讲解减少涂装颗粒的控制措施.doc

讲解减少涂装颗粒的控制措施
颗粒在涂装中是最常见的涂膜缺陷之一，在任何一个涂装生产线都会不同程度的存在。它是影响涂装一次交检合格率的最大的也是最难以根除的涂膜弊病。因为颗粒造成的车体返修大大增加了涂装成本，经核算，每台车的中修费用100元左右，而一台车返大修，重新喷涂一遍面漆大约需要成本350元。在外观上修理过的涂膜也略差于一次成型的涂膜。在涂装生产中，涂膜颗粒弊病可以说是顽疾，几乎是无法杜绝的，只能是在生产过程中不断摸索，分析 总结 ，采取相应的措施，使颗粒的产生降到最低，从而减少生产成本，提高生产效率。

Particles in the coating is one of the most 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 the 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 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颗粒的定义

2.1 the definition of particle

涂膜上的突起物叫做颗粒，也称脏点，用目视或触摸可以辨别。

Bumps called particles on film, also called dirty points, with visual or touch you can identify.

2.2颗粒的分类

2.2 the classification of particles

由于造成涂装颗粒的因素众多，很难制订一个统一的分类标准，按照经验可大致分类如下：

Due to the coating particles caused by many factors, it is difficult to formulate a unified standard of classification, according to the experience can be broadly classified as follows:

（1）环境颗粒：由环境因素导致的涂膜颗粒。（2）干燥炉颗粒：因干燥炉不干净而产生的涂膜颗粒。多为黑色坚硬，难以修整，易造成批量返工。（3）涂料颗粒：产生原因多为调输漆系统的涂料沉淀、喷枪或喷杯清洗不净，或雾化效果不好等。（4）喷胶颗粒：因注焊缝胶或喷抗石击底盘胶时，产生的多余胶颗粒。（5）前处理颗粒：白皮车身残留的铁屑、焊渣所致，多发生在门口部位，打磨极其困难。（6）静电颗粒：喷涂金属底漆时，喷涂设备造成的颗粒。

(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 coating 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 slag, 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 涂装生产线颗粒产生的原因及防治措施

3 coating production line particles causes and prevention measures

根据颗粒产生的定义和分类，对不同类型的颗粒产生原因加以治理，以下按生产线的工艺顺序，分析影响漆膜质量的原因并介绍为防止颗粒所采取的措施，提出可以试用的一些办法。

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 measures taken to prevent the particles, can try some measures are put forward.

3.1前处理线

3.1 before the processing line

污染源分析：主要是焊装车间在生产过程中产生的铁屑，积存在车身内部不易清理的部位，随车进入涂装线，在车身表面形成不同颗粒的形式，直接影响到车身涂层质量，危害性较大。

Pollution source analysis: mainly is the welding workshop in the production process of iron filings, accumulate 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.

解决措施：在前处理的热水洗槽、预脱脂、脱脂槽各加一组磁力回收装置，每组装置由3根磁力棒组成，磁力回收装置安装在槽液循环吸口处，槽液循环时通过磁力棒做循环流动，铁屑随槽液在通过磁力棒时，利用磁力吸附特性，达到过滤槽液中铁屑的作用。

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 magnetic 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电泳线

3.2 electrophoresis line

污染源分析：在电泳过程中，多余的残液会附在吊具上，经过多次的烘干和电泳，在吊具表面留下很厚的残渣，漆渣会从吊具上剥落，进入槽液和其他区域，再粘附车体表面形成颗粒。

Pollution source 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 car body surface to form particles.

预防措施：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）高压水洗，用专业的高压水枪洗掉漆渣。（3）采用吊具保护法。在吊具的表面涂上防护底漆和防护清漆，使吊具反复进入电泳槽基本不再粘附电泳漆。从而防止颗粒的产生。常规处理的吊具经电泳涂装后表面形成的沉积漆膜不能冲洗掉，浮漆也不易完全冲洗干净，再经碱性脱脂液、酸性磷化液浸泡后形成多孔隙的不规则沉积漆膜，进一步增加了清洗难度。而挂具保护涂料通过优化组合树脂官能团，添加高性能纳米材料，涂布在挂具上后使其具有优良的电绝缘性，电泳涂装时不易形成沉积酱油漆膜，且具备优异的机械性能，耐化学品性能和耐水性能。目前我们哈飞汽车微车涂装线已经采用此方法，效果很好。有效的减少了吊具上的沉积漆膜对电泳槽液的污染。

(1) artificial knock sling, sling on the paint slag. (2) the high pressure water washing, wash 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 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. 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 properties, 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注胶、喷胶线

3.3 note glue, glue line

污染源分析：在注胶过程中会产生需要清理的多余密封胶，这些多余胶一般情况下使用纱布或纯绵布进行擦拭，这就会使一些纤维留在焊缝边缘或车体内部，污染车身。

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.

预防措施：改用低纤维擦布或长涤纶纤维擦布擦净会大大改善，降低车身的纤维污染。

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：操作者在喷胶过程中，胶雾会溅落在车身上，经过注胶烘干炉烘干后，形成密集的颗粒，造成车身污染。

Pollution source analysis: the operator in the process of spray glue, glue the fog will be splashed down in the car, after injecting drying oven drying, forming dense granules, cause body pollution.

预防措施：

Preventive measures:

（1）将可能喷入车体内表面的装配孔，螺纹孔用隔离胶带充分隔离，防止胶雾喷入车体内腔。（2）可在喷胶工位安装护板，在不影响车体行进的情况下将车体的下半部分遮挡，可减少车体的污染和擦净工位的工作量。

(1) will be sprayed into the assembly hole 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, to reduce car pollution and wipe location of work.

3.4打磨线

3.4 cutting line

污染源的分析：涂装车间一般都会设置中涂打磨和面漆打磨，打磨车体电泳漆缺陷或中涂漆缺陷，打磨过程中会产生大量的打磨灰，而一般打磨工位和擦净工位在同一区域，打磨灰会污染擦净后的车身。

Pollution sources analysis: coating workshop will typically set in grinding, polishing and paint grinding, car body paint defects in electrophoretic 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.

预防措施：

Preventive measures:

（1）分离打磨区和擦净区，有效的减少打磨灰对车身的污染。（2）将中涂打磨到面漆喷漆室的通道全部密封，打磨工位网格板下设水槽，避免打磨灰在整个厂房的扩散和对车身的污染。（3）有一种新工艺就是打磨后将整个车身经过去离子水浸系洗后再喷淋，烘干，然后喷面漆。这样可以将车身内外的灰尘洗干净，大大有利于减少面漆的颗粒。

(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, to 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 greatly beneficial to reduce the paint particles.

3.5喷漆线

3.5 paint spray line

污染源分析：在喷漆过程中我们国内涂装线基本都是采用的静电喷涂，涂料的利用率基本在60%~80%，在喷漆过程中会有大量的漆雾形成，其中大部分形成漆渣，也有一部分会漂浮在空气中，落到自动喷涂设备和喷漆间的壁板上，或者喷漆工的衣服帽子，手套等上面，聚集形成颗污染车体，这样的颗粒尤其会污染喷过漆湿膜上，形成较难处理的颗粒，这样形成的颗粒占颗粒形成总量的40%以上。

Pollution source analysis: in the process of spray painting line in my country are basically adopts electrostatic spraying, coating the utilization rate of basic in 60% ~ 80%, and in the process of spray paint will have a lot of paint fog formation, most of the paint slag formation, also has the part will be floating in the air, landed on automatic spray equipment and paint on the wall between the board, or spray painting work clothes hat, gloves, etc., gathered to form pollution body, in particular, such particles will pollution of the spray paint on the wet film, forming particle, more difficult to deal with this form of granular particles formed by more than 40% of the total.

3.6残留异色漆颗粒污染

3.6 residual paint particle pollution

污染源分析：喷漆时会因所需喷涂车体颜色的变化频繁更换漆管，喷涂时漆雾会落到漆管上和喷枪上，当更换颜色时漆管和枪体上的色漆颗粒就会掉到更换颜色后的车身上，形成异色颗粒。

Pollution source analysis: painting when because of the tube body color changes frequently replace painting, spray paint mist will fall to paint on the pipe and spray gun, when change the color paint paint particles on the tube and the gun body will drop to change the color of car body, form different color particles.