Spraying waterworks Hardware flow refers to the hardware, the special shop to carry out large-scale transformation of the spray shop, installation of rails and the special design of the barn and primer room formed after the flow of water forms. Hardware running water is a kind of large investment and effective water flow method. It is suitable for large-scale blow-molding workshops. The implementation of hardware water flow has high requirements for plant and investment, and the vehicles on the ground track are vertical or horizontal rows. The paint shop must be 30-80 meters long to accommodate the entire line. In addition, due to the need to increase the ground rails, the conversion or addition of barns, primer rooms, so the overall investment will be quite large. Since the hardware flow is mostly a straight line that leads to the end, it generally adopts a beat-type connection. Generally divided into demolition parts - sheet metal - putty - sanding / shading - finish - baking - polishing - installation of parts and other processes, each process time is fixed and equal, this time is called Beats, such as 1 hour. Only in this way can the advantages of the hardware flow in the assembly line be as follows: Compared with the traditional squeezing spray shop, the efficiency is greatly improved; the equipment is excellent; the employees have a good operating environment; the tempo is fixed so that it is convenient to manage; the vehicle is parked on the rail car The technicians push forward, so under normal circumstances, the vehicle does not need to be started from the beginning to the end. On the other hand, hardware running water has its shortcomings, which include: First, large investment and high demand for factory buildings; Second, the time for each beat is difficult to determine, and in most cases, the time of the beats is what people come up with out of nowhere; Third, the lack of flexibility, because as long as the time of each beat a fixed, in theory, you can calculate how many cars out of every day. However, it is difficult for special shops to ensure that there are such fixed vehicles every day. This will affect the flow of hardware water. This can easily lead to flaws in the assembly line. It is up to the workshop managers to dispatch and coordinate with high skill.

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Spray waterworks Process flow refers to the division of flow patterns in different functional areas in a blow room spray shop. According to the time-consuming degree of each process, how much their workstations occupy is different. The most time-consuming process of painting is the “putty-ashing” and “primer/grinding” processes, so the number of stations assigned to them is relatively large. Moreover, because the entire flow of water is not strictly a "straight line", the use of "non-beating flow" forms is more often used in the cohesion mode. Therefore, there are no strict time limits for each process.

Its disadvantages are: Because the connection time between each process is completely "fuzzy", it is necessary to have a competent manager who knows how to manage this line, otherwise it may cause inefficiency.

Spray production line process

1. Sheet metal correction: First, technicians at the sheet metal correction station will put the cleaned vehicles on the track assembly line. After the calibration and disassembly work has been completed, the vehicle will move along the track to the scraping station.

2, squeegee (scratch putty): scrubbing workers to check the quality of sheet metal correction, the workpiece surface after processing to scrape gray, you can choose natural drying or infrared baking, after the completion of the vehicle to the polishing operation station

3, grinding operations, grinding personnel according to the needs of the process to select the appropriate sandpaper and grinding tools, the operation, the job is completed and moved to the next paint station

4. Primer: After the primer technician checks the quality of soil and sanding, it performs primer spraying, secondary polishing, etc. After the completion, the vehicle moves to the shelter station along the track.

5. Masking: The masking station technician checks the quality of the primer and masks the non-sprayed surface, and cleans all the gaps with compressed air. After the masking is completed, the vehicle moves along the track to the painting booth.

6, spray paint: paint technicians check the quality of cover, clean, spray, after the completion of the vehicle was moved to the paint room,

7. Baking: The paint operator shall set according to the time and temperature required for the paint, turn on the power and monitor the work of the equipment. The sound of the paint is complete with sound and light alarm, and the vehicle will be cooled and launched.

8. Polishing: After the polishing technician checks the paint quality, the wax type is selected according to the size and size of the surface of the vehicle, and the polishing and cleaning operations are completed. After the completion, the vehicle is moved to the assembly station.

9. Assembling: Assembling technicians will completely disassemble the disassembled parts and complete the repair work. The spray water line has improved the ability to repair paint vehicles by 35%, the overtime time of technicians has been reduced by 90%, and the cycle of vehicle owners' refinish paint has been shortened. 50%.

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Spraying waterworks is an extension of lean production methods from automobile manufacturing to vehicle maintenance. It refers to the re-planning of the squeezing spray shop, the use of specific methods to transform the workshop into different functional areas, and the specific working methods are performed by specific operators. Because the different processes of the vehicle to be repaired are performed in different areas and by different mechanics, it is similar in form to the “assembly line” of the automobile production plant and is therefore called “flowing operation”. According to its implementation form, it can be divided into hardware flow and process flow. According to the connection method of each process, it can be divided into non-beat flow and rhythm flow. The traditional refinish process is one-to two-person repairs. A repair process consists of more than 10 process steps. The spray line is a reasonable process for the paint repair process. The equipment and personnel are divided according to the process flow. Thus, a complex matter is simplified, and a complete refinish paint process is generally divided into 7-9 workstations (sheet metal, squeegee, sanding, primer, cover, finish, drying, throwing, Assembly,), each according to their own circumstances, the flexibility to choose the number of workstations hardware flow The construction time of each workstation is almost similar, each workstation according to the workload of each repair vehicle to adjust personnel, respectively, responsible for the work of different processes, To ensure that each station has similar working hours, just like the assembly line of a car assembly, the working time of technicians at each workstation is strictly controlled to ensure that the vehicles are completed according to the planned time, and the maintenance quality of each workstation is also strictly controlled. After the completion of the maintenance of quality, all the cars were completed in accordance with the expected time. Let's explain one by one:

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When most of repair shop or vehicle warehouse buy auto paint booth, they usually will choose some other parts for them paint booth.

Such as below:

1. Safety Thermostat

The safety thermostat(shown in Fig.1.10), placed in the generator group near to the heat exchanger, switches off the electric system if the air flow reaches a temperature superior to 90°C

2. Anti-vibration Joint  

The anti-vibration joint (shown in Fig.1.11), placed between the generator groups, and exhaust air unit with active charcoals and the spray booth, is necessary to isolate the vibrations produced by the motor and the fan. The joint is formed by two edges of zinced plate connected by a belt of PVC that by contorting does not transmit the vibrations to the work environment.

3. Active carbon system

The exhausting air device have active charcoals, which the air from the paint booth environment and to decrease the percentage of polluting agents. It is composed of:

Metal frame, there rock in the panel which can keep the temperature Filtration group, composed of seven layer of active charcoal which remove the solvent fumes (purification plant).

When the Auto Paint booth working, It will have many paint mist, in order to protect the environment. We have to recycling paint mist, it can be divided into two parts:

First, when spraying the workpiece in the paint booth, the paint mist collides with the water curtain, and the water curtain dissolves into the paint mist and falls into the water tank;

Second, the paint mist that has not dissolved into the water curtain enters the water washing chamber through the gap at the bottom of the water curtain plate, and is fully mixed with the water mist sprayed from the atomizing nozzle, and the gas and water are separated and settled into the water tank. A paint mist coagulant is periodically added to the water tank to form a paint residue.

The design editor Key points

1. Determine a reasonable configuration form.

2. Determine the reasonable average flow rate of the horizontal plane air in the spray booth.

3. The air supply and exhaust system are reasonably matched to ensure a slight positive pressure in the painting room.

4. The thickness of the water curtain should be uniform. Pay attention to the structure of the water tank and the distribution of the water supply pipeline.

5. The distance from the lower part of the water curtain board to the liquid level of the water tank should be reasonable.

6. Washing atomizing nozzles and pipelines should be easy to disassemble, replace and clean.

7. Separation of gas and water should be sufficient and easy to clean.

Offer by GL Auto Paint booth.

Common Treatment Methods The main pollutants produced by spray painting are organic solvents and organic gases generated by the volatilization of thinners. Common methods for handling such organisms are:

1. Direct combustion method: using oil or natural gas as an auxiliary fuel to burn and heat the mixture to a certain temperature (700°C-800 °C), the use of heating and high temperature methods, the direct treatment of organic waste gas to achieve the purpose of exhaust gas purification;

The method is simple in technology, low in equipment investment, but high in energy consumption and high in running cost.

2. Water spray method: Spray paint exhaust water treatment water spray technology is widely used in air pollution control, and has been applied in the spraying process. For example, the water curtain cabinet is used as an example. The principle is to spray water in the exhaust, water-soluble or large particles. Settlement to achieve the purpose of separation of pollutants. After sedimentation and filtration at the same time, the water can be reused to reduce the waste of water resources. The water spray has a very high efficiency in the treatment of large particles and is usually used in the pretreatment of exhaust gas treatment.

3. Activated Carbon Adsorption: Activated carbon is used as an adsorbent because of its large adsorption surface area and strong adsorption capacity. When exhaust gas passes through an adsorbent, harmful substances in the exhaust gas are adsorbed and the exhaust gas is purified; the organic gas is directly adsorbed, and the equipment It is simple, small in investment and convenient in operation, but it requires frequent replacement of activated carbon and subsequent treatment of activated carbon that is replaced after use.

4. Photo-Oxygen Catalytic Degradation: The mercury lines in the UV tube are excited to produce characteristic lines of mercury, and ozone is generated by ionized air. Ozone is a strong oxidant, which has the functions of sterilization and deodorization; meanwhile, when photo-oxygen catalysis, Its nano-wavelength light energy can effectively cut, break chain, burn, crack the molecular chain of exhaust gas, change the molecular structure of exhaust gas, and then through strong oxidization, combine the destroyed exhaust gas molecules or atoms with O3, organic or inorganic polymer The odorous compound molecular chains are converted into low-molecular compounds such as C02, H2O, etc. during the catalytic oxidation process. UV photo-catalysis can be regarded as a kind of cold combustion. The catalyst uses a honeycomb metal mesh as a carrier, catalyzes the reaction under full-scale contact with a light source, and amplifies the effect of a light source of 10-30 times, making it fully react with the exhaust gas. Shorten the contact time between the exhaust gas and the light source, thereby improving the efficiency of exhaust gas purification and deodorization.

 

5. Plasma reaction method: The exhaust gas molecules are decomposed using a plasma containing a high-energy reactive group to generate carbon dioxide and water, thereby achieving the purpose of purifying the exhaust gas. However, this method is not suitable for use in the treatment of flammable and explosive paint organic exhaust gas. It has potential safety hazards and the maintenance of the equipment is complicated.

(6) Condensation method: Spray paint treatment Direct condensation or adsorption Concentration condensation After recovery, the condensate is recovered by separating organics of value. This method is used for high concentration, low temperature, and small volume of exhaust gas treatment. However, large investment, high energy consumption, high operating costs. This method is generally not used to purify paint exhaust gas.

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The Wall man lift access platform is a product from GZ Guangli EFE Co.,Ltd which is a pneumatic driven person elevator with replaces ladders, scaffolding etc. to create a safe and effective working place when painting or fixing some large vehicles in the spray booth.

The liftman GL1010 is a three dimensional elevator that hangs and runs on rails mounted high on the sidewalls. It can up, down, forward, back, left and right move when painting or fixing

The cage is equipped with a simple control panel for up/down, in/out and sideway movement. For the vertical and the horizontal movement, the GL1010 man lift is equipped with pneumatic drives, where as a pneumatic motor takes care the lateral movement.

The wall man lifts has been designed with a great attention for the safety of the user, that’s the reason there is a protection against cracks in the pneumatic circuit, overload and collision detection, it’s important to mention, that the safety instructions, mentioned in this manual.

Additional there is a possibility for the compressed air outlet in the cage to avoid the need for trailing hoses to the tools.

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The clutch slave cylinder is a crucial component of a vehicle's manual transmission system. It plays a vital role in engaging and disengaging the clutch to facilitate smooth gear shifting. This blog aims to provide insights into the classification of the clutch slave cylinder, shedding light on the different types available and their respective working principles.

1.    Hydraulic Clutch Slave Cylinder:
The hydraulic clutch slave cylinder is the most common type and utilizes hydraulic pressure to operate the clutch system. It consists of a piston, a cylinder, and a hydraulic line connected to the master cylinder. When the clutch pedal is depressed, hydraulic fluid is forced into the slave cylinder, pushing the piston, and actuating the clutch release arm to disengage the clutch. The hydraulic slave cylinder offers precise and smooth clutch engagement.

2.    Mechanical Clutch Slave Cylinder:
Less commonly used, the mechanical clutch slave cylinder operates using mechanical force instead of hydraulic pressure. This type typically employs a lever system that translates the movement of the clutch pedal to engage or disengage the clutch. Mechanical slave cylinders are simple in design but may require more effort to operate compared to hydraulic ones. They are often found in older vehicles or specific applications.

3.    Concentric Clutch Slave Cylinder:
The concentric clutch slave cylinder, also known as an internal slave cylinder, is a design variation that integrates the slave cylinder into the clutch assembly. Instead of being external, the concentric slave cylinder is installed inside the bell housing, directly around the transmission input shaft. This design provides a more compact and streamlined system, reducing hydraulic fluid volume and potential leaks. Concentric slave cylinders are commonly used in modern vehicles.

4.    Non-Concentric Clutch Slave Cylinder:
Unlike the concentric design, the non-concentric clutch slave cylinder is a separate component mounted externally on the transmission bell housing. It operates in a similar manner to the hydraulic slave cylinder by using hydraulic pressure to actuate the clutch release mechanism. Non-concentric slave cylinders are often found in older vehicles or in certain performance applications where specific design requirements are met. 

Understanding the different types of clutch slave cylinders and their respective classifications is crucial for vehicle owners, mechanics, and automotive enthusiasts. By recognizing the various working principles and designs, one can make informed decisions regarding maintenance, repairs, and upgrades. Whether it's the hydraulic, mechanical, concentric, or non-concentric slave cylinder, each type serves a specific purpose in ensuring smooth clutch operation.

The brake cylinder, like the brake master cylinder, is an important component of the vehicle braking system, and the braking system is the component that controls the vehicle.

Due to wear and tear or improper usage habits, there may be some problems with the brake cylinder during use. One common problem is leakage, which can be caused by damage to the internal seals of the brake cylinder or corrosion due to long-term use. Leakage of the brake cylinder can lead to the loss of brake fluid, resulting in a decrease in braking performance or complete failure. The second problem is that the piston is stuck due to internal corrosion or debris, causing the brake pedal to not fully engage, resulting in uneven braking or a soft feel on the brake pedal.

Regular maintenance is the key to maintaining the good condition of the brake cylinder. As a car owner, with some professional knowledge, you can regularly check the wheel cylinder for signs of leakage, such as wet spots or dripping brake oil; Regularly flush brake oil according to the manufacturer's recommendations to prevent corrosion and maintain hydraulic pressure; Check if the brake pads are worn and replace them if necessary to prevent damage to the brake cylinder; Regularly clean the brake components, remove debris, prevent corrosion, and avoid affecting the performance of the brake cylinder. In addition, if you find any problems with the brakes, such as noise or decreased braking performance, please contact a professional to inspect the vehicle's braking system, including the brake cylinder.

The brake cylinder is a crucial component in vehicles, so remember to pay attention to the vehicle's driving status to ensure your road safety.

When your car encounters difficulties in shifting and starting, the acceleration of the car becomes weak, the car stops driving directly, and there is abnormal noise and odor when pressing the clutch, it may be a problem with your car's clutch system.

The hydraulic clutch control system consists of clutch pedal, clutch master cylinder, clutch slave cylinder, oil pipe, release bearing, release fork, and reservoir.

During the use of the vehicle, the long-term closure and release of the clutch can cause wear on the rubber cups and cylinder walls on the piston of the clutch master cylinder and the slave cylinder, which may lead to internal leakage of the master cylinder, resulting in a decrease in oil pressure, oil leakage, and other problems. It may also cause problems such as incomplete clutch separation and difficulty in shifting.

Common clutch system faults include clutch slipping, clutch shaking, abnormal clutch noise, difficulty shifting, weak driving, starting shaking, incomplete separation, unstable oil pressure, and increased fuel consumption.

It is necessary to regularly check the condition of the vehicle, and if any faults are found, relevant parts should be replaced in a timely manner to ensure the normal use of your car.