Automatic powder coating equipment is an automated mechanical device used to evenly spray powder coating on the surface of workpieces. It is widely used in industrial production, which can improve coating efficiency, ensure the stability of coating quality, and reduce errors and labor intensity caused by manual operation.
（1） Automatic spray gun system
Spray gun type
Electrostatic spray gun is one of the core components of automatic powder spraying equipment. It charges the powder coating through a high-voltage electrostatic generator, allowing it to better adhere to the grounded surface of the workpiece. For example, the built-in electrostatic spray gun sets the electrode inside the spray gun, which has a compact structure and is suitable for spraying operations in small spaces; The electrode of the external electrostatic spray gun is located outside the gun, and the electric field distribution is relatively more uniform, which can achieve finer spraying effects.
Motion control of spray gun
The spray gun in automatic powder spraying equipment is usually installed on a robotic arm or reciprocating machine. The robotic arm can precisely control the movement of the spray gun in three-dimensional space through pre programmed paths, and can flexibly adapt to various complex shaped workpieces. The reciprocating machine mainly controls the reciprocating motion of the spray gun in the linear direction, and is suitable for workpieces with relatively regular shapes and large flat areas, such as large metal sheets. By precise control of parameters such as spray gun movement speed and spraying angle, the uniform distribution of powder coating on the surface of the workpiece can be ensured.
（2） Powder supply system
Powder feeder
The function of the powder feeder is to stably deliver the powder coating to the spray gun. Common types include fluidized bed powder feeders and pressure type powder feeders. Fluidized bed powder feeder is a device that uses airflow to make powder in a fluidized state inside a container, and then uniformly transports the powder out. The pressure type powder feeder uses compressed air to extrude powder from a container, which can provide a relatively stable powder supply pressure and is suitable for large-scale continuous production.
Powder conveying pipeline
The powder conveying pipeline connects the powder supplier and the spray gun. The material of the pipeline is usually selected as anti-static material to prevent powder from being blocked or unevenly transported due to static electricity accumulation during transportation. The diameter and length of the pipeline should be designed reasonably based on factors such as the flow rate of powder and the number of spray guns. Generally speaking, a too small diameter of the pipeline can cause excessive resistance to powder transportation, while a too large diameter may cause powder deposition inside the pipeline.
（3） Powder recycling system
Recycling method
Automatic powder spraying equipment generally adopts a dry recovery system, such as cyclone separators and filter recovery devices. A cyclone separator utilizes the principle of centrifugal force to separate powder from air. When air containing powder enters the cyclone separator, the powder is thrown towards the wall by centrifugal force and then falls into the collection container by gravity. The filter cartridge recycling device filters air through a high-precision filter cartridge, trapping powder on the surface of the filter cartridge, and discharging clean air through the filter cartridge.
Recycling efficiency and powder reuse
An efficient powder recovery system can achieve a recovery efficiency of over 90%. After screening and removing impurities, the recycled powder can be mixed with new powder in a certain proportion for use. This can not only reduce production costs, but also minimize the impact on the environment. However, when mixing recycled powder, it is important to control the proportion of recycled powder, generally not exceeding 30% of the new powder, to avoid affecting the quality of the coating.
（4） Control system
Automation control software
The control system adopts advanced automation control software, which can be programmed to set the motion trajectory of the spray gun, spraying parameters (such as spraying voltage, current, powder spraying amount, etc.), powder supply speed, and the running time of the recycling system. Operators can intuitively set parameters and monitor on the touch screen. For example, when spraying automotive parts, the spray path of the spray gun can be pre designed in the control software based on the 3D model of the parts, ensuring that each part can receive a uniform coating.
Sensor monitoring
The automatic powder spraying equipment is equipped with various sensors, such as powder flow sensors, electrostatic voltage sensors, air pressure sensors, etc. The powder flow sensor can monitor the powder supply in real-time, and when there is an abnormality in the powder supply, the system can adjust it in a timely manner; The electrostatic voltage sensor is used to monitor the electrostatic voltage of the spray gun, ensuring that the powder can be effectively charged; The air pressure sensor monitors the pressure of the compressed air to ensure the spray effect of the spray gun and the normal powder delivery.
（1） Improve production efficiency
Continuous homework ability
Automatic powder spraying equipment can perform spraying operations without interruption, unlike manual spraying that requires rest and shift changes. It can work continuously and stably within 24 hours, greatly improving the continuity of production. For example, in the furniture manufacturing industry, for mass-produced components such as tables, chairs, legs, etc., automatic powder spraying equipment can quickly complete the spraying task, and the daily output can be several times higher than manual spraying.
High speed spraying performance
The spraying speed of automatic spray guns is much faster than that of manual spray guns. The automatic spray gun can move and spray on the surface of the workpiece at a speed of several meters per second according to preset parameters, and can ensure the uniformity of the coating. In contrast, manual spraying has a slower speed and is prone to uneven coating thickness.
（2） Improve coating quality
Good coating uniformity
Due to the precise control of the spray gun movement and powder conveying of the automatic powder spraying equipment, a very uniform coating can be formed on the surface of the workpiece. For example, when spraying electronic product casings, automatic powder spraying equipment can control the coating thickness error within a very small range, ensuring consistency and high quality of product appearance.
High quality stability
Automatic powder spraying equipment is not affected by factors such as artificial emotions and fatigue. As long as the equipment parameters are set correctly, the quality of each spray can be highly consistent. This is very important for industries that require strict quality control, such as automotive parts manufacturing, high-end home appliance manufacturing, etc.
（3） Reduce costs
Reduce labor costs
Automatic powder spraying equipment can reduce reliance on manual operation and lower labor costs. Although the investment and maintenance of the equipment itself require certain costs, in the long run, especially in large-scale production, its overall cost is reduced. For example, a large metal processing plant can reduce the number of coating workers by more than half after adopting automatic powder spraying equipment.
Save powder coating
The precise control of automatic powder spraying equipment can effectively reduce the waste of powder coatings. Through accurate powder supply and recycling systems, the utilization rate of powder can be increased to over 90%, significantly reducing costs compared to powder waste caused by improper operation in manual spraying.
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No.1 Fanchuan Science and Technology Park, Jiangdu District, Yangzhou City, Jiangsu Province, China
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