Filter fineness
|
||
|
Filter bag arrangement form: 1×2 integrated-type rectangular array
|
||
| 09 |
Waste powder emission (sealed on the bottom) |
Vacuum and isolated automatic blow-off valve 1 set |
|
Power: 1.1kw |
||
|
Manner of working: interrupted, PLC self-timing emission control |
||
| 10 |
Waste powder traveling bogie |
Quantity: 1 set
|
|
Material: square tube 60×40/A3
|
||
| 11 |
Pulse controller |
PLC |
| 12 |
Overhauling ladder |
Combined type and integrated, ladder (step) material: square tube 40×40/A3
|
Electrodynamic-type reciprocating elevator:
Technical description:
d. Quantity available to equip spray guns: 24pcs
e. Standard wear-resisting T track and wear-resisting guide pulley combinational design, which have the features of strong stability and long service life.
f. German-made products are used as supporting to the key components, such as speed reducer, motor and PLC, etc.
g. Double-insurance machinery safety design of, and it will reset automatically when it’s shut down, human-computer interface is centralized for operating control.
|
No. |
Name |
Structure specification |
| 01 |
Boundary dimension |
L815×W572×H10500mm |
| 02 |
Main body |
Internal frame: square tube 120×60×3.5mm |
|
External sealing board: A3 board, thickness is 2mm |
||
|
Guide rail: standard T track |
||
|
Foundation: thick steel plate 15MM |
||
| 03 |
Lifting trolley |
Guide pulley: N66 finish machining |
|
Body frame: steel plate installed and welded |
||
|
Drive chain: 5 chains on triplex row |
||
| 04 |
Bob-weight trolley |
Guide pulley: N66 finish machining |
|
Body frame: angle iron |
||
|
Bob-weight chain: 5 chains on double rows |
||
|
Clump weight: umpty |
||
| 05 |
Guide bearing |
NACHI |
| 06 |
Gear motor |
Power: 2.2KW |
|
Manufacturer: German SEW |
||
| 07 |
Gun barrel and gun rack |
A3 structural steel, 1 set |
| 08 |
Caterpillar chain |
Engineering plastic chain, W250 type |
| 09 |
Dust seal |
Nylon hairbrush |
| 10 |
Travel control |
Encoder and Siemens PLC |
| 11 |
Speed regulation |
Frequency converter+PLC |
| 12 |
Error correction |
1 type |
2.6 Powder curing oven
(A)Technical feature and function:
Powder curing oven is used in curing aluminum profile after it’s sprayed with powder. Up-draft and down-blow heated air circulation is adopted to cure and spray the aluminum product and make wind screen area and powder curing area operate independently, thus making outlet and inlet inside of oven form an air curtain to reduce the heat overflow. Unique carrying wind system in the curing area makes air temperature inside of the oven more uniform, which is easy for curing and leveling powder. Frame structure has nice rigidity, less heat leakage, and is energy-saving.
The top of the oven is equipped with guard railing, and ladder stand for staff use, which are conducive to maintenance.
Upper cover of wind screen and air flue adopts separable grating plate and sets access door, which are conducive to clear the inner oven.
|
No. |
Name |
Technical specification
|
| 01 |
Operating temperature
|
200℃ |
| 02 |
Boundary dimension
|
L9480*W6410*H9280 mm. |
| 03 | Temperature difference between oven wall and indoor | ﹤15℃ |
| 04 | Temperature difference in workpiece area | ≦+5℃ |
| 05 |
Curing time
|
22 min |
| 06 |
Chain speed Designed |
2.0 m/min (national standard workpiece, wall thickness is 1.0mm aluminum profile) |
| 07 |
Temperature rise time
|
≦45min |
| 08 |
Track length of oven inside
|
41+15meter |
| 09 |
Temperature control mode
|
Heated air circulation and automatic temperature control
|
| 10 |
Energy
|
Heated directly by natural gas
|
| 11 |
Installed power
|
﹤27KW |
| 12 |
Workpiece outlet and inlet
|
Dimension: W400*H8300mm
|
| 13 |
Side frame of oven body
|
Galvanized bolt assembled and connected
|
| 14 |
Outside surface of oven body
|
Stand square tube is sprayed with anti-corrosive primer+ blue finishing coat, board: primary color
|
(B) Structure specification:
|
No. |
Name |
Instruction |
| 01 |
Side plate of oven |
Main body framework: flat tube 120*40*3.0mm/A3, 120*40*3.0mm/A3
120*40*3.0mm/A3,120*40*3.0mm/A3 |
|
Insulating layer: thickness of standard rock beam laminboard is &150mm (external &0.8mm/A3 color plate, internal &0.8mm/A3 zinc plate). |
||
|
Weight of rock wool: 100K |
||
| 02 | End plate of oven body |
Main body framework: flat tube 120*40*3.0mm/A3,120*40*3.0mm/A3 |
|
Insulating layer: thickness of standard rock beam laminboard is &150mm (external &0.8mm/A3 color plate, internal &0.8mm/A3 zinc plate). |
||
|
Weight of rock wool: 100K |
||
| 03 | Hot air flue of oven inside |
Main body framework: flat tube70*70*2.0mm/A3, 40*40*2.0mm/A3 |
|
Inner plate: &1.0mm/A3 zinc plate |
||
| 04 | Median septum of oven body |
Main body frame work: flat tube 70*70*2.0mm/A3,40*40*2.0mm/A3 |
|
Insulting plate: thickness of standard rock beam and laminboard is &150mm. |
||
| 05 |
Oven top |
Crossgirder of oven top: flat tube 200*100*4.0mm/A3, angle iron: 40*40*4.0mm/A3 |
|
Permanent seat of draught fan: assembled by &6mm/A3 and angle iron 7#, which is convenient for maintenance. |
||
|
Insulating layer: &1.0mm/A3 zinc plate 150mm 100K rock wool plate |
||
|
Top pinch plate: internal &1.0mm/ zinc plate, external &1.0mm/A3 plate. |
||
| 06 | Baseplate |
Bottom pinch plate: &1.0mm/A3 zinc plate |
|
Insulating layer: &1.0mm/A3 zinc plate 50mm 100K rock wool plate |
||
|
Inner frame work: angle iron 25*2.5 |
||
| 07 | Heating ystem | Hearth: heat resistant stainless plate &2.5mm, flange form connection, which is convenient for disassembly. |
|
Hearth flange connection: &8.0mm/Q235 heat resistant steel plate |
||
| Burner: BG550, 1 sets | ||
| 08 |
Hot air blower |
Air-cooled and vane air blower, temperature resistance is 250℃ |
|
Motor: 3KW |
||
|
Flow: ﹥12500M3/H |
||
|
Full pressure: 230Pa |
||
|
Quantity: 4sets in total |
||
| 09 | Air outlet of oven bottom |
Hot galvanizing flat iron grille |
|
Zinc plate, angle iron 25/A3 |
||
| 10 |
Ladder |
Main body framework: square tube 80*40*2.5mm/A3 |
|
Ladder guardrail: 40mm*&3.0mm flat iron. |
||
|
Ladder step: square tube 30*30*2.0mm/A3 |
||
| 11 | Guardrail of oven top |
Flat tube: 40*20*1.5mm/A3 |
|
Guardrail height: 1100 mm
|
||
| 12 | Chimney air hose |
&0.6mm zinc plate spiral air hose
|
| 13 | Access door |
Quantity: 1 set
|
|
Material: stand square tube 120*40*3.0mm/A3, insulating layer: &150mm rock wool
|
2.7 Electronic control system
(A) Feature description:
(1) Production line adopts centralized control cabinet to control, operated by man-machine interface, which is of perpetual intuition and easily operation.
(2) Display of monitoring appropriately of curing oven temperature.
(3) Display of operation status of the equipment.
(4) Key position of production line sets emergency stop button to assure safety.
(5) Main components and parts select original import or co-invested brand, which lengthen service life, thus lowering failure rate.
(6) Adopting chain design and sound-light alarm system to avoid sudden failure and component damage.
(B) Detailed configuration:
| No. |
Name |
Instruction |
| 01 |
Electric control cabinet |
A3 plate powder spraying |
| 02 |
Touch screen |
10.4 inch color, manufacturer: Siemens |
| 03 | PLC |
Siemens |
| 04 | Frequency converter |
Mitsubishi |
| 05 | Temperature control module |
Siemens |
| 06 |
D/A module |
Siemens |
| 07 | Temperature probe | PT100 |
| 08 | Contractor |
Schneider |
| 09 | Thermorelay |
Schneider |
| 10 | Disconnector |
Schneider |
| 11 | Indicator light |
Schneider |
| 12 |
Button |
Schneider |
| 13 | Electric wire and cable |
Produced in Guangdong |
| 14 | Wireway |
Galvanized plate, pretreatment part is plastic wire groove |
2.8 Power source configuration sheet:
The biggest operational consumption (reference value) of each stand-alone when spray the powder (not including wood grain)
| No. | Equipment name |
Electricity consumption (Kw/h) |
Compressed air (m3/min) |
Industrial water consumption (T/h) |
Natural gas (m3/ h) |
| 01 | Feeding and blanking platform and supplementary blanking machine | 4.0 | |||
| 02 |
Suspension pipeline |
6.0 | 0.5 | ||
| 03 | Pretreatment (heating oven excluded) | 65.0 | 4.0 | ||
| 04 |
Moisture drying oven |
12.0 | 30.0 | ||
| 05 | Spray room and elevator (1 set of configurations) | 50.0 | 6.5 | ||
| 06 |
Curing oven |
24.0 | 50.0 | ||
| 07 | |||||
|
Total |
161.0 | 7.0 | 4.0 | 80.0 | |
|
Remark: the above is the biggest installation energy consumption, not including consumption of furnace, air compressor, spray gun, workshop illumination and sewage treatment. |
|||||
2.9 Equipment color matching sheet:
Main equipment color spraying in production line
| No. |
Name |
Instruction |
| 01 |
Equipment main body |
Pretreatment: panel—hoary PP plate (primary color); panel stand sectional material—peacock blue
|
|
Curing oven: insulating panel—hoary color plate (primary color); insulating panel square tube external stand—peacock blue
|
||
| 02 |
Upright and hanging bracket |
Peacock blue |
| 03 |
Elevator |
Peacock blue |
| 04 |
Chain track |
Nacarat |
| 05 | Guardrail |
Yellow |
| 06 |
Electric machine and outsourcing supporting |
Primary color |
| 07 | ||
|
Remark: the above is the color matching of main equipments. Please refer to relevant pictures for others. |
||
3, Engineering scope of responsibility (equipments not in price, etc)
| No. |
Project content |
Division of responsibility |
||
|
Buyer |
Seller |
|||
| 01 | Workshop and configuration |
Workshop, floor of workshop, equipment basis |
√ | |
|
Wall and rooftop tapping and leakage repairing, etc |
||||
|
Fire fighting and ventilation facilities of workshop |
||||
|
Pretreatment of pool and antiseptic |
||||
|
Pretreatment sewer, pool and antiseptic, etc |
||||
| 02 |
Power supply |
Workshop power supply, from wall electricity box to various equipment electric cabinet tube and wire, etc. | √ | |
|
Workshop illumination |
||||
|
Internal wiring and trunking of equipment |
√ | |||
|
Internal electricity box and electric cabinet of the equipment |
||||
| 03 | Water supply |
Water pipe of the workshop is connected to water supply point of equipments |
√ | |
|
Preparation of pure water is connected to water consuming point of equipments |
||||
|
Internal water pipe and valve, etc of equipment |
√ | |||
| 04 |
Water drainage |
Underground embedded pipe and groove |
√ | |
|
Drainage ditch and cover plate |
||||
|
Sewage treatment, etc |
||||
| 05 | Energy | Energy (liquefied gas) supply depot and pipeline | √ | |
|
Connected to the place of equipments operation |
||||
|
Steam and pipeline are joined up to equipment |
||||
| 06 |
Air compression |
air compressor ,cooling equipment and pipeline |
√ | |
|
Connected to pipe and valve of equipments |
||||
| 07 | Electrostatic powder spraying gun |
Powder spray gun and control system |
√ | |
|
Powder barrel and powder supply system |
||||
| 08 |
Others |
Powder spraying room and isolation room |
√ | |
| Install necessary water supply, power supply and gas cutting, etc | ||||
|
Unloading and lifting tools, etc in the equipment field |
||||
| Note: √ refers to responsible party | ||||
