Coating Line of Passenger Car

Preliminary Design Proposal


Project：Coating Line of Passenger Car


Design company:




July 13rd, 2010


Part two: Description of tender cargo

Design basis and technical requirements
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The design is based on the relevant technical specification and requirement described in the document of passenger car coating line of your company.

Process overview
1



This production line mainly undertakes the coating of passenger cars, including the work procedures of treatment before painting, primer, foaming, damping gluing,puttying,floating coating, surface coating,shadowing,spraying of color bar, glaring, drying,checking,modification of workpieces, and the check of paint material and coated products as well.The producing mode of the line is batch production. The transfer of work pieces among different workstations of the line is done manually, which meets the process requirements of primer, floating coating and surface painting. The line process is perfect and the design of process equipment meets the coating requirements. The design is implemented strictly in accordance with the state standard of safety, health, and fire fighting and environment protection. Taking the current status of workpieces and paint into consideration, the design is based on user’s requirements and could be adjusted according to coating process requirements.

2：Design principle
GB11380-89
The design adopts triple-layer coating process, which means the primer, floating coating and surface coating of workpieces.Therefore,the corrosion resistance,dicoration ,
mechanical property and so on of the coating could reach the international advanced level. The coating quality meets the requirement of Grade KT4-1 in the state standard of Technical Specification of Passenger Car Coating GB11380-89.


Local puttying quick-drying process is used according to the car body flatness. The workstations of puttying and polishing are set. The daub of putty is done based on process design of secondary puttying. With the improvement of body manufacturing process, the daubing of putty has been reduced gradually.



The layout of workshop processing equipment is draw-out type. The zones of painting, burnishing and drying are relatively layed concentratedly based on their different requirements on processing environment.

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Wet-type painting is done in water-rotating spray room by means of upper supply &bottom exhaust. The waste water containing paint slag is treated in sewage treatment station. It is discharged after meeting relevant standard.

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Puttying zone, shadowing zone and testing zone is equipped with lifting platform and lighting system. In the puttying zone, grilles are set on the two sides of workpieces. And shallow puddle and drainage devices are set at the bottom of the grilles.



The equipment in manual finishing room, foaming room, finishing room and polishing
room includes the chamber, lighting system, operation grilles, air supply system, exhaust system,pit,lifting platform ,electronic control device and so on. Shallow puddles and drainage devices are set at the bottom of all the rooms except the foaming room. The sewage is drained at regular intervals.

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The drying uses indirect heating of hot blast convection. The indoor air-flow organization adopts the way of side lower blow-out and side upper blow-back. Electric side-by-side door is set and through which cars come into the drying room. The heat source of drying is nature gas. Waste gas is treated by direct-fired burning device and then exhausted after it reaches relevant standard.



Anti-noise measures are taken to kinds of painting equipment which always produce noise. The air supply device of air conditioner is placed on the A/C platform. So that the noises could be controlled under 85dB（A）

All the parts, auxiliary equipment, materials and electrical elements are advanced products with high quality. The key equipment and materials among them such as top filter pad, burner and some important electrical elements are original parts with famous brands imported from other countries. Therefore, they can ensure the overall performance and reliability of the equipment

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Basic investment should be reduced as much as possible under the premise of ensuring the original performance of the equipment.

3、Description of main process
Production process flow


Workpieces are conveyed to painting workshop from welding workshop→chassis primer→prefoaming→foaming→manual pretreatment→primer→drying of primer→puttying→polish and block up sand holes→puttying again→polishing→float coating→drying of float coating→preparation for surface painting→surface painting→drying of surface painting→check and modification→send the qualified car body to assembly workshop
Equipment selection
3座
Chapter 1: Three water-rotating spray rooms

1
Process objective: To provide a good coating place, cozy operation environment and improve the quality of painting.

2。
Process equipment: The water-rotating painting room consists of the chamber, air cleaning facility, floor grills, air supply system of air conditioner, exhaust system ,lighting facility, spraying device, water circulatory system, air supply&exhaust platform, electrical door and three-dimensional trolley ect.

3
Operating principle: Fresh air is sent in through the air inlet of air supply facility. After being filtered and current shared, it is sent to the dynamic and static pressure room
at the top of the equipment. There it is distributed by bag filter and filtered by nonwovens. Then it is sent homogeneously into the room at sectional wind velocity (high than 0.4m/s). The air flow encircles workpieces and contracts towards the middle gradually. The spraying paint should not splash. So that the labor sanitary condition of the working environment is improved. The spraying treatment is done by many water-rotating devices in one row set below the equipment centerline. Water is impacted and atomized by the air flow. Then the paint mist is captured in the water and the clean air is exhausted by exhaust device. The processing efficiency of this kind of wet-type spraying room is high than 99%. The water containing paint mist flows to circulatory pond under the action of gravity’s he clean water after being filtered and precipitated is sent back to spraying room by circulatory water pump for recycling.

Schematic of water-rotating spraying room

1. preliminary filter net for air inflow 2.air blower 3.precise and high-efficiency filter net 4.grille board 5.lighting device 6.induced draft fan 7.exhaust air nozzle 8.wash board 9.hydraulic spinning machine 10.striking plate 11.guide rail

4Description of equipment constitution
4.1
4
Chamber: The frame of chamber is made by square steel tube to ensure its intensity. The chamber wall is made by galvanized plate(δ=2mm).There are four air supply sources at the two sides of the chamber wall.
W×H）mm：3200×4800。。
The access for workpieces: The chamber is non-passing type. There is a electrical side-by-side door at one side of the chamber. The door could be controlled by electricity. But if the power is cut off suddenly, the door could be opened or closed manually. The door is made by the same material as the wall, its specification is 3200×4800 （W×H）mm.There is sight glass on the door.

Emergency door and decompression facility: There are two emergency doors at the lengthways side of the chamber. The door size(W×H)mm: 650×1800.They are made by the same material as the side wall. There is sight glass and pressure protection device on the door to ensure the safety in use. When the pressure in the chamber is higher than authorized pressure (120pa), the emergency door would open automatically and personnels could be evacuated and go through.
4.2
Air cleaning facility: Cleanliness is an important indicator for evaluating the quality of spraying room. This indicator is guaranteed by air cleaning system. The entire air filtration falls intoⅢ-grade filtration, preliminary filtration(inflow filtration+top filtration) and efficient filtration(top filtration). The initial efficiency filtration is in bag-type.It could lower the wind resistance, increase dust-holding capacity and reduce replacements. The top filtration material 十堰华昌达机电有限公司 第 8 页 共 45 页
is set at the bottom of dynamic &static pressure room and is supported by top net. The top net is in C-type steel struction, which could be kept from rust and corrosion. The top cotton could be replaced easily. There are dynamic &static pressure room at the upper part of the chamber. There is air distributor in the dynamic pressure room There is nonwovens filter layer and trolley for nonwovens replacement in the static pressure room. Therefore the air flow uniformity and air cleanliness is ensured.

4.2.1、：
The preliminary filter material is made in Italy and its model is KLD－913.It could easily capture the grit with diameter longer than 10μm.Its main technical parameters are as follows:
型号 model KLD－913
原始阻力original resistance 24Pa
最终阻力 final resistance 250Pa
平均捕捉率(计算法) Average capture rate(calculating method) 86%
容尘量dust-holding capacity 620g/㎡
厚度 thickness 20mm
4.2.2、亚高效过滤材料采用CC－600G精密级过滤棉，该过滤棉具有多层结构，其中间油性夹层具有极高的粘附力，可确保空气洁净度达到尘埃量≯1.5mg/m3，尘埃粒子数≯200个/cm3，且最大尘粒≯5μ。过滤棉上下面设置压差计，当过滤棉严重堵塞而使送风风速明显减小压差增大时报警提示更换，避免送风、排风不匹配而引起室内外压差过大影响喷漆效果。其主要技术指标为：
Sub-high efficient filter material is precise filter pad with CC－600G grade. The filter pad is in multi-layer structure. The oily interlayer in the middle of it with high adhesive power. It could ensure air cleanliness: dust level≯1.5mg/m3, ,dust partical≯200 piece/cm,the biggest grit≯5μ.There are differential pressure gauges at the top and bottom surface of the filter pad. If the filter pad is blocked seriously, the blast velocity reduces, and the differential pressure increases, there will be alarm for replacement. So the painting will not be affected .The main technical parameters are as follows:
型号model CC－600G
原始阻力original resistance 19Pa 十堰华昌达机电有限公司 第 9 页 共 45 页
最终阻力final resistance 230Pa
平均捕捉率 Average catch rate 98%
容尘量 Dust Holding 419g/m2
厚度 Width 25mm
阻燃能力 Anti-flaming capacity 符合F5级标准 F5-grade standard
4.3地板格栅：喷漆室下部±0.00处铺有碳钢地板格栅，该格栅由扁钢和圆钢焊接而成，其表面平整、光滑。
Floor grid: carbon steel floor grid is placed on ±0.00 point at bottom painting room, which is made up with flat bar and round bar with smooth and level surface.

4.4空调送风装置：喷漆室采用上送下吸的气流组织方式，送风装置采用空调送风的方式，由新风段、初效段、风机段、加热段、消音段、风量调节段等组成，设备运行平稳、可靠。
A/C air supply device: Painting room adopts the air diffusion mode of “upper supply, lower suction”. The air supply device blows out through A/C, which is composed of fresh air section, initial section, fan section, heating section, muffling section, and air regulation section, so this device operates smoothly and reliably.

 新风段：从厂房顶部吸进新风，设置防鸟格栅、防雨棚等。

Fresh air section: fresh air is blown in from the roof of plant. Anti-bird grid and rain-proof shelter are set in it.

 初效段：选用袋式无纺布过滤装置，便于安装和拆卸。具有初阻低、容尘量大，可多次清洗并重复使用，在过滤器前后设置压差仪，以便于监控。

Initial section: bag-type non-woven fabric filter unit is adopted for assembling and disassembling, with advantages of low initial resistance, huge dust-hold capacity and repeated use after cleaning. Differential pressure gauges are set in the front and rear of filter unit for monitoring.

 风机段：送风均匀，工件两侧工作区域内层流风速最大误差在±0.2m/s以内。送风量的确定：由涂装要求，喷漆房内有载风速≥.5m/s，确定送风量计算如下：

Fan section: uniform air supply. Max deviation of laminar flow at ends of workpieces in working zones is ±0.2m/s. The air supply is based on painting requirments. The speed with load in painting shop is more than 0.5 m/s. The amount of air supply is calculated as follows.

QS=FSV×3600 十堰华昌达机电有限公司 第 10 页 共 45 页
式中(in such formula)：QS－送风量 air output 单位unit：M3/h
FS－送风区截面积(sectional area of air supply zone) 单位unit：m2
FS =15×5.5=82.5m2
V－送风端面流速 (flow of air supply surface) 单位 unit：M/s
V取0.5m/s(V=0.5m/s)
则Qs= FsV×3600=82.5×0.5×3600=148500m3/h
设计选用空调总的送风量为150000 m3/h。
The general air output of A/C is designed to be 150,000 m3/h
 加热段：主要由加热器、换热器等组成。

Heating section is mainly composed of heater and heat exchanger.

采用热风对流间接加热的方式，加热能源采用天然气加热，选用意大利原装进口百得牌二段火天然气燃烧器，换热器选用的SUS304耐热不锈钢制作。其特点是结构合理，安全可靠，交换面积大，热交换率达75%以上。从而在规定的时间内满足升温要求。
The indirect heating mode of hot air convection is adopted. The heat source is natural gas which produces heat through exported BALTUR secondary fire natural gas burner form Italian. The heat exchanger is made of SUS304 heat-resistance stainless steel featured with reasonable structure, safety and reliability, huge exchanging area and heat exchange rate higher than75%, so it can meet the warming requirements within specific time.

制热量计算：The calculation of heating capacity
考虑到冬季室温≥8℃，加热空气所需热量：
In view of room temperature in winter which is higher than ≥8℃, the heat for warming-up the air:
已知参数(冬天)：室外新风温度t1：－10℃
Given parameter: fresh air outside t1: －10℃
出风温度t2：18℃
Output temperature t2: 18℃
风量Q：148500m3/h
Air flow Q：148500m3/h
加热空气所需热量Q＝Gρ(t2-t1)＝0.24×148500×1.2×28＝1197504kcal/h
The heat for warming-up the air: Q＝Gρ(t2-t1)＝0.24×148500×1.2×28＝1197504kcal/h 十堰华昌达机电有限公司 第 11 页 共 45 页

 消音段：设置消音隔声段，使喷漆室内噪音低于85dB。

Muffling section: muffling and sound isolation section is set to make the noise in painting room lower than 85dB.

 风量调节段，设置多叶调节风阀对送风量进行调节，调节阀体为Q235，叶片为铝合金型材制作，连杆传动，配合排风阀的调节可保证喷漆室微正压状态。

Air regulation section: multiblade adjusting damper, Q235, is set for air regulation. The blade is made of aluminum sections with linkage drive, which works with the regulation of relief damper to make painting room in micro-barotropic state.

4.5排风系统：由排风机、风量调节阀及风管等组成。排风机采用离心风机，电机防爆。风管采用镀锌钢板δ.2和角钢制成。通过送排风风阀的调节，保证喷漆区微正压状态。排风系统安装在辅房的排风室内。
Exhaust system consists of fans, air regulation damper and air pipes. Fans are Centrifugal. The motor is anti-explosion. Air pipes are made of Zinc-coated steel plate δ.2 and angle steel. Relief damper is adjusted to make painting room in micro-barotropic state. The exhaust system is set in exhaust chamber of auxiliary room.

排风量的计算：the calculation of air output
QP＝0.95QS =141075m3/h
并综合考虑风阻等因素，选用：B4－72型No16B防爆离心风机2台，功率为37kw。
Wind resistance and other factors are taken into full consideration. Two sets of B4－72 No16B anti-explosion centrifugal fans are adopted with the power of 37kw.
4.6漆雾处理装置：由水盆、水旋器、挡水板组成，水盆为碳钢结构，水旋器和挡水板材质为不锈钢。水旋器高出水盆60～75mm，供水管采用孔状供水以保持一定液位，满足漆雾处理需要，水旋器之间的间距为1000mm。
Paint mists processing unit is composed of basin, water cyclone and baffle board. Basin is constructed of carbon steel. And water cyclone, 60～75mm higher than basin, and baffle board are of stainless steel. Water supply pipe adopts cavernous supply mode in order to maintain specific level to meet paint mists processing requirements. The clearance between water cyclones is 1000mm.
4.7照明装置：在室体的顶侧部和腰侧部安装照明灯。顶侧灯组呈45º角安装，布置方式为：8×36W×4组×2行；腰侧灯组安装于墙板内，竖立布置为双排灯箱。灯管采用隔爆型飞利浦高效光源，既安全又节能且维护方便，镇流器采用本公司设计特制的喷烤十堰华昌达机电有限公司 第 12 页 共 45 页
房隔爆型专用镇流器，从而保证光强≥1000Lux。在动静压室内设有防爆照明装置，便于更换、检修用。在空调送风钢结构平台下布置隔爆型飞利浦照明灯具，从而保证光强≥00Lux。整个照明系统均采用隔爆装置，设置按GB14444－93规程要求。
Lightings: Lamps are mounted at the top-side and waist-side of chamber. The lamp sets on top-side are mounted with the mode of 8 by 36W by 4sets by 2 lines at an angle of 45 degree. The lamp sets on waist-side are mounted in the wall and placed vertically as a double-row light box. Anti-explosion Philips efficient light source, with advantages of safety, energy saving and convenient maintenance, is adopted in the tube. The inverter is of self-made anti-explosion inverter in painting and baking room to maintain the light intensity more than 1000Lux. Anti-explosion units and lightings are set in dynamic and static pressure chamber for replacement and repair. Anti-explosion Philips lamps are set below the steel structure platform of A/c air supply units to make the light intensity more than 200Lux. Anti-explosion units are adopted in whole lighting system, whose settings are as stated in GB14444－93.
4.8电控系统：采用国内外先进的电子原器件组装的智能控制箱，操作者一次设定，便可完成全部操作过程。主回路设有多重保护：过电流、过负载、短路、缺相等保护。选用国内外先进的电子原器件组装的智能控制箱，控制具有精度高、功能全、操作方便、安全可靠等优点。控制柜中装有换气扇，可及时排出控制柜中电器元件散发出来的热量。电器元件的布线采用室外线槽布线并采取与墙壁隔离走线。
Electronic control system: advanced electronic units at home and abroad are adopted to assemble intellectual control boxes. Once finishing primary setting, operators could complete the whole operation process. Multiple protections, such as overcurrent, overload, short circuit and phase loss, are set in major loop. Intellectual control box assembled with advanced electronic units at home and abroad has advantages of high accuracy, complete function, convenient operation, safety and reliability. Ventilating fans are set in control cabinet to exhaust the heat produced by electronic units in cabinet. Outside slot wiring isolated with walls is adopted by electronic units for wiring.

4.9钢结构平台：为了节省室内空间、充分利用车间高度，其中空调送风系统布置在室体侧面邻近工位上部的钢结构平台上，室体外径尺寸不影响整体工艺排布。钢平台由型钢、花纹钢板焊接而成，满足强度、承重的要求，在平台四周焊接圆管护拦，并配备爬梯以便上下维护保养。送风机座、排风机座、加热系统布置合理，结构紧凑。
Steel structure platform: in order to save space and workshop height, the A/C air supply 十堰华昌达机电有限公司 第 13 页 共 45 页
system is placed on the steel structure platform above the adjacent station of side chamber, ignoring the effect of external diameter of chamber to overall process layout. Steel platform is welded with formed steel and riffled sheet to meet the requirements of intensity and load-bearing. Round bar guard is welded around the platform equipped with ladder for maintenance up and down. Blower foundation, exhaust fan foundation and heating system are arranged reasonably in intense structure.

4.10三维工作台 Three-dimensional workstation
 在房体内两侧均设置1套三维工作台，计2套，在室体及地面上固定上下两道滑轨。此装置结构简单，操作、维修方便。

One set of three-dimensional workstation is set in each side of inner chamber, 2 sets in total. Two sliding rails are fixed on chamber and ground with one at top and the other at bottom.

 设有三个方向的动作，第一是沿地面轨道的水平运动；第二是沿双立柱上下的升降运动；第三是垂直于立柱的伸缩运动，从而实现三维动作要求。

There are movements in three directions in the setting. The first is the horizontal movements along the ground rail; the second is the lifting and hoisting movements along double stand columns; the third is the stretching movements normal to stand columns to meet the three-dimensional motion requirements.

 工作台设置有防坠落装置，工作台栏杆保护及平衡重锤保护等安全装置。

Safety devices such as fall protection unit, guard protection and counterweight balance protection are set on workstation.

 主要参数 Key parameter

根据贵司要求,在室体内部两侧各设一套悬挂式三维工作台，操作人员可在车体侧面和端面施工，升降高度0.6-3.5m，纵向最大行程14m，横向伸缩0.5m，工作台面L×W＝1500×1000mm，载重大于300kg，该工作台工作运行平稳，并有喷涂两端之功能。喷涂机和漆桶可放置在平台上，随三维工作台一起移动。
One set of three-dimensional overhead workstation is set in each side of inner chamber as required by your company. Operators can construct on the side surface and end surface of chamber. The lifting altitude is 0.6 to 3.5m; the Max vertical stroke is 14m; the horizontal stretching length is 0.5m. The workstation is 1500 by 1000 with the load of more than 300kg. Such workstation operates stably and smoothly with the function of 十堰华昌达机电有限公司 第 14 页 共 45 页
spraying two ends. Spraying machine and cans could be placed on the platform moving with three-dimensional workstation.

三维工作台具有安全可靠，操作方便，噪声低等性能，涂装作业时，可任意做纵向移动、横向升缩及上下升降运动。同时三维工作台有安全保护装置，可确保操作人员的安全。

Three-dimensional workstation has features of safety, reliability, convenient operation and low noise. When painting, vertical movements, horizontal stretching and lifting up and down are made easily. In addition, safety protection unit is set on three-dimensional workstation to assure the safety of operators.

4.11消防报警系统： Fire fighting and warning system
 报警系统： warning system

采用可燃气体浓度报警仪，该仪器具有中央控制系统及2个巡检通道，可连接2个探头，2个探头分别放置在房体内的不同位置上，随时对房内可燃气体浓度进行监测。
The alarm of combustible gas strength with central controlling system and two tour- inspection access connecting two probes placed on different positions in chamber is adopted to detect combustible gas strength in chamber.

主控系统具有以下功能：The master control system has the following functions:
 测量并数码显示被测气体浓度。

Measuring and digitally displaying the measured gas strength

 设置报警极限(可选择PPm或%爆炸下限)。

Alarm limit is set (options for PPm or %lower explosive limit)

 单独调整每个报警进口的极限值。

Individually regulate the limit value of each imported alarm

 故障自检。

Error self-checking

 输出继电器检测。

Detection of output relay

 LED检测。LED detection

报警仪设定两个报警值(即Ⅰ、Ⅱ级报警)，并发出不同的报警信号。来自传感器探头的标准信号(4－20mA)，经I/V转换成电压信号，该电压信号经放大与预先设定的报警设定值进行比较，然后分别送声光报警及数字显示单元。当信号电压低于报警设定值十堰华昌达机电有限公司 第 15 页 共 45 页
时，无声光报警发生；当信号电压高于报警设定值Ⅱ级时(可燃气体浓度达到25%LEL)，主机报警断续发声，黄色灯光指示；当信号电压高于报警设定值I级时(可燃气体浓度达到50%LEL)主机报警，急促发声，红色灯指示。
Two values, which are gradeⅠand gradeⅡ, are set in each alarm sending different alarming signals. Standard signals (4－20mA) from sensor probes is switched into voltage signal via I/V. Such voltage signal is amplified, made contrast with preset alarming setting value and then sent to audible and visual alarm and digital display units. When signal voltage is lower than preset value, there is no audible and visual alarm; when signal voltage is higher than gradeⅡsetting value, which means the combustible gas strength reaches 25%LEL, the engine alarms on and off with yellow indicator on; when signal voltage is higher than grade Ⅰ setting value, which means the combustible gas strength reaches 50%LEL, the engine alarms rapidly with red indicator on.
同时，可燃气体报警仪与控制系统联动，Ⅱ级报警信号发出的同时，控制系统自动切断电源确保安全。

Meanwhile, the combustible gas strength alarm and control system influence each other. Once the grade Ⅱ alarming signal is sent, the control system will cut power to assure safety.
 灭火系统：Fire fighting system

在喷漆室内配备水喷淋灭火系统；在车间内配置多个自动二氧化碳灭火器喷雾系统（由客户自备），以减少车间的火灾危险。

The spraying room is equipped with raining fire-fighting system. There are many automatic carbon dioxide fire extinguishers (prepared by users themselves) in the workshop. Therefore, fire risk in the workshop could be reduced.

4.12主要技术参数：Main technical parameters 序号No.	项 目Project		单位Unit		规 格Specification
1		喷漆室型式type of spraying room		非通过式non-passing type
2		送排风方式air supply&exhaust mode		上送下抽 upper blow-in and lower blow-out
3		漆雾处理方式processing mode of mist spraying		水旋water-rotating