講解減少涂裝顆粒的控制措施

1、 講解減少涂裝顆粒的控制措施顆粒在涂裝中是最常見(jiàn)的涂膜缺陷之一，在任何一個(gè)涂裝生產(chǎn)線都會(huì)不同程度的存在。它是影響涂裝一次交檢合格率的最大的也是最難以根除的涂膜弊病。因?yàn)轭w粒造成的車(chē)體返修大大增加了涂裝成本，經(jīng)核算，每臺(tái)車(chē)的中修費(fèi)用100元左右，而一臺(tái)車(chē)返大修，重新噴涂一遍面漆大約需要成本350元。在外觀上修理過(guò)的涂膜也略差于一次成型的涂膜。在涂裝生產(chǎn)中，涂膜顆粒弊病可以說(shuō)是頑疾，幾乎是無(wú)法杜絕的，只能是在生產(chǎn)過(guò)程中不斷摸索，分析 總結(jié) ，采取相應(yīng)的措施，使顆粒的產(chǎn)生降到最低，從而減少生產(chǎn)成本，提高生產(chǎn)效率。Particles in the coating is one of the most

2、common coating defects, in any coating production line will be the existence of different level. It is an especially affects the qualification rate of the largest and most difficult to eradicate the coating of ills. Because particles caused by the body repair greatly increase the painting cost, by t

3、he calculation, each vehicle repair costs about 100 yuan, while a car back to overhaul, spraying the paint again need to cost about 350 yuan. The appearance of repaired it does slightly less coating applied to the molding of a coating. In painting production, coating grain ills can be said to be the

4、 ills, almost impossible to eliminate, can only fumble ceaselessly is in the process of production, analysis summary, take corresponding measures to make the generation of particles to a minimum, thus reducing the production cost, improve production efficiency. 2.1顆粒的定義2.1 the definition of particle

5、 涂膜上的突起物叫做顆粒，也稱臟點(diǎn)，用目視或觸摸可以辨別。Bumps called particles on film, also called dirty points, with visual or touch you can identify. 2.2顆粒的分類(lèi)2.2 the classification of particles 由于造成涂裝顆粒的因素眾多，很難制訂一個(gè)統(tǒng)一的分類(lèi)標(biāo)準(zhǔn)，按照經(jīng)驗(yàn)可大致分類(lèi)如下：Due to the coating particles caused by many factors, it is difficult to formulate a unifie

6、d standard of classification, according to the experience can be broadly classified as follows: （1）環(huán)境顆粒：由環(huán)境因素導(dǎo)致的涂膜顆粒。（2）干燥爐顆粒：因干燥爐不干凈而產(chǎn)生的涂膜顆粒。多為黑色堅(jiān)硬，難以修整，易造成批量返工。（3）涂料顆粒：產(chǎn)生原因多為調(diào)輸漆系統(tǒng)的涂料沉淀、噴槍或噴杯清洗不凈，或霧化效果不好等。（4）噴膠顆粒：因注焊縫膠或噴抗石擊底盤(pán)膠時(shí)，產(chǎn)生的多余膠顆粒。（5）前處理顆粒：白皮車(chē)身殘留的鐵屑、焊渣所致，多發(fā)生在門(mén)口部位，打磨極其困難。（6）靜電顆粒：噴涂金屬底漆時(shí)，噴涂設(shè)備造成

7、的顆粒。(1) environmental particles: coating particles caused by environmental factors. (2) the drying furnace particles: due to drying oven isn't clean coating particles. Mostly black hard, difficult to repair, easy to cause the batch rework. (3) coating grain: reason for more adjustable paint coat

8、ing deposition, spray gun or cup cleaning not net, or atomization effect is bad, etc. (4) : spray adhesive particles due to weld plastic injection or spray chassis with resistance to stone glue, the excess glue granules. (5) pretreatment particles: white body caused by residual scrap iron, welding s

9、lag, tend to occur in the entrance area, burnish is extremely difficult. (6) electrostatic particles: spraying metal primer, paint spraying equipment caused by the particles. 3 涂裝生產(chǎn)線顆粒產(chǎn)生的原因及防治措施3 coating production line particles causes and prevention measures 根據(jù)顆粒產(chǎn)生的定義和分類(lèi)，對(duì)不同類(lèi)型的顆粒產(chǎn)生原因加以治理，以下按生產(chǎn)線的工藝

10、順序，分析影響漆膜質(zhì)量的原因并介紹為防止顆粒所采取的措施，提出可以試用的一些辦法。According to the definition of particle generation and classification, causes to run on different types of particles, the following order according to the production line process, analysis reasons of affecting the quality of paint film and introduces the meas

11、ures taken to prevent the particles, can try some measures are put forward. 3.1前處理線3.1 before the processing line 污染源分析：主要是焊裝車(chē)間在生產(chǎn)過(guò)程中產(chǎn)生的鐵屑，積存在車(chē)身內(nèi)部不易清理的部位，隨車(chē)進(jìn)入涂裝線，在車(chē)身表面形成不同顆粒的形式，直接影響到車(chē)身涂層質(zhì)量，危害性較大。Pollution source analysis: mainly is the welding workshop in the production process of iron filings, accu

12、mulate in the body, not easy to clean up the parts in the accessory into the painting line, on the body surface to form different granular form, directly affect the coating quality of car body, more destructive. 解決措施：在前處理的熱水洗槽、預(yù)脫脂、脫脂槽各加一組磁力回收裝置，每組裝置由3根磁力棒組成，磁力回收裝置安裝在槽液循環(huán)吸口處，槽液循環(huán)時(shí)通過(guò)磁力棒做循環(huán)流動(dòng)，鐵屑隨槽液在通過(guò)磁

13、力棒時(shí)，利用磁力吸附特性，達(dá)到過(guò)濾槽液中鐵屑的作用。Solutions: in the pretreatment of hot water to wash tank, skim, skim each plus one set of magnetic recovery unit, each group of device is composed of three magnetic rod, magnetic recovery unit installed in the slot suction fluid cycle, bath do circulating loop through the m

14、agnetic rod, iron filings with the slot liquid through a magnetic rod, using magnetic adsorption characteristics, to achieve filtering tank liquid iron filings in the role. 3.2電泳線3.2 electrophoresis line 污染源分析：在電泳過(guò)程中，多余的殘液會(huì)附在吊具上，經(jīng)過(guò)多次的烘干和電泳，在吊具表面留下很厚的殘?jiān)?，漆渣?huì)從吊具上剝落，進(jìn)入槽液和其他區(qū)域，再粘附車(chē)體表面形成顆粒。Pollution sourc

15、e analysis: in the electrophoresis process, redundant residual liquid will be attached to the spreader, after several times of drying and electrophoresis, thick residue left in the surface of spreader, the paint residue will be peeling off from the sling, into the bath and other areas, to adhere to

16、car body surface to form particles. 預(yù)防措施：定期清理吊具，防止吊具上存留大量的漆渣。Preventive measures: regular cleaning spreader, prevent the spreader saved a lot of paint slag. 清理的方法包括：Cleaning methods include: （1）人工敲打吊具，清理吊具上的漆渣。（2）高壓水洗，用專(zhuān)業(yè)的高壓水槍洗掉漆渣。（3）采用吊具保護(hù)法。在吊具的表面涂上防護(hù)底漆和防護(hù)清漆，使吊具反復(fù)進(jìn)入電泳槽基本不再粘附電泳漆。從而防止顆粒的產(chǎn)生。常規(guī)處理的吊具經(jīng)電泳

17、涂裝后表面形成的沉積漆膜不能沖洗掉，浮漆也不易完全沖洗干凈，再經(jīng)堿性脫脂液、酸性磷化液浸泡后形成多孔隙的不規(guī)則沉積漆膜，進(jìn)一步增加了清洗難度。而掛具保護(hù)涂料通過(guò)優(yōu)化組合樹(shù)脂官能團(tuán)，添加高性能納米材料，涂布在掛具上后使其具有優(yōu)良的電絕緣性，電泳涂裝時(shí)不易形成沉積醬油漆膜，且具備優(yōu)異的機(jī)械性能，耐化學(xué)品性能和耐水性能。目前我們哈飛汽車(chē)微車(chē)涂裝線已經(jīng)采用此方法，效果很好。有效的減少了吊具上的沉積漆膜對(duì)電泳槽液的污染。(1) artificial knock sling, sling on the paint slag. (2) the high pressure water washing, was

18、h water cannon with professional paint slag. (3) using spreader laws. In sling surface coated with protective primer and protective varnish, sling repeatedly into basic no longer adhere to electrophoresis paint electrophoresis tank. To prevent the formation of particles. Normal processing surface of

19、 the hook after electrophoresis coating forming cannot be washed away, deposition film floating paint is not easy to rinse off completely, then through alkaline degreasing, acid phosphating liquid after soaking chinky irregularly deposited film formation, further increases the difficulty of cleaning

20、. And linked with protection coating through optimizing combination resin functional groups, adding high performance nano materials, coating on the hanging fixture after make it has good electrical insulation, electrophoresis coating formed on deposition film, and have excellent mechanical propertie

21、s, chemical resistance and water resistance. Currently our hafei car minicars painting line has been using this method, the effect is very good. Effectively reduce the spreader on deposition film electrophoresis tank liquid pollution. 3.3注膠、噴膠線3.3 note glue, glue line 污染源分析：在注膠過(guò)程中會(huì)產(chǎn)生需要清理的多余密封膠，這些多余膠

22、一般情況下使用紗布或純綿布進(jìn)行擦拭，這就會(huì)使一些纖維留在焊縫邊緣或車(chē)體內(nèi)部，污染車(chē)身。Pollution source analysis: in the process of injecting produce need to clear the redundant sealant, the excess glue is normally use gauze or pure cotton cloth to wipe, it will make some fiber in weld edge or inside the car body, car pollution. 預(yù)防措施：改用低纖維擦布或

23、長(zhǎng)滌綸纖維擦布擦凈會(huì)大大改善，降低車(chē)身的纖維污染。Preventive measures: to switch to low fiber brush long cloth or polyester fiber brush cloth rub-up will improve greatly, reduce the pollution of the body fabric. 污染源分析：操作者在噴膠過(guò)程中，膠霧會(huì)濺落在車(chē)身上，經(jīng)過(guò)注膠烘干爐烘干后，形成密集的顆粒，造成車(chē)身污染。Pollution source analysis: the operator in the process of spr

24、ay glue, glue the fog will be splashed down in the car, after injecting drying oven drying, forming dense granules, cause body pollution. 預(yù)防措施：Preventive measures: （1）將可能?chē)娙胲?chē)體內(nèi)表面的裝配孔，螺紋孔用隔離膠帶充分隔離，防止膠霧噴入車(chē)體內(nèi)腔。（2）可在噴膠工位安裝護(hù)板，在不影響車(chē)體行進(jìn)的情況下將車(chē)體的下半部分遮擋，可減少車(chē)體的污染和擦凈工位的工作量。(1) will be sprayed into the assembly h

25、ole on the surface of the car body, screw thread hole sufficient isolation with isolation tape, rubber prevent mist spray into the car in the body cavity. (2) which can be installed in spray JiaoGong a guard plate, in the case of travel does not affect the body to the lower part of the body block, t

26、o reduce car pollution and wipe location of work. 3.4打磨線3.4 cutting line 污染源的分析：涂裝車(chē)間一般都會(huì)設(shè)置中涂打磨和面漆打磨，打磨車(chē)體電泳漆缺陷或中涂漆缺陷，打磨過(guò)程中會(huì)產(chǎn)生大量的打磨灰，而一般打磨工位和擦凈工位在同一區(qū)域，打磨灰會(huì)污染擦凈后的車(chē)身。Pollution sources analysis: coating workshop will typically set in grinding, polishing and paint grinding, car body paint defects in elect

27、rophoretic paint defects or process will produce a lot of polishing ash, and general grinding station and wipe location in the same area, polishing ash will wipe the body after the pollution. 預(yù)防措施：Preventive measures: （1）分離打磨區(qū)和擦凈區(qū)，有效的減少打磨灰對(duì)車(chē)身的污染。（2）將中涂打磨到面漆噴漆室的通道全部密封，打磨工位網(wǎng)格板下設(shè)水槽，避免打磨灰在整個(gè)廠房的擴(kuò)散和對(duì)車(chē)身的污染

28、。（3）有一種新工藝就是打磨后將整個(gè)車(chē)身經(jīng)過(guò)去離子水浸系洗后再噴淋，烘干，然后噴面漆。這樣可以將車(chē)身內(nèi)外的灰塵洗干凈，大大有利于減少面漆的顆粒。(1) separate grinding area and wiping area, effectively reduce grinding dust pollution to the body. (2) will be painted in the grinding to channel all sealing paint spray paint room, grinding station grid plate under the sink, t

29、o prevent the spread of ash in the whole plant of polishing and pollution to the body. (3) there is a kind of new technology is tied the whole body in deionized water immersion after polishing spray again after washing, drying, and then spray paint. Such dust clean, inside and outside body can be gr

30、eatly beneficial to reduce the paint particles. 3.5噴漆線3.5 paint spray line 污染源分析：在噴漆過(guò)程中我們國(guó)內(nèi)涂裝線基本都是采用的靜電噴涂，涂料的利用率基本在60%80%，在噴漆過(guò)程中會(huì)有大量的漆霧形成，其中大部分形成漆渣，也有一部分會(huì)漂浮在空氣中，落到自動(dòng)噴涂設(shè)備和噴漆間的壁板上，或者噴漆工的衣服帽子，手套等上面，聚集形成顆污染車(chē)體，這樣的顆粒尤其會(huì)污染噴過(guò)漆濕膜上，形成較難處理的顆粒，這樣形成的顆粒占顆粒形成總量的40%以上。Pollution source analysis: in the process of spray painting line in my country are basically adopts electrostatic spraying, coati