Automatic Powder Coating Lines

SURFACE PRETREATMENT LINE

Tunnel Construction:

The tunnel frame is made of AISI-304 stainless steel panels with partitions to prevent mixing of solutions. The bottom of the condensate drain zone is inclined. Special intermediate openings are provided after each stage of surface preparation. The length of these zones is designed individually for each project. Sealed, thermally and chemically resistant lamps are installed inside the tunnel.

Baths:

The baths are made of AISI 304 stainless steel welded construction and are equipped with a system for cleaning and draining through overflow channels of surface layers of oil, sludge, or other contamination of solutions. Filters are arranged in two rows in all tanks to prevent rapid contamination of the circulating solution.

Pumps:

The supply of solutions is carried out using vertical feed pumps, which are a pump section consisting of a pump motor and a pressure control system. All pumps used for preparation line with integral casting.

Valves, pressure gauges, filters:

At the inlets and outlets of all pumps there are butterfly valves for pressure adjustment. There are also pressure gauges mounted on the pump discharge pipe. The filters are arranged in two rows.

Thermoregulation:

In heated baths, the thermostat provides the temperature set by the program on the control cabinet.

Cascading system:

A controlled water transfer system is installed between the baths.

Spray system:

The liquid soaked up from baths with chemical. substances are supplied by centrifugal pumps to the spray nozzles. All collectors, connection and spray tubes are made of pressure-resistant materials. The spray circuits are individually designed and can be easily dismantled and cleaned.

Steam and exhaust gas removal system: (positive pressure)

In order to prevent steam from spreading through the plant and condensing it back into the bath, which will reduce water consumption, a special positive pressure tunnel is provided, at both ends of which there are exhaust fans.

DRYING OVEN

Heating type:

Natural gas or Diesel or Electric

Circulation fan:

2 pcs. Direct-coupled, with oled and cooling fan.

Isolation:

All walls isolated with 150 mm stone wool. bottom panel islated with 100 mm stone wool

Oven body:

The body of the oven is made of powder-coated steel . The inner side is galvanized steel sheet . 150 mm stone wool is used for isolation. Sandwich panels of the oven are attached to each other with high-temperature-resistant silicone.

Heating unit :

The heating unit, which can reach temperatures up to 150°C, is mounted on the furnace's side wall. It has a heat exchanger with 4 connections and is insulated with 150 mm stone wool. Dry hot air is distributed evenly throughout the oven by adjustable galvanized steel air ducts. Two belt driven fans are used to circulate the air, together with the heat exchanger and circulating fans. This system ensures that heated air is distributed uniformly inside the volume of the polymerization oven.

Exhaust fan:

An exhaust fan is installed to release the steam that is generated during the baking process. Its frequency is regulated through the control panel.

Thermoregulation and control of exhaust fans:

The temperature can be controlled using a digital thermostat through the panel. The thermostat can be adjusted to any temperature and operating range. The burners automatically adjust to the controlled temperature.

In addition, automation is made especially for the exhaust fan and it is possible to separately adjust the time of its operation.

AUTOMATIC POWDER COATING BOOTH WITH CYCLONE

The booth locks in place and is suitable for both manual and automatic paint application on both sides. Chamber and recuperation system AISI 304. Housing, base, racks and group of filters ST-37. On both sides there are places for workers and manipulators who spray paint. The cyclone block is completely made of cold rolled sheets, painted and phosphated on the inside. It is made to collect paint.

Principle of operation:

The booth has been designed in such a way that the powder paint that does not fall on the part during painting, enters the suction channels located on the floor of the booth and is transferred to the cyclone by means of an exhaust. The paint that has descended into the tank, having passed through an automatic sieve, is transported to the recovery system and from there, with the help of injectors, it again enters the guns. Small particles of paint that cannot be reused are sent to the waste tank.

Recovery system

The powder collected under the cyclone and already sieved is automatically sent to the paint tank (recuperator). The powder paint accumulated in the lower tank of the cyclone unit is sucked into the recovery unit by suction through the injector and deposited in the tank. This ensures that the ink is reintroduced into the system and the ink is not transferred manually.

Components: 100 liter hopper, shielded (mini cyclone), made of AISI 304 stainless steel . Suitable for connecting 10 devices.

STANDART TYPE MANIPULATOR WITH PLC CONTROL

The manipulator has PLC control. Speed and height can be adjusted according to the product to be painted. All these settings can be made on the touch screen. The pulley trigger ensures quiet operation without excessive vibration.

The lower and upper stroke and the speed of the manipulator are controlled digitally. stroke and speed can be controlled on the display during operation. Thus setting the appropriate speed and stroke for the part to be painted. This system provides standard staining.

Our manipulator is located on both sides of the cabin. The manipulators can work separately. Our manipulator can be adjusted in height up to 3 zones in the required sizes, and each zone can be accelerated separately from the control panel to the required speeds. Thus, significant savings in paint consumption are achieved. Convenience of use is ensured by 10 different recipes that can be loaded into its memory.

MANUAL POWDER COATING EQUIPMENT

The control module consists of two sections:

Electronic section - this part includes the circuitry, transformer, voltage regulator, voltage indicator and fuses. It provides control over the output voltage of the guns.

Pneumatic section - this part includes celenoid valves, air regulation and pressure gauges. It provides control over paint flow and air pressure.

CURING OVEN

Heating type:

Natural gas

Circulation fan:

2 pcs. Direct-coupled, with oled and cooling fan.

Isolation:

All walls isolated with 150 mm stone wool . bottom panel islated with 100 mm stone wool

Oven body:

The body of the oven is made of powder-coated steel . The inner side is galvanized steel sheet . 150 mm stone wool is used for isolation. Sandwich panels of the oven are attached to each other with high-temperature-resistant silicone.

Heating unit:

The heating unit, which can reach temperatures up to 250°C, is mounted on the furnace's side wall. It has a heat exchanger with 4 connections and is insulated with 150 mm stone wool. Dry hot air is distributed evenly throughout the oven by adjustable galvanized steel air ducts. Two belt driven fans are used to circulate the air, together with the heat exchanger and circulating fans. This system ensures that heated air is distributed uniformly inside the volume of the polymerization oven.

Air curtains:

Air curtains are installed at the outlet and inlet of the furnace, ensuring minimal heat loss.

Exhaust fan:

An exhaust fan is installed to release the steam that is generated during the baking process. Its frequency is regulated through the control panel.

Thermoregulation and control of exhaust fans:

The temperature can be controlled using a digital thermostat through the panel. The thermostat can be adjusted to any temperature and operating range. The burners automatically adjust to the controlled temperature.

In addition, automation is made especially for the exhaust fan and it is possible to separately adjust the time of its operation.

Safety thermostat:

In case of failure of the thermostat that controls the temperature of the furnace, and an excessive increase in temperature, an alarm system is triggered.

CONVEYOR LINE: (SUSPENDED CARDAN TYPE CONVEYOR)

Chain:

The material of the chain is entirely made of high quality steel and has been heat treated.

Rails:

The rails are specially made from ST 37 sheet steel, painted with electrostatic powder paint. The rails have a through opening at the top.

Frequency inverter:

An inverter that provides speed control on the conveyor and a protective function in case of motor failure, preferably Siemens and Schneider Electric brands.

Drive unit:

The drive unit is caterpillar, provide silent movement of the conveyor line without vibration.

Automatic lubrication unit:

A special lubrication system is provided for this purpose using Festo greases. It allows lubrication of 4 bearings at a time.

The supporting structure of the conveyor:

Special rails are used to prevent expansion of the conveyor due to temperature in the ovens.

MAIN CONTROL PANEL ( PLC )

The entire painting complex operates from one control panel. An electrical panel with PLC control and a remote connection function will be installed here. PLC brand DELTA. Language supports: English, Russian, Turkish.

Electrical equipment Schneider Electric, Siemens

It will be built in such a way that it can be shipped and driven comfortably and safely and using world class materials.

The Plc panel will have a main hand type switch, a digital thermostat, an emergency stop button, a fault circuit warning light and sound, and warning lights. The panel has lighting, exhaust and fresh air systems,1. Class products perform the function of dispatcher and control. The speed controller for conveyors is available on the board. Electrical diagrams are available on the board.

The plant has an aesthetic and healthy electrical distribution system, cable ducts, etc. with excellent quality.