Oil mist and dust cleaning solution for flywheel processing workshop


Flywheel is an important part of the automobile engine, which plays a role in the storage of engine energy. With the development of the automotive industry, the use of flywheel is increasing. I'm sorry. I'm sorry.

During flywheel processing, a large amount of welding fume and processing oil mist is generated in the workshop, which endangers the health of the workers in the workshop. Therefore, cleaning oil mist and dust produced in flywheel processing workshop has become an urgent problem for managers.


Flywheel production line of a famous machine manufacturer

Location conditions

 

The flywheel is machined according to the principle of "rough machining first, then fine machining and primary machining first, then secondary machining". There are 18-welding robots and more than 200-machine tools in a company's workshop. The surface of gear and flywheel is covered with anti-rust oil, so a large amount of welding fume is produced during welding and machining, and a large amount of oil mist is produced during machining of gear and flywheel.

 

Welding fume cleaning

 

The surfaces of flywheel and gear are oily, so a large amount of oily welding fume is generated during welding. Welding fumes are usually cleaned by gas-solid separation. The methods of gas-solid separation mainly include mechanical sedimentation dedusting, wet dedusting, mechanical filtration dedusting and electrostatic adsorption dedusting. Mechanical sedimentation dedusting and wet dedusting can cause particles with particle size greater than 10um or more. 5um clean. Both mechanical filter dust removal and electrostatic adsorption dust removal can clean particles with particle size above 0.1um. The particle size of the welding fume is between 0.1um and 5um, so both the mechanical filter dust removal and the electrostatic adsorption dust removal can meet the cleaning requirements. The space in the workshop is small, and there is no installation space for the cleaner. It is necessary to build a steel structure platform above the logistics channel to install the cleaner on the platform. Since electrostatic adsorption dust requires cleaning of the electrostatic core every month and requires high maintenance, mechanical filter dust is chosen to clean the welding fumes.


Schematic representation of mechanical module products

 

In the workshop there are 18-welding machines for circumferential welding of gears and flywheels. The exhaust air quantity of each welding unit is calculated according to formula 3-1.

 

L=60Vn  Formel3-1 

 

L. Exhaust air volume, m3/h; V. Internal volume of production facilities; N number of air changes, times/min, the general production rhythm is less than 3min, n is taken as 10, 3-5min, n is taken as 8, 5-10min is taken as 6, and over 10min is taken as 5.

 

The cavity size of the welding unit is about 1.2m × 1.2m × 1.5m, with a volume of 2.16m3. The processing rhythm is less than 3min, and the air exchange rate is 10-times/min.

 

L=60×2.16×10=1296m3/h 

 

The total air volume of 18 automatic welding units is 23328m3/h. Select a SCF23000-D8 produced by Dalian Zhaohe Environmental Technology Co., Ltd × 2. Cartridge dust remover. The welding fume contains oil fume, and the direct contact of the oily welding fume with the filter cartridge will cause the filter cartridge to be blocked quickly, which is difficult to remove by pulse dust removal. Therefore, a pre spraying device is added in the dust removal system. The pre spraying device evenly sprays talcum powder on the surface of the filter cartridge to form a layer of powder. The oily smoke and dust adhere to the powder layer formed by talcum powder, which is easy to be removed by the pulse ash removal system, and can effectively extend the service life of the filter cartridge.

 

Oil mist treatment

 

Currently, centrifugal, mechanical filtering and electrostatic adsorption cleaners are generally used for oil mist processing.

The centrifugal oil mist cleaner mainly uses the principle of centrifugal impact to suck the oil mist particles into the collector and hit the inner wall of the shell by centrifugal rotation to form large oil droplets that flow down the inner wall to collection. Although the operating cost of this method is low, it is difficult to form large oil droplets hanging on the wall by centrifugal rotary impact because small oil mist particles are formed during the machining process. Therefore, the cleaning efficiency is low, and can only be used as a primary treatment device to pre-treat large oil droplets, protect the secondary oil removal device, and improve the cleaning efficiency.

The principle of the mechanical filter type oil mist cleaner is to let the oil mist pass through the filter medium under the pump of the fan, the oil drops are caught on the surface of the filter medium, and the purified clean air is discharged into the atmosphere. The use of filter materials to remove pollutants in the air has been used since the 19th century. After more than a hundred years of development, the technology is very mature. At present, the mechanical filter type oil mist cleaner is the most efficient and widely used oil removal device. With the continuous development of filter material production process, the cleaning efficiency has 99%.

High Voltage Electrostatic Oil Mist Cleaner applies the principles of mechanical filtration and electrostatic adsorption to clean oil mist gas. The collision between inertia and prefilter initially adsorbs and filters large oil droplets and some impurities. At the same time, the air flow enters the high-pressure ionization device more evenly through the function of the front filter screen. High pressure ionization device is divided into ionization wire and collecting plate. The oil mist passes through the high voltage ionization wire, and the voltage range of the ionization wire is from thousands of volts to ten kilovolts. The high voltage electric field generated by the ionization wire charges the oil mist particles around it. Under the action of tension, the collecting plate forms a corona between its plates. The charged oil mist particles are adsorbed on the collecting plate. Under the influence of gravity, they flow into the collecting device and are partially carbonized. The purified air is released into the atmosphere. More and more attention has been paid to the use of high voltage electrostatic treatment of oil mist, which has the advantages of relatively high cleaning efficiency, low operating costs and no loss of filter devices. However, it is strongly affected by the filter wind speed, and the cleaning efficiency is unstable.

There are more than 200 machine tools in the workshop. Due to the large number, the maintenance pressure of using electrostatic cleaners is high, so mechanical cleaners are used to treat oil mist. The exhaust air quantity of each machine tool is calculated according to formula 3-1. According to the calculation, the exhaust air volume of each machine tool is 1000-2000m3/h. Nine mechanical oil mist cleaners manufactured by Dalian Zhaohe Environmental Technology Co., Ltd. are used. The total air volume is 320000m3/h.

 

Cleaning effect

 

9-sets of particle concentration testers are installed in the workshop to detect indoor air quality. If the internal cleaner is not switched on, the internal particle concentration can reach 3-4 mg/m3. If the cleaner is opened for one hour, the internal concentration can be reduced to 0.2-0.3mg/m3. The indoor climate has improved significantly.


Application case of mechanical cleaner in flywheel workshop


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