China LPG Cylinder Production Line Powder Coating Line

1. Powder coating line design

NoNameDetails1Workpiece Gas cylinder2Workpiece materialmetal 3Max. workpiece sizeΦ300xH570(mm)4Workpiece weight≤30kg5Braced chainQXT250/50Kg light common chain6Machine capacity2000pcs/12hours7Hanging typeOne cylinder every two pitch, that means one cylinder per 500mm.8Linear speed2000pcs÷12h÷60minx0.5m/hang=1.4m/min9Heating sourceNature gas(LPG)10Location areaSee layout drawing, beam bottom height 8.5 meters

2. Process flow diagram
This line consists of powder coating chamber, booth, curing bake, suspend conveyor and electric control system.

NoNameTransit timeWorking temperatureOperation 1Loading RTManual 2Powder coating RTAuto+manual3baking17-18min180-190ºCHeated air circle4cooling20min 5unloading Manual

3. Curing bake
The drying tunnel consists of three parts: drying tunnel. Heating system and exhaust system.

3.1 Drying tunnel

NoNameTechnical parameter1Overall structure Bridge type2No of tunnels43Size of the inner tunnelL14xW3.2xH2.1(m). Leg height 2.5meters4Thickness of the insulation150mm 5Material of the insulationHigh quality rock wool board6Unit weight of the insulation100Kg/m37Material of the inner plateδ0.8 galvanized steel sheet8metarial of the outer plateδ0.8 color sheet9Structure of inner and outer plateAssembly structure10Material of the inner angle plateδ1 galvanized steel sheet11Material of the outer angle plateδ3 hot-rolled sheet with paint12Supporter material of the tunnelδ3 carbon steel sheet, edgefold with paint13Outer temperature of the tunnelLower than environment temperature 15ºC14Inner temperature of the tunnel180ºC15Drain cracking-offTop of the tunnel

3.2. heating system: consists of heating chamber, burner, heated air recycling fan, return airway and temperature control system.
(1)heating room: an access door is on the side of the heating chamber for future repairing.

NoName Technical parameter1Position and number of heating roomBottom of the bake tunnel, 1 set2Heating room configuration300000 calories, 1 set3Inner plate of the heating roomGalvanized steel, δ14Outer plate of the heating roomCold-roll steel sheet, δ1.55Thickness of the insulation150mm6Material of the insulationHigh quality rock wool board7Unit weight of the insulation100Kg/m38Material of the inner angle plateδ1 galvanized steel sheet9Material of the outer angle plateδ3 hot-rolled sheet with paint10Supporter material of the tunnelδ3 carbon steel sheet, edgefold with paint11Structure of inner and outer plateAssembly structure

(2) burner
1 set, 300000 calories
Gas consumption: 10-15m3/h
Brand: Italian Riello RS34

(3)burning tank
Heat exchanger is used to transfer the heat to heating room, then hot-air blower will bring the heat to the tunnel. Adopts direct-fired heating, the burning tank is stainless steel with high temperature filter.

(4)Thermal cycling fan: adopts special air-cooled centrifugal fan

NoNameParameter1Model GCF-630C2Rotation speed1250r/min3Air flow volume13500m3/h4Total pressure900Pα5Motor power5.5KW6Fan structureImpeller is in the heating room7Insulation thickness150mm9Impeller material16Mn10No. Of fans1 set11Fans supplierShanghai Shuyuan or Kewangda

(5) Air delivery & returning duct

NoNameParameter1Hot air recyclingInternal recycle, no outer tubes2Air delivery typeUnder floor air delivery3Air returning typeUnder floor air returning4Duct materialGalvanized steelδ15No of air regulation plate1 set6Material of air regulation plateGalvanized steelδ1

(6) Temperature control system
Drying tunnel uses digital temperature controller to adjust the temperature automatically, it can display and control the drying tunnel temperature in real-time.
The temperature measurement uses platinum resistor temperature sensor.
The drying tunnel temperature can be adjusted continuously from normal temperature to 200°C.

3. Exhaust pipe
The entrance/exit of the drying tunnel on the top equips with exhaust pipe and butterfly valve, it is used for draining the exhaust gas of the drying tunnel.
The material of the exhaust pipe is δ1mm galvanized sheet.

4. Hang type conveyor
Hang type conveyor consist of driving device, tension device, variable-frequency governor, chain, straight conveyor, bend conveyor, temperature flexible conveyor, inspection conveyor and lubrication system etc.
Variable -frequency governor uses Mitsubishi. The speed is 1.4 m/min.
The lubrication system uses automatic oil drop device.
Hang type conveyor equips with 1 set driving device, 1 set weight-loaded type tension device, using frequency to adjust speed.

NoNameTechnical specification1Driving device modelQXT-2502Driving device quantity1 set3Overload protection for driving deviceAdjustable safety clutch+travel switch4Driving device power3.0KW5Tension device typeWeight-loaded type6Tension device quantity1set7Turning radius of tension device≥R800(mm)8Frequency converterMitsubishi 1 set9Conveyor chain length125m10Conveyor chain pitch250mm11Hoisting weight of conveyor chain single point50Kg12Production speed1.4m/min13Production speed adjustable methodFrequency control(0.6-2.0m/min)14Column quantity,materialComplete set, steel section15Bottom plate quantity,materialComplete set, hot-rolled sheet steel16Beam quantity,materialComplete set, steel section17Diagonal bracing quantity,materialComplete set, steel section18lubrication systemAutomatic oil drop device 1 set19"C" type jig and rotary rack250 pcs20Rotary rack1set

5. Powder coating system
Using color-changed single grade filter core recycling powder room.
5.1. Technical parameter

Machine typeManual
Max. Hang range of the workpiece
W310xH570Conveyor speed
about 1.4m/min
Type of conveyorSuspend conveyor
Coating material
Polyester powder and epoxy powderColor2 kindsPowder supplier
LocalType of coating chamber
Filter type powder coating chamberType of powder coating systems
Corona torchNo of powder coating systems
6 sets auto, 1 set manual spraying torchType of hoister
Reciprocating hoisterNo of hoister1 setNo of the torch on the hoister2 sets on left, 2 sets on top, 2 sets on bottomSuction capacity of coating chamber11000 m3/h Required pressure for compressed air
6 - 8 bar , + 0.1 barRemaining water in the compressed air
Max. 1.3 g/N m3 Remaining oil in the compressed airMax. 0.1 mg/N m3 Estimated air consumption for chamber
120 N m3/h Power supply220/380 VAC, 50Hz, 3L/N/PE, 3 phase 5 wiresEstimated power consumption for powder coating
Approx. 10 KVAEstimated power consumption for chamber
15KVA -- powder coating chamberRequirement for operation conditionRelative humidity<80%
Ambient temperature< 30ºC
Air speed near the chamber< 0.1 m/sec

5.2. Configuration
(1) Powder coating room
The shell of powder coating room is made of high-quality stainless steel, the side sheet thickness is 1.5mm, the top gate thickness is 1.5mm, the bottom of powder coating room uses metal support structure. Powder coating room equips with the floodlight, luminance is 500 Lux.
The powder coating room equips with a manual spraying opening, it can be used for pre-spraying and repair spraying. The light color of powder coating room and the integration lighting guarantee the excellent working condition, the operators can enter into the powder coating room and clean the room by a extended air suction pipe.
(2)Filter cartridge recycling device
The back filter cartridge is used for splitting the micron powder from the air that is sent by the cyclone separator. In addition, the recycling fan guarantees the constant wind speed of the powder coating room. The material of filtration uses Toray. The air drained by fan can drain into the workshop. Airflow: 11000m3/h, motor power: 11KW, filter area: 165m2, compressed air consumption: 22 Nm3/h.
Filter control instrument is the intelligent control system using cartridge recycling reverse blowing device, it can not only control the pressure of the filter inside/outside automatically, once the pressure reaches the pre set point, the system will start the filter pulse blowback cleaning process automatically, but also has automatic optimize function, with the increase of working time, the filter control instrument will realize the filter pulse blowback according to the optimize process automatically. This system can save the consumption of compressed air greatly, extend the cartridge working life, reduce the manual cleaning number, lower the equipment noise at the same time.
Back filter cartridge recycling device incl.:
1. Back filter cartridge device equips with the shell.
2. Filter device equips with cartridge, fan impulse type filter
3. Filter
4. Clean air outlet equips with muffler
5. Residual powder collection box and vibrating screen
6. Air storage tank

(3)Spray gun
Total: 1 sets manual spray gun, 2 sets automatic spray gun, 4 sets fixed spray gun.

6. Isolating room
The room consists of δ50 rock wool color steel plate + A3 steel compound. The inner plate of rock wool color steel plate is Galvanized, shell plate is color steel plate. The aisle has windows for inspecting. Equip with workpiece in/out copying door and personnel in/out door. The room is equipped with lighting.

The powder coating line adopts scattered setting and centralized control.
In every important part of the line, there is emergency stop button, which is easy for worker to operate.
The temperature control of each part adopts digital auto controller. It will show the temperature of each heating point and auto control the temperature automatically at the same time.
The design, model, production and installation of the electric components all conforms with the national standards.
The electric control cabinet has the following features: neat surface, good appearance, reasonable panel layout, which is easy for observation and operation.
Adopts new series components with reliable performance and advanced technology.
There is lockset on the handle of the cabinet door.
The guide wire of the cabinet door is very tidy, the wire arrangement is standard, which is bundled into a bunch, horizontal and vertical emphasis.
If the wire needs go through corner, it will be arc-shaped.
The wires have good connection with each components. The insulation resistance between each wire > 1mge.
The connection between wire and components all have clear mark, and will not wear faded.
Every connector has the mark to show the connection secure.
The marks in the cabinet are uniform with the electric drawings, easy for check and repair.
All the components are from national standard factory or imported factory.
The ground resistance conforms with national standards.

8. Main components supplier

NoMain componentsSupplier1Fan Shanghai Shuyuan or Kewangda2Conveyor chainShanghai Qingpu or Suzhou Youxin3Frequency converterMitsubishi4Digital temperature controllerFuji or Omron5Contactor and buttonShanghai Schneider6Spraying torchDomestic

9. Power and nature gas consumption

No NameConsumption1Electric Hot-air blower5.5KWExhaust fan3.0KWPowder coating chamber15KWConveyor 3.0KWOther 3 KWTotal 29.5KW2Compressed airabout 2-2.5m3/h3Nature gas10-15m3/h(5-7.5kg/h)