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的涂膜缺陷之一，在任何一個涂裝生產(chǎn)線都會不同程度的存在。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。因為顆粒造成的車體返修大大增加了涂裝成本，經(jīng)核算，每臺車的中修費用100元左右，而一臺車返大修，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是頑疾，幾乎是無法杜絕的，只能是在生產(chǎn)過程中不斷摸索，分析 總結 ，采取相應的措施，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，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，很難制訂一個統(tǒng)一的分類標準，按照經(jīng)驗可大致分類如下：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膠時，產(chǎn)生的多余膠顆粒。（5）前處理顆粒：白皮車身殘留的鐵屑、焊渣所致，多發(fā)生在門口部位，打磨極其困難。（6）靜電顆粒：噴涂金屬底漆時，噴涂設備造成

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，對不同類型的顆粒產(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：主要是焊裝車間在生產(chǎn)過程中產(chǎn)生的鐵屑，積存在車身內(nèi)部不易清理的部位，隨車進入涂裝線，在車身表面形成不同顆粒的形式，直接影響到車身涂層質(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)時通過磁力棒做循環(huán)流動，鐵屑隨槽液在通過磁

13、力棒時，利用磁力吸附特性，達到過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：在電泳過程中，多余的殘液會附在吊具上，經(jīng)過多次的烘干和電泳，在吊具表面留下很厚的殘渣，漆渣會從吊具上剝落，進入槽液和其他區(qū)域，再粘附車體表面形成顆粒。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，用專業(yè)的高壓水槍洗掉漆渣。（3）采用吊具保護法。在吊具的表面涂上防護底漆和防護清漆，使吊具反復進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，進一步增加了清洗難度。而掛具保護涂料通過優(yōu)化組合樹脂官能團，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，電泳涂裝時不易形成沉積醬油漆膜，且具備優(yōu)異的機械性能，耐化學品性能和耐水性能。目前我們哈飛汽車微車涂裝線已經(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：在注膠過程中會產(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行擦拭，這就會使一些纖維留在焊縫邊緣或車體內(nèi)部，污染車身。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. 預防措施：改用低纖維擦布或

23、長滌綸纖維擦布擦凈會大大改善，降低車身的纖維污染。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：操作者在噴膠過程中，膠霧會濺落在車身上，經(jīng)過注膠烘干爐烘干后，形成密集的顆粒，造成車身污染。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. 預防措施：Preventive measures: （1）將可能噴入車體內(nèi)表面的裝配孔，螺紋孔用隔離膠帶充分隔離，防止膠霧噴入車體內(nèi)腔。（2）可在噴膠工位安裝護板，在不影響車體行進的情況下將車體的下半部分遮擋，可減少車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：涂裝車間一般都會設置中涂打磨和面漆打磨，打磨車體電泳漆缺陷或中涂漆缺陷，打磨過程中會產(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，打磨灰會污染擦凈后的車身。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車身的污染。（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)格板下設水槽，避免打磨灰在整個廠房的擴散和對車身的污染

28、。（3）有一種新工藝就是打磨后將整個車身經(jīng)過去離子水浸系洗后再噴淋，烘干，然后噴面漆。這樣可以將車身內(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：在噴漆過程中我們國內(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%，在噴漆過程中會有大量的漆霧形成，其中大部分形成漆渣，也有一部分會漂浮在空氣中，落到自動噴涂設備和噴漆間的壁板上，或者噴漆工的衣服帽子，手套等上面，聚集形成顆污染車體，這樣的顆粒尤其會污染噴過漆濕膜上，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