粉末涂料应用过程中的注意事项.doc

粉末涂料应用过程中的注意事项在粉末涂料的应用过程中，只要注意对过程的跟踪和关注便可避免许多问题。但是，整个应用过程中的任何部分的不完善均能引起问题的复杂性。这些问题可能来自于前处理，粉末回收系统或任何公用设施，同时造成对本系统和其他系统带来负面影响，最终导致工件涂装的质量下降。 以下表格为粉末涂料应用中经常出现的一系列问题提供一些导致原因和解决方法。这些原因和解决方法分为以下六个部分：1. 供粉系统，粉管，粉泵，文丘里管2. 静电粉末涂装系统3. 回收、循环4. 底材和涂层的污染5. 粉末涂料固化6. 金属粉末涂料注意：除本说明书外，请仔细阅读设备、化学品粉末涂料供应商的使用说明书。In the process of powder coating application, pay attention to the process of tracking and concerns can avoid many problems. However,any part imperfections in the entire application process can cause complex problem . These problems may come from the pre-treatment, powder recovery system or any utilities,in the mean time ,it cause the negative impact of the system and other systems, which eventually led to the decline in the quality of the workpiece coating.The following sheet is a series of problem for powder coating applications and its solutions. These causes and solutions are divided into the following six parts: 1. Powder supply system, powder tube, powder pump, venturi tube.2. Electrostatic powder coating system. 3 Recovery cycle .4. Contamination of the substrate and coating 5. powder coating curing6. Metallic powder coating 7. Note: In addition to this manual, please read the manual of equipment, chemical powder coating from suppliers.表1：供粉系统，粉管，粉泵，文丘里管问题可能引起的原因解决方法粉桶内流化差 粉末太少 加入粉末至正常水平粉末比重过大或潮湿A人工将粉桶内粉末疏松B检查压缩空气质量流化板部分堵塞检查粉桶底部和流化板的阻塞物粉末粒径A降低回收粉量B检查新粉的粒径分布粉管，粉泵，文丘里管堵塞正常堆积清洗或更换零件空气压力过大降低粉泵和喷枪的空气压力空气受潮检查供气系统粉管材料选择不当更换粉管粉管过长改进构造，缩短粉管文丘里管或粉泵老化更换文丘里管或粉泵粉末过细A降低粉桶内回收粉量B检查新粉的粒径分布粉末从粉桶中溢出空气压力过大降低流化床的气压粉末过细A降低粉桶内回收粉量B检查新粉的粒径分布Sheet 1Powder supply system ,powder tube,powder pump ,venturi tubeProblemReason Solution Bad Fluidized property in powder barrel Too little powder Add more powder to reach the standard Powder proportion is too large or powder is moist ALoose the powder BCheck the air qualityFluidized board is blocked Check the block in the powder barrel Powder particle A Decrease the recycled powder B Check the particle size of new powder Powder tube ,powder pump ,venturi tube blocking accumulationClean or renew the parts Air pressure is too large Reduce the air pressure of powder pump and spray gun The air dampCheck the gas supply systemImproper material of powder tube Change the powder tube Powder tube is too longShorten the powder tube Venturi tube break down Change the venturi tube or powder pumpPowder particle is too smallA Reduce the recycled powder in the powder barrelB Check the new powder particle Powder spill from the powder barrel Too much air pressure Reduce the pressure of fluidized bed Powder particle is too smallAReduce the recycled powder BCheck the new powder particle 表-2：静电粉末涂装系统问题可能引起的原因解决方法工件涂膜太薄电压不正确检查电压，清理或更换喷枪接地不良清理接地装置和挂具挂具接地性不良清理挂具喷房中有潮气检查喷房的供气系统喷枪空气压力太大降低送粉空气压力喷枪位置不当重新布置喷枪位置挂具设计不当重新设计挂具，减少屏蔽送粉量过小设置正确的输送压力检查文丘里管尺寸、清洁程度及安装情况如何喷涂时间不足降低链速，增加喷涂时间增加静电电压，送粉气流，更换喷枪位置法拉第效应（屏蔽）调节电压，送粉气流，更换喷枪位置挂具表面积过大减小挂具的尺寸粉末受潮更换粉末，使用粉末以前要保持密封工件涂膜太厚粉末输送量过大降低喷枪的粉末流量 增加喷枪和工件之间的距离喷枪电压过高调整喷枪电压喷涂时间过长降低工件在喷枪前的时间 A 提高链速B 提高升降机的往返速度预热温度过高降低预热温度喷枪出粉不稳定压缩空气受潮A 检查空气干燥器 B 安装冷冻系统 C放尽管内的粉末压缩空气供应不稳定检查空压机是否过载粉末过细检察新粉和回收粉的比率，并做相应调整穿透性能差粉末输送量过小增加粉末流量接地不良检查接地情况，并做改善喷涂方式不正确更换不同的喷嘴电压过高降低电压，使近喷枪处工件表面不排斥粉末粉末输送速度不正确降低气量，使气流不会将粉末吹走。喷枪位置放置不当调整喷枪的位置，使粉末能直接进入凹槽粉末过细A 降低粉桶回收粉末的比率 B 检测未用粉末的粒度分布固化前涂层表面不均匀、残缺。粉末部分被电离A 降低电压B 检查接地点是否良好。C 降低粉末上粉率和膜厚D 确保系统的干燥。E 拉开喷枪与工件的距离F 检查喷枪中有无金属颗粒的堆积，有必要时，清理喷枪Sheet-2：Electrostatic powder coating systemProblem Reason Solution Coating film is too thin Improper voltage Check the voltage and clean or change the spray gun Poorly grounded Clean the grounded equipment and hangerPoorly grounded Clean the hangerHumidity in spray roomCheck the air supply system of the spray roomSpray gun air pressure is too largeReduce the air pressure Improper gun positionRe-arrange the gun position Improper design of hanger Re-design the hanger Too little powder supply Set up the proper deliver pressure check the venturi tube s size ,cleanliness,installation .Time of spraying is not enough Add time of spray increase the voltage,change the gun position Faraday effect Adjust the voltage ,change the gun position Spraying area is too large Reduce the hanger area Powder become dampChange new powder ,keep it sealed before using Coating film is too thick Powder supply is too largeReduce the powder amount in spray gun ,increase the distance between spray gun and workpieces Voltage is too high Adjust the voltage of spray gun Spraying time is too long Reduce the spraying time AImprove the speed of chain B Increase the round-trip speed of lifts Preheating temperature is too high Reduce the preheating temperature Unstable spraying powderThe compressed air become damp A Check the air dryer B Install the cooling system C.Remove all the powder from the tube Compressed air is unstableTo check the compressor if overload The powder particle is too small Check the rate of new powder and recycled powder ,and adjust corresponding Poor penetration performance Too little amount of powder delivery Add the amount of powder Poor grounded Check ground connection Improper ways of sprayingChange the new spray nozzleToo high voltage Lower the voltage Improper delivery speed Reduce the airflow Improper gun position Adjust the position of spray gun Powder particle is too smallA Reduce the proportion of recycled powder B Check the powder particle distribution The coating film is uneven before curing Some powder is ionized A Reduce the voltage B Check the ground connection C Reduce the coating filmD Ensure the system is dryE Increase the distance between spray gun and workpiecesF Check the spray gun if there is metallic particle ,clean the spray gun if necessary 表-3：回收粉末的回收和循环问题可能引起的原因解决方法粉房粉末外泄空气过滤器损坏或堵塞A 清理或更换滤袋B 检查反吹系统的清洁情况C 检查压缩空气质量由于主过滤器损坏，二级空气过滤器过载A检查、更换滤袋B清理或更换滤芯喷房开口过大缩小喷房开口喷枪位置不当重新布置喷枪粉末输送量过大减少喷枪数量工件表面受污染悬挂链或挂具上掉下的粉末或其它外来物经常清理悬挂链和挂具受回收粉污染，系统内筛子损坏更换筛网车间内的外来物污染喷房检查污染物，保持环境卫生压缩空气污染检查压缩空气质量循环回收粉末污染回收循环系统清理不够有效根据设备厂商的说明书彻底清理系统粉末回收效率低空气输送速度过低比较空气流量与标准的差别粉末过细检查粉末粒径分布，与粉末供应商联系Sheet-3：Powder of recovery and recycledProblem Reason solutionPowder escape from powder roomThe air filter was breakdown or it was blocked A Clean or change a new filter-bagB Check the blowback system and clean it C Check the quality of compressed air As the main filter was breakdown ,the secondary was overload ACheck and change new filter-bagBClean or change the filter cartridgeSpraying room opening too much Reduce the opening area Improper gun position Change the spray gun position Powder delivery amount is too large Reduce the quantity of spray gun The surface of workpiece was polluted Hanging chain or hanger have powder drop out Clean the hanging chain and hanger frequently Polluted by recovery powder ,the screen breakdown Change the screen The spray room was polluted Check the pollutant ,ensure the cleaning The compressed was polluted Check the quality of compressed air Recycled powder polluted Recovery system is not effective in cleaning Clean the system thoroughgoing according to the instruction book from supplier The powder recycling efficiency is lowAir delivery speed is too lowCompare the difference between air flow and standard Powder particle is too smallCheck the powder particle distribution ,and contact with the powder supplier 表-4：底材和粉末涂膜的污染问题可能引起的原因解决方法涂膜中的异物清洗效果不佳A 检查或调整流量、喷嘴位置和每段前处理的温度B 检查或调整化学品的规格C 清理喷枪，喷房和回收系统粉末过粗或未过筛过筛所有回收粉，检查筛网孔，检查或更换筛网目数粉末粒径不均匀与供应商联系化学交叉污染工件装载、放置不当A 检查、调整工件，争取最大的排放空间B 检查、调整工序，争取最长的排放时间颜色污染换色时，清理不当彻底清理整个工厂，喷枪和回收系统。而后重新装入新粉。制造时，交叉污染与粉末供应商联系表面针孔或缩孔硅污染找出硅污染，并清除污染源油污染检查脱脂装置供气系统有油/水检查供气系统的油水分理器Sheet -4：Contamination of substrate and powder coating filmProblem Reason Solution Other impurity on the film Not clean enough A Check or adjust the flow,检查或调整流量、喷嘴位置和每段前处理的温度B 检查或调整化学品的规格C 清理喷