Process equipment materials, automotive practical technology, coating production, compressed air supply transformation, Song Chaofeng, Zhao Yong, Yang Dexin (Shaanxi Heavy Vehicle Co., Ltd., Xi'an 710200, China), equipment supply, saving supply station to provide compressed air usage, saving production costs, reducing equipment failure rate.
Introduction Compressed air is an indispensable production resource in the car painting process. Without compressed air, it is like a car losing power. Compressed air controls various pneumatic valves in the coating production process, so that various technical parameters meet the process requirements; provide a safe driving force for coating grinding; transport paint materials for the spraying production line; atomize the paint materials during the spraying process and many more. Therefore, sufficient and constant pressure compressed air is a favorable guarantee for normal coating production.
1. Overview of the status quo In the production process of pre-treatment, pre-treatment electrophoresis, coating polishing, topcoat spraying, robot spraying, under the premise of large-scale use of compressed air in the refrigeration unit, the compressed air attack station can provide sufficient pressure on the body shop.
Air shrinkage ensures normal operation of the production. However, during the production interval, the part of the equipment that needs to continuously supply compressed air in the coating production unit has a relatively large amount of gas, and in the absence of production, the production cost is invisibly increased. After weighing the supply pressure and cost, it was decided to modify the supply mode of compressed air.
Compressed air supply station normal production of all equipment gas air compressor production intermittent part of equipment gas 2, transformation background In the state of no production, the equipment that needs continuous supply of compressed air mainly has centralized paint supply system, painting robot, refrigeration unit Three major equipment systems for chilled water circulation systems.
In the centralized paint supply system, the paint material needs to be continuously circulated so that the paint material is always at the proper temperature, thereby ensuring the viscosity of the paint and the normal parameters of the paint and the smooth flow of the paint. These aspects require the paint reciprocating pump and The paint bucket agitator continues to run and the driving force is compressed air. At the same time, the air control water jacketed air valve is compressed in the system to ensure the temperature required for the paint bucket.
When the spraying robot is intermittent, it must be in the standby state, and the whole system must be maintained under pressure to prevent dust and foreign matter from entering the robot body, causing fouling inside the robot and affecting the quality of the spray after recovery. At the same time, the cup of the robot arm must be in continuous operation to prevent adhesion to the arm body and affect the life of the cup. Compressed air is the only source of power in this standby situation.
Under the premise of no production, the chilled water must be continuously circulated to ensure the uninterrupted operation of the refrigeration unit. In the chilled water circulation system, all pneumatic valves must be controlled by compressed air.
The continuous operation of these three major equipment systems has led to the necessity of compressed air in the absence of production. It is also because only these three systems require compressed air. The gas consumption is only 50% of normal production, so in other words, the compressed air of the supply station is used. It is a "waste" of production costs.
3. Reconstruction and implementation It is the ultimate goal of this transformation to switch the compressed air supply to the air compressor supply end to the entire compressed air pipeline for production and production. We also need to consider whether the industrial power supply is supplied without production, and whether the air compressor can work normally, so the power supply of the air compressor will also be transformed into a switchable mode for industrial power and self-generation.
First, we have to choose the point of entry of the air compressor supply end in the entire compressed air line. First, select the appropriate space for the air compressor; second, facilitate the introduction of industrial power and self-generating switchable modes; third, lay the pipeline at the shortest distance, connect the air compressor and the workshop compressed air system pipe Secondly, the optimization of the reforming pipeline is to ensure the quality of compressed air. First, choose the same pipe diameter as the compressed air system pipeline to ensure the compressed air flow; second, install the appropriate valve to make it switch freely and easy to maintain; third, install an air filter to improve the purity of the compressed air. .
Finally, the verification and debugging after the transformation is particularly important. After the three verifications and commissioning of the inflation pressure verification seal, the production intermittent switching compressed air supply, the industrial power and the self-generation switch, all normal means the completion of the transformation.
4. Equipment maintenance The equipment of the compressed air supply station is naturally not required for maintenance, but the state of the air compressor requires close attention to ensure its normal use at any time. The air compressor should be installed in a place with good ventilation, clean environment, smooth ground, low air humidity, and free space around it for operation and management.
In use, it is found that the fasteners such as bolts and pipe joints are loose, and when abnormal noise or leakage occurs, it must be shut down and tightened; when disassembling the machine, it must be stopped first, and then it can be operated after completely releasing pressure and cooling. With thermal disassembly, ensure the safety of man-machine, disassemble parts with appropriate force, elastic bolts operate symmetrically to prevent bumping; needle roller bearings should be lubricated normally, check every 500 hours of operation and grease to the piston pin hole, fill up and fill; The rated pressure has been set, and the operation of the whole machine must not increase the pressure arbitrarily, otherwise the valve life will be reduced.
The compressed air supply mode is modified, and the air compressor is used to provide the air source during the production stoppage, which reduces the supply of air to the compressed air supply station, thereby saving energy and reducing consumption. At the same time, it also avoids the shutdown of the compressed air supply station. The main pump of the centralized paint supply system cannot be operated normally due to the lack of gas supply, and the paint cannot circulate in the pipeline, causing equipment failure and waste of coating materials caused by paint deposition. System, painting robot, refrigeration unit chilled water circulation system equipment damage. Due to the inability to supply air properly, the paint system was transferred.
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