Recyclable Vacuum Pressure Impregnation Equipment, Automobile Components Impregnation Surface Treatment

Recyclable Vacuum Pressure Impregnation Equipment ,  Automobile Components Impregnation Surface Treatment
 
I.Impregnating Pretreatment Process
 
1.1 1.2 Ultrasonic Cleaning Tank and Hot Water Rinsing Tank (combined) 
 Feeding
forward ultrasonic cleaning 
Reverse ultrasonic cleaning 
Discharge
                         
1.1.1 Process Features
 
In the impregnation processproducts must be kept clean and dryBecause dirtgreasecutting fluids and other contaminantswill not only affect important indicatorssuch as infiltration pass rateetc.but also contaminate Baptist exude and degrade its performanceand causes other serious consequences or even scrappedSo impregnation pre-treatment process is particularly importantespecially to the industries which have no professional cleaning equipment or heavily polluting productsthe following pre-treatment station is not enough for themThe pretreatment step is adding optional cleaning agents in washing waterwith the turnover mechanism and ultrasoundthe product can get a better cleaning.
 
1.1.2 Flip Ultrasonic Cleaning Tank Instructions
 
a. Tank with 1.5 3mm thick SUS304 stainless steel.
b. Tanks with insulated water storage tanksinsulation thickness no less than 40mmwith good insulation effect.
c. The tank is equipped with electric heatingadjustable room temperature 100 ºC.
d. Upper and lower tanks are both equipped with level control systemto prevent dry heating accidents and pollution of overflow.
e. Tank equipped with ultrasonic generatorwith good cleaning effect.
f. It is equipped with centrifugal pipeline pump to achieve clean water circulationmeet the production capacity and process requirements.
g. Water circulation system is equipped with filtration devices to filter larger particles of debris.
h. Flipping mechanism with automatic locking deviceis safereliable and easy to operate.
i. Pneumatic switch lidsis fast and stablewith low noise.
 
1.3 Vacuum Drying Tank
  Feeding Vacuum Drying Discharge
 
1.3.1 Process Features
 
The principle of vacuum drying is boiling point of water reduces with pressure reducingPut the product with heat into the drying tankreduce pressure through a vacuum pump in the tankso that water of product surfaceblind holesdeficiencies easily reaches boiling pointvaporizes into steam and sucked out by vacuum pumpthen the product is dryVacuum drying is not only effectivebut also low energy consumption compared to conventional heating drying methodit saves energy
 
A lot of experiments provedThe water can vaporize at room temperature or even lower temperature under enough pressure conditionbut it requires heat during evaporationwater vapor in the defect porous is easy to appear a "freezingphenomenon in an instantdue to the temperature is too lowthat is why to raise the rinsing product's temperature above 60 ºCAt the same timeexpect the water should reach boiling pointthe other requirement "pressure decreasingis no longer so strictsince the product temperature is increasedThis will not only speed up the productionbut also improve the product drying effectand reduces the risk of incomplete-drying within a fixed time at room temperature.
 
1.3.2 Vacuum Drying Tank
 
aTank is made of 6 8mm thick stainless steel plate.
bFirst-class brand of vacuum pumpswith reliabilityeasy maintenance and good vacuum effect.
cVacuum system is equipped with a dedicated isolation tank to extend pump life span.
dIt is equipped pneumatic ball valve at each work cycle to ensure idiomatically discharge the condensate water from the dried tank.
ePneumatic switch lidsis fast and stablewith low noise.
 
1.4 Air-cooled Tank FeedingAir Cooling Discharge
 
1.4.1 Process Features
 
Product is still hot (40 50 ºCafter vacuum drying but typically Baptist exude should be stored below 25 ºC(the stable condition)If infiltration operations begins immediately after dryingit will inevitably raise the temperature of dip exude and causes impregnation liquid storage risksSo product temperature is required to lower to or close to room temperature before impregnation beginsThe process cools the products in the reversing mechanism by axial fansensures work-piece temperature closed to room temperature.
 
1.4.2 Flip-air-cooled Tank
 
a. Tank is made of 1.5 3mm thick stainless steel SUS304 material.
b. Flipping mechanism with automatic locking deviceis safereliable and easy to operate
c. Axial fans for hair flip work-piece uninterruptedly blowfast cool the product by air convection.
d. Pneumatic switch lidsis fast and stablewith low noise.
 
II.Vacuum Impregnation Plant
 
2.1 Production Programme20 minutes basket
2.2 Process Description:

Equipment is designed with dry vacuumwet vacuumpressurein which the negative pressure -0.098
-0.100Mpa   with integrated tank structure for infiltration and glue storage.
·Liquid removal and recovery is designed into 2 stepsthe first step is centrifugal liquid removal from the 4 surfacesthen the work basket auto-flip 90 °the second step is centrifugal liquid removal from the upper and lower 2 surfacesso that it fully guaranteed blind holes on six machined surface of the work-piece were treated with liquid removal processIt has 2 benefits1Glue consumption dropped2It is conducive to the subsequent cleaningto ensure that no adhesive residue on the blind holes after curing .
 
It washes the work-piece by two-stage flipping and counter-currentinsure the blind hole 100unblocked by glue.
The curing tank has a rotary system to reduce a lot of steam into the workshop when the lid opens;
Vacuum drying design fast dry the water on the surface under low consumption improve the drying effectSo that it can fully meet quickly and thoroughly drying process requirements (no more than 10min).
 
2.Production Process
 
 
 
 
 

 
2.4 Equipment Specifications
 
Infiltration line is including the following devices:
Vacuum impregnation tankInner Diameterφ1200 (including automatic lifting device(≤28 ºC)
Rotary glue rejection(removaldevice and glue recovery tank:
Flipping counter-current spray and rinsing tank I
Flipping counter-current spray and rinsing tank II
Flipping spray hot water curing tank (90 93 ºC)
Vacuum drying tank
 
Vacuum Impregnation -Liquid Flipping Off -Back Washing I -Back Washing II -Hot Water Curing -Vacuum Drying
 
2.5 Vacuum Impregnation Tank
 
Tank inner diameterφ1200
Process requirements1Dry vacuumed to 1KPa 1.6KPakeeping pressure 3~5 minutes.
2Humidly vacuumed to 1KPa 1.6KPakeeping pressure 3~5 minutes.
3Keeping pressure 3~5 minutes
Impregnation tank is made of high quality SUS304 stainless steel plate6mm thickness and 1.5 mmThe flange is made of machined whole forgings and safereliablebeautifulFast pneumatic switch lidsThe degree of vacuum is no less than 0.098Mpaenables the vacuum,pressuring and pressure holding keeping ≥24 hoursLiquid inlet and outlet pipingpumping and draining vacuum pipe line fitted with high-quality SUS304 stainless steel pneumatic valvefast and reliableThe lid is quipped with observation sight glass and lightsit is also equipped with digital vacuum pressure sensor and pressure gaugeTo prevent impregnation liquid flowing into the vacuum pump when pumping vacuumit is equipped with an isolation tankthe gas discharge nozzle are installed mufflerThis system uses the principle of vacuum pressure infiltrationto fill the pores of the work-piece with sealantThe system includes impregnation tank automatic lifting systemsvacuum pumps and chillers.
 
The following are its unique features:
?The top cover is equipped with observation windows to monitor the situation inside impregnation cylinder.
Two absolute vacuum gauges with different ranges mounted in striking position adjacent the impregnation cylinderso that the operator can monitor vacuum conditions inside the impregnation cylinder .
Programs include dry vacuum impregnationwet vacuum into the state.


 The chiller of impregnation cylinder keeps the sealant at temperatures below 0 28 ºCwith adjustable temperature settings.
The temperature control device sirens when the sealant temperature is higher than the preset temperatureand equipped with a temperature
display allows the operator to monitor the temperature of the sealant.
It has degassing function to best cures the sealant.
The insulation thickness is 40mmand makes the cylinder cooling system for maximum effectiveness.
 
 FeedingDry Vacuum PumpingWet Vacuum Pumping Impregnation Discharge
 
2.6 Flip rotary glue rejection and recovery tank
 
Process requirements
1Forward and reverse rotary time 5 7min each2Forward and reverse rotary speed 0~100r/min adjustable
The glue rejection and recovery tank is made of SUS304 stainless steel no less than 3mm thicknesswith quick pneumatic switch to open and close lidsAfter the impregnation process is completedmost of the sealant adhesion can not be discharged but adhere in the complex shape of the work-pieceSo put the work-piece into the recovery tank after impregnation make six surfaces of the work-piece subjected to centrifugal force with the centrifuge rotor system(while flip 90 °)It solves the problems scrapped parts caused by work-piece hole plugging gumPut the work-piece basket in the rotating jig to rotate inside the tankthe inverter controls forward reverse rotary and their speed within a speed range of 0 100r/min adjustableForward and reverse rotary time is adjustable and controllableso that the excess sealant adhesion of the surface can be dischargedsealant in the recovery tank will be automatically transferred back to the impregnation tank for recycling use.

Feeding -High Speed Centrifuge Liquid Rejection -- Flip 90Centrifuge -Discharge
 
2.7 2.8 Flipping counter-current spray and rinsing tank (combo)
 
Process requirementsForward and reverse rotary time 5 8min each
Cold water tank is made of SUS304 stainless steel no less than 3mm thicknessequipped with two floors water storage tanksequipped with convenient removable filter mesh at the nozzlewith quick pneumatic switch to open and close lidsAfter the recovery process is completedplace the work-piece into a cold water tank to clean sealant adhesion from its surfacewith rotary systems and spraying tap designspray on the rotary work-piece with a lot of waterto maximally ensure the cleanliness of the work-pieceIt is different from traditional way of directly soaking the work-piece in the water to cleanbecause two-stage flip spray cleaning can spray cleans the six surfaces of the work-piece effectThe work-piece is spray cleaned by circulating water while rotating in the cleaning tankcompletely solve the plugging gum problems in work-piece threaded holes and blind holesIt has particularly prominent cleaning effect on work-pieces in complex shapes or varsitiesIt maximally avoids possible contaminants adhering to the surface of the work-pieceparticularly in the threaded holesthe contaminants may pollute or clogging the work-piece after curing.
    Feeding Washing IWashing IIDischarge
 
2.9 Hot water curing tank
 
Process requirements1Curing time15min
2Curing temperature90 93 ºC
Hot water curing tank is made of SUS304 stainless steel no less than 3mm thicknessequipped with two floors insulated water storage tanks,the insulation layer is made of SUS304 stainless steel no less than 1.5 mm thicknessequipped with convenient removable filter mesh at the nozzlewith quick pneumatic switch to open and close lidsHot water temperature is adjustable with 0~99ºCAfter the cleaning process is completedplace the work-piece into a hot water curing tank to cure the sealantthen fast and effectively dry its surfacethreaded holes and blind holes with rotary system
  FeedingHot Water Curing Discharge
 
2.10 Vacuum drying tank
Drying tank is made of high quality SUS304 stainless steel plate6mm thickness The flange is made of machined whole forgings and safereliablebeautifulFast pneumatic switch lidsVacuum is 0.093Mpa to 0.098Mpavacuum holding ≥24 hoursPumping and draining vacuum pipe line fitted with high-quality SUS304 stainless steel pneumatic ball valvefast and reliableThe tank body is quipped vacuum pressure sensor and pressure gaugeTo prevent impregnation liquid flowing into the vacuum pump when pumping vacuumit is equipped with an isolation tankthe gas discharge nozzle are installed muffler   FeedingVacuum DryingDischarge
 
2.11 Material baskets Cages (10pcs)
 
The operator places the work-piece in the material basketsbaskets are transported by crane to each tank for reprocessing.
Material baskets are made of SUS304 750mm 750mm 900mm
To avoid collision between the work-piece and material basket while the material basket is movingdryingpouring the liquid between the work-piece and the work-piecethey are apart with PP screen.
Since the total weight of the work-piece and the basket up to 200 400Kgto reduce labor intensity in the production linewe design movable carriage for the production line and discharge step. 


 
2.12Isolation tank
 
It is equipped with drying filterpressure relief valveand large diameter outletThe relief valve closes automatically when the vacuum pump startsthe relief valve automatically opens when the vacuum pump stopsIt promptly discharges water and impuritiesavoiding them flow into the vacuum pumpeffectively prevent impregnation liquid into the vacuum pump ensure the vacuum pump to reach its optimum working conditionextend its life span.
  
 
2.13Vacuum pump
 
Specific parameters:
  
 
2.14Working platform
 
The platform is designed for keeping employees safeit has a working channel and safety barriers to meet the safety requirements.
(2It is made of carbon steel checkered platformthe platform bracket is made of No.6-10 Channel Steel.
(3Platform color is coated according to customer requirements.
 
Specific parameters:
Platform deck material safety barriers set 1
1 set of escalators
Q235 checkered jacket platform 1
Hoardings set 1
  
2.15Lifting device
 
Electric lifting hoist is Zhejiang Kaidao brandTrack bearing load ≥1T.
The top crane is made of 140MM round tubewith oblique support ribs to ensure running stability.
It is compactsmall and light.
It runs in linear single-trackit has reasonable structuresmooth operation and low noise.
The support is stable and safe.
It has motor drive and smooth operation.
 
Specific parameters:
  
2.16 Electrical Control System
 
The system has programmable PLC controller to control the entire infiltration process the process parameters can be set on the display screen by entering the relevant valuesDisplay screens show the operating status of each unitthe related parameters and fault alarm in real time.
The operator control panel is set on the aisleto facilitate operator control each tankThe operation of each unit is divided into automatic mode and manual modeDigital meter can display temperature heating and coolingand set various parameters.