Third, process equipment selection
1, process equipment parameters
1.1, glass bottle requirements:
The surface of the glass bottle is clean, and if the surface has oil to be cleaned, the surface of the bottle body is smoothly transitioned, and there is no sharp shape and partial deep depression.
1.2, transmission system requirements: smooth operation, adjustable speed. The design speed is 0.5~5m/min.
1.3. The drying oven for imitation ceramic bottles requires a furnace temperature of 50-120°C. The bottle needs 10 minutes in the heating furnace to intelligently control the temperature.
1.4, coating thickness 40 ~ 60μm.
1.5, the top bracket device: in the spraying room with a rotating function, speed is 30 ~ 80rpm. Ensure that each glass bottle is sprayed evenly and there is no dead zone for spraying. Device center distance 100mm.
1.6. The compressed air is oil-free and clean with a pressure greater than 0.4 MPa.
2, equipment configuration (1) transmission system, including chain drive, rack, reducer, glass bottle jacking, spin system and other devices.
(2) Spraying system, including stainless steel slurry tanks, pipelines and valves, nozzles, static generators, spray booths, collectors, filters, and dust collectors.
(3) Drying furnace system, including electric heating elements, furnace body, air supply fan, temperature measurement and temperature control system.
(4) Roasting Kiln, using existing equipment.
(5) Oil-free lubricated air compressors and freeze dryers are general equipment.
3. Equipment Features (1) Shotcrete chamber The shotcrete chamber body is made of high-quality stainless steel plate (δ=1.5mm) and bent by spraying and tying. It is firm and stable, and the top and both sides are beveled and easily cleaned.
The main body of the spraying chamber is 1200mm in length, 1500mm in width and 1500mm in height.
The bottom of the chamber body is designed to be recessed in the middle to facilitate the recovery of the slurry. The rear has a dust outlet.
In order to ensure that the fog does not overflow, the open surface wind speed of the chamber body is 0.3~0.6m/s.
The dust-proof lighting system is installed on the top of the room and the room illumination is >300 lux.
The entire room body is assembled.
(2) high-voltage electrostatic generator High-voltage integrated circuit components ---- the whole volume is reduced, the performance is stable and reliable.
Constant current output characteristics ---- When the spray gun and the working interval within the normal operating range, the generator output current value is basically constant. Facilitate the surface coating quality of the workpiece is stable.
Multi-level overload protection circuit ---- safe and reliable equipment.
Vacuum solid-state voltage doubler rectifier - Compared with "oil seal", the volume is reduced by 6-8 times, the performance is stable, and the transportation is convenient.
Equipment Performance Power 220V 50Hz
Output voltage 0-150KV
Short circuit current <100μA
Constant current output 50μA
Power consumption <30W
4. Major production equipment and price estimation Unit: Yuan serial number Equipment name Quantity Price Remarks
One spraying room 1 set
1 stainless steel spraying room body 1 set 10000
2 exhaust system + dust removal 1 set 3000
3 Lighting System 1 Set 500
4 filter processing system 1 set 16000
5 piping and valve system 1 set 15000
6 imported spray gun 15 9000
7 high voltage electrostatic generator 1 set 15000
8 cold dryer 1 set 5000 repair
9 stainless steel supply barrel 1 15000
Two slurry recovery systems 1 set
1 Stainless steel recovery device 1 set 15000
2 low noise fan 1 set 2000
3 Polyester antistatic filter and bracket 1 set 2000
Three drying furnace system 1 set
1 Drying oven furnace 1
2 Hot air circulation system in a drying tunnel 1 set 2500600000
3 power controller 1 set 10000
Four transmission system 1 set
1 chain 50 meters 180000
2 Drive 1 set 3500
3 lubrication device 1 set 1000
4 jacking device 500 sets 125000
V Centralized control system control cabinet and instrument 1 set 40000
Six Control Rooms 1 Room 5000
Total 426500
1, process equipment parameters
1.1, glass bottle requirements:
The surface of the glass bottle is clean, and if the surface has oil to be cleaned, the surface of the bottle body is smoothly transitioned, and there is no sharp shape and partial deep depression.
1.2, transmission system requirements: smooth operation, adjustable speed. The design speed is 0.5~5m/min.
1.3. The drying oven for imitation ceramic bottles requires a furnace temperature of 50-120°C. The bottle needs 10 minutes in the heating furnace to intelligently control the temperature.
1.4, coating thickness 40 ~ 60μm.
1.5, the top bracket device: in the spraying room with a rotating function, speed is 30 ~ 80rpm. Ensure that each glass bottle is sprayed evenly and there is no dead zone for spraying. Device center distance 100mm.
1.6. The compressed air is oil-free and clean with a pressure greater than 0.4 MPa.
2, equipment configuration (1) transmission system, including chain drive, rack, reducer, glass bottle jacking, spin system and other devices.
(2) Spraying system, including stainless steel slurry tanks, pipelines and valves, nozzles, static generators, spray booths, collectors, filters, and dust collectors.
(3) Drying furnace system, including electric heating elements, furnace body, air supply fan, temperature measurement and temperature control system.
(4) Roasting Kiln, using existing equipment.
(5) Oil-free lubricated air compressors and freeze dryers are general equipment.
3. Equipment Features (1) Shotcrete chamber The shotcrete chamber body is made of high-quality stainless steel plate (δ=1.5mm) and bent by spraying and tying. It is firm and stable, and the top and both sides are beveled and easily cleaned.
The main body of the spraying chamber is 1200mm in length, 1500mm in width and 1500mm in height.
The bottom of the chamber body is designed to be recessed in the middle to facilitate the recovery of the slurry. The rear has a dust outlet.
In order to ensure that the fog does not overflow, the open surface wind speed of the chamber body is 0.3~0.6m/s.
The dust-proof lighting system is installed on the top of the room and the room illumination is >300 lux.
The entire room body is assembled.
(2) high-voltage electrostatic generator High-voltage integrated circuit components ---- the whole volume is reduced, the performance is stable and reliable.
Constant current output characteristics ---- When the spray gun and the working interval within the normal operating range, the generator output current value is basically constant. Facilitate the surface coating quality of the workpiece is stable.
Multi-level overload protection circuit ---- safe and reliable equipment.
Vacuum solid-state voltage doubler rectifier - Compared with "oil seal", the volume is reduced by 6-8 times, the performance is stable, and the transportation is convenient.
Equipment Performance Power 220V 50Hz
Output voltage 0-150KV
Short circuit current <100μA
Constant current output 50μA
Power consumption <30W
4. Major production equipment and price estimation Unit: Yuan serial number Equipment name Quantity Price Remarks
One spraying room 1 set
1 stainless steel spraying room body 1 set 10000
2 exhaust system + dust removal 1 set 3000
3 Lighting System 1 Set 500
4 filter processing system 1 set 16000
5 piping and valve system 1 set 15000
6 imported spray gun 15 9000
7 high voltage electrostatic generator 1 set 15000
8 cold dryer 1 set 5000 repair
9 stainless steel supply barrel 1 15000
Two slurry recovery systems 1 set
1 Stainless steel recovery device 1 set 15000
2 low noise fan 1 set 2000
3 Polyester antistatic filter and bracket 1 set 2000
Three drying furnace system 1 set
1 Drying oven furnace 1
2 Hot air circulation system in a drying tunnel 1 set 2500600000
3 power controller 1 set 10000
Four transmission system 1 set
1 chain 50 meters 180000
2 Drive 1 set 3500
3 lubrication device 1 set 1000
4 jacking device 500 sets 125000
V Centralized control system control cabinet and instrument 1 set 40000
Six Control Rooms 1 Room 5000
Total 426500
Fourth, the development of special equipment In order to ensure the smooth implementation of the pottery-resistant production line, the use of a mature operating system in the selection of equipment. In general, the equipment will be divided into three parts, namely the transmission system, the spraying system and the drying system. The above three parts have matured in the industry, five, difficulties and technical problems
1, the original imitation ceramic spray line problems 2, the corresponding solution
(1) Inhomogeneous spray distribution of ceramic coatings (1) Uniform nozzle with multiple opportunities
(2) There is no effective drying method; (2) After the spraying room is used, the drying oven is connected
(3) Low efficiency, and can't scale production; (3) Adopt automatic spraying, producing 20,000 per day
(4) The qualified rate of spraying in the original production line is low; (4) The effective combination of spraying and mechanical movement
(5) Low effective slurry utilization; (5) Combination of electrostatic process and slurry recovery
(6) The suspension stability of glass bottles is poor; (6) The use of jack bracket structure
(7) Large dust pollution in the slurry; (7) Spray booth and dust recovery device
(8) The layout of the process route is irrational. (8) Organic combination of spraying and drying process
The main difficulty lies in the development of automatic spray booths. We have set up 15 spray guns in the automatic spray booth, three teams and a total of five groups. A main spray gun is aligned with the bottle body, an auxiliary spray gun is aligned with the bottom of the bottle, an auxiliary spray gun is aligned with the bottleneck, and the electrode is inserted into the bottle with positive charge; the spray gun is not charged. The electrostatic network is arranged opposite to the spray gun and carries a negative electricity of 100,000 to 150,000 volts. The plasma mist is negatively charged due to ionization of the air and can cause the mist to be uniformly adsorbed on the bottle. In addition, a modifier is added to the slurry to make the slurry. The body adapts to the requirements of industrial spraying. At the same time, considering that the spray gun has a vertical swing function, the bottle body is more efficiently pulped. The shape of the mist is considered to be rectangular, and the pressure, mist shape, flow rate, slurry viscosity, specific gravity of the slurry, nozzle position, and nozzle swing angle can be adjusted as needed.
In the three modes of microwave drying, far-infrared drying, and hot air drying, hot air drying is used.
The bottle was put into the spraying chamber with a jacking device, and the bottle mouth was sealed with a temperature-resistant rubber stopper.
Due to the need to use the current kiln, taking into account the curing temperature of the flower paper, the process parameters of the ceramic products must not be different from the white roasted flowers. However, when the temperature at the scene shows 580°C, the milk bottle has started to soften, which is the reason why the bottle bottom belt is printed. If the bottle is inverted into a kiln on a stand, most of the bottle will produce a licking phenomenon. Taking into account the implementation of the investment and time factors, the manufacturer of the bottom of the belt network printing requirements are more stringent, the bottom is still to adopt asbestos cloth silk cloth method.
Sixth, the production line site imitation pottery production line using the existing plant, 17.25m long from north to south, east-west width of about 6.50m.
Seven, workshop environment requirements 1, the ground paved terrazzo.
2. There is a drainage ditch on the ground.
3, wall painting.
4, the workshop uses fluorescent lighting.
5. There are 3 tap water pipes in the workshop.
Summary: The pottery production line we research and develop is currently the only industrialized production line in China that operates stably. In actual operation, the daily output is not less than 20,000. It is also the most complete imitation pottery production line in the domestic color system with considerable economic benefits.
1, the original imitation ceramic spray line problems 2, the corresponding solution
(1) Inhomogeneous spray distribution of ceramic coatings (1) Uniform nozzle with multiple opportunities
(2) There is no effective drying method; (2) After the spraying room is used, the drying oven is connected
(3) Low efficiency, and can't scale production; (3) Adopt automatic spraying, producing 20,000 per day
(4) The qualified rate of spraying in the original production line is low; (4) The effective combination of spraying and mechanical movement
(5) Low effective slurry utilization; (5) Combination of electrostatic process and slurry recovery
(6) The suspension stability of glass bottles is poor; (6) The use of jack bracket structure
(7) Large dust pollution in the slurry; (7) Spray booth and dust recovery device
(8) The layout of the process route is irrational. (8) Organic combination of spraying and drying process
The main difficulty lies in the development of automatic spray booths. We have set up 15 spray guns in the automatic spray booth, three teams and a total of five groups. A main spray gun is aligned with the bottle body, an auxiliary spray gun is aligned with the bottom of the bottle, an auxiliary spray gun is aligned with the bottleneck, and the electrode is inserted into the bottle with positive charge; the spray gun is not charged. The electrostatic network is arranged opposite to the spray gun and carries a negative electricity of 100,000 to 150,000 volts. The plasma mist is negatively charged due to ionization of the air and can cause the mist to be uniformly adsorbed on the bottle. In addition, a modifier is added to the slurry to make the slurry. The body adapts to the requirements of industrial spraying. At the same time, considering that the spray gun has a vertical swing function, the bottle body is more efficiently pulped. The shape of the mist is considered to be rectangular, and the pressure, mist shape, flow rate, slurry viscosity, specific gravity of the slurry, nozzle position, and nozzle swing angle can be adjusted as needed.
In the three modes of microwave drying, far-infrared drying, and hot air drying, hot air drying is used.
The bottle was put into the spraying chamber with a jacking device, and the bottle mouth was sealed with a temperature-resistant rubber stopper.
Due to the need to use the current kiln, taking into account the curing temperature of the flower paper, the process parameters of the ceramic products must not be different from the white roasted flowers. However, when the temperature at the scene shows 580°C, the milk bottle has started to soften, which is the reason why the bottle bottom belt is printed. If the bottle is inverted into a kiln on a stand, most of the bottle will produce a licking phenomenon. Taking into account the implementation of the investment and time factors, the manufacturer of the bottom of the belt network printing requirements are more stringent, the bottom is still to adopt asbestos cloth silk cloth method.
Sixth, the production line site imitation pottery production line using the existing plant, 17.25m long from north to south, east-west width of about 6.50m.
Seven, workshop environment requirements 1, the ground paved terrazzo.
2. There is a drainage ditch on the ground.
3, wall painting.
4, the workshop uses fluorescent lighting.
5. There are 3 tap water pipes in the workshop.
Summary: The pottery production line we research and develop is currently the only industrialized production line in China that operates stably. In actual operation, the daily output is not less than 20,000. It is also the most complete imitation pottery production line in the domestic color system with considerable economic benefits.
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