一、完整工艺流程

1、 Complete process flow

自动化粉末喷涂生产线包含以下标准工艺流程：上件工序→前处理工序（喷抛丸除锈/自喷式）→烘干工序→静电粉末喷涂系统→固化处理→下件工序。在前处理阶段，必须对工件进行全面的表面预处理，包括但不限于脱脂除油、防锈处理、氯硅烷转化处理以及多道水洗等工序。对于特殊要求的工件，还需增加机械打磨和喷砂处理等工艺，以显著提升涂层结合强度。只有经过规范前处理的工件，才能确保获得均匀的膜厚分布和优异的涂层附着力。喷涂完成后，必须在规定时间内将工件送入固化炉进行烘烤，使粉末涂层在受热条件下按照不同工艺要求形成完整的高性能涂层。目前行业普遍采用的固化方式主要包括热风循环烘烤和辐射加热烘烤两大类型。

The automated powder coating production line includes the following standard process flow: upper part process → pre-treatment process (spray shot blasting rust removal/self spraying) → drying process → electrostatic powder coating system → solidification treatment → lower part process. In the pre-processing stage, the workpiece must undergo comprehensive surface pretreatment, including but not limited to degreasing and degreasing, rust prevention treatment, chlorosilane conversion treatment, and multiple water washing processes. For workpieces with special requirements, it is necessary to add processes such as mechanical polishing and sandblasting to significantly improve the bonding strength of the coating. Only workpieces that have undergone standardized pre-treatment can ensure uniform film thickness distribution and excellent coating adhesion. After the spraying is completed, the workpiece must be sent to the curing furnace for baking within the specified time, so that the powder coating can form a complete high-performance coating according to different process requirements under heating conditions. The commonly used curing methods in the industry currently include two types: hot air circulation baking and radiation heating baking.

二、静电粉末喷涂系统构成

2、 Composition of electrostatic powder spraying system

完整的静电粉末喷涂系统主要由以下几个核心部件组成：专业喷粉房、高效供粉设备、一套或多套静电喷枪及智能控制系统、高压静电发生器以及先进的粉末回收处理装置。喷粉房采用优质不锈钢板材制造，具有优异的耐用性和防腐性能；其内部气流分布基于流体力学原理进行优化设计，既能有效防止粉末外溢，又能在喷涂区域形成稳定的气流场，最大限度地降低排风气流对喷涂过程的干扰。

The complete electrostatic powder spraying system mainly consists of the following core components: a professional powder spraying room, efficient powder supply equipment, one or more sets of electrostatic spray guns and intelligent control systems, high-voltage electrostatic generators, and advanced powder recycling and processing devices. The powder spraying room is made of high-quality stainless steel plates, which have excellent durability and anti-corrosion performance; The internal airflow distribution is optimized based on fluid mechanics principles, which can effectively prevent powder overflow and form a stable airflow field in the spraying area, minimizing the interference of exhaust airflow on the spraying process.

三、供粉系统工作原理

3、 Working principle of powder supply system

在供粉系统中，粉末通过压缩空气的作用保持流化状态，随后利用虹吸原理被流动气流携带，形成均匀的粉气混合物。该混合物经过文丘里管或HDLV粉泵、输粉管道，最终输送至喷枪。系统可精确调节输气量和雾化气压参数，灵活控制出粉量和粉末雾化状态，从而实现不同涂层厚度的精确控制，满足各类产品的差异化需求。高性能供粉设备具备强大的输送能力，即使喷枪的输粉管长达50英尺，仍能提供充足的压力和流量保证稳定喷涂。

In the powder supply system, the powder is maintained in a fluidized state by the action of compressed air, and then carried by the flowing airflow using the siphon principle to form a uniform powder air mixture. The mixture is transported through a Venturi tube or HDLV powder pump, powder conveying pipeline, and finally delivered to the spray gun. The system can accurately adjust the parameters of gas transmission and atomization pressure, flexibly control the powder output and powder atomization state, thereby achieving precise control of different coating thicknesses and meeting the differentiated needs of various products. High performance powder supply equipment has strong conveying capacity, even if the powder delivery pipe of the spray gun is up to 50 feet long, it can still provide sufficient pressure and flow to ensure stable spraying.

四、静电喷枪技术特点

4、 Technical characteristics of electrostatic spray gun

专业静电喷枪的结构设计必须满足粉末充电的严格要求，其功能性设计需适应各种喷涂作业方式和不同形状工件的喷涂需求。与传统的液体喷涂技术相比，静电粉末喷涂形成的涂层在机械强度、附着力、耐腐蚀性、耐老化性等方面具有显著优势，在同等效果下更具成本效益。

The structural design of professional electrostatic spray guns must meet the strict requirements of powder charging, and their functional design needs to adapt to various spraying operation methods and the spraying needs of different shaped workpieces. Compared with traditional liquid spraying techniques, coatings formed by electrostatic powder spraying have significant advantages in mechanical strength, adhesion, corrosion resistance, aging resistance, etc., and are more cost-effective under the same effect.

五、固化室结构设计

5、 Structural design of solidification chamber

粉末固化室在结构上主要分为直通式固化室和桥式（或π型）固化室两种类型。为有效减少热量散失对车间环境的污染及能源浪费，高温粉末固化室通常采用桥式结构设计；而脱水烘干室则可根据实际情况选择直通式或桥式结构。采用直通式设计的烘干室必须在进出口处设置高效风幕或自动门系统，以最大限度减少热量损失。这种科学的结构设计不仅能提升能源利用率，还能显著改善车间工作环境。

The powder solidification chamber is mainly divided into two types in structure: straight through solidification chamber and bridge (or π - type) solidification chamber. To effectively reduce the pollution and energy waste caused by heat loss in the workshop environment, the high-temperature powder solidification chamber is usually designed with a bridge structure; The dehydration and drying chamber can choose a straight through or bridge structure according to the actual situation. Drying rooms with a straight through design must be equipped with efficient air curtains or automatic door systems at the inlet and outlet to minimize heat loss. This scientific structural design not only improves energy efficiency, but also significantly improves the working environment in the workshop.

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