車間整體除塵設備：車間焊接煙塵的集中式除塵系統
車間整體除塵設備的集中式除塵系統是一種通過統一收集、集中處理多工位煙塵的高效環保方案，尤其適用于焊接工位分散、煙塵產生量大或需統一管理的規模化車間。其核心是通過吸塵罩－管道網絡－除塵設備－風機的閉環系統，實現煙塵的高效捕捉、凈化和達標排放。
The centralized dust removal system of the overall dust removal equipment in the workshop is an efficient and environmentally friendly solution that collects and processes smoke and dust from multiple workstations in a unified manner, especially suitable for large-scale workshops with dispersed welding workstations, large smoke and dust generation, or requiring unified management. Its core is to achieve efficient capture, purification, and standard emission of smoke and dust through a closed-loop system of vacuum hood pipeline network dust removal equipment fan.
一、集中式除塵系統的核心設計邏輯集中式除塵的核心理念是“源頭捕捉+集中處理+資源優化”，通過以下步驟實現：
1、 The core design logic of centralized dust removal system The core concept of centralized dust removal is "source capture+centralized processing+resource optimization", achieved through the following steps:
源頭捕捉：在每個焊接工位或區域設置吸塵罩，主動捕獲焊接過程中產生的煙塵（包括金屬氧化物、助焊劑揮發物等）。
Source capture: Install vacuum hoods at each welding station or area to actively capture the smoke and dust (including metal oxides, flux volatiles, etc.) generated during the welding process.
管道傳輸：通過密閉管道將各工位的煙塵匯總至中央除塵器，管道設計需平衡風量分配，確保各工位收集效率。
Pipeline transmission: The smoke and dust from each workstation are collected by a closed pipeline to the central dust collector. The pipeline design needs to balance the distribution of air volume to ensure the collection efficiency of each workstation.
集中凈化：利用除塵器（如袋式、濾筒式）過濾煙塵中的顆粒物，凈化后的氣體達標排放。
Centralized purification: using dust collectors (such as bag and filter cartridges) to filter particulate matter in smoke and dust, and the purified gas is discharged in compliance with standards.
資源優化：通過自動化控制（如變頻調速、風量調節）降低能耗，部分系統可回收煙塵中的有價值物質（如貴金屬粉塵）。
Resource optimization: Reduce energy consumption through automated control (such as variable frequency speed regulation and air volume adjustment), and some systems can recover valuable substances (such as precious metal dust) from smoke and dust.
二、關鍵環節的環保實現機制
2. Environmental protection implementation mechanism for key links
1.吸塵罩設計：源頭控制的關鍵類型選擇：根據焊接方式（手工焊、機器人焊、激光焊等）和工位布局，選擇固定式、移動式或柔性吸塵罩。例如：手工焊工位：移動式吸塵罩（帶萬向臂）可靈活調整捕捉角度，覆蓋焊槍周圍1～2米范圍。機器人焊工位：固定式吸塵罩（包圍焊接區域）配合封閉式艙體，減少煙塵擴散。捕捉效率：吸塵罩需形成負壓區，確保煙塵產生后立即被吸入管道。設計時需滿足“三面圍擋+一面吸風”原則，吸塵口風速建議≥1.5m/s（手工焊）或≥2.0m/s（機器人焊）。
1. Vacuum hood design: the key to source control Type selection: Based on the welding method (manual welding, robot welding, laser welding, etc.) and workstation layout, choose fixed, mobile, or flexible vacuum cleaners. For example: Manual welding position: Mobile vacuum hood (with universal arm) can flexibly adjust the capture angle, covering a range of 1-2 meters around the welding gun. Robot welding position: Fixed vacuum hood (surrounding welding area) combined with enclosed cabin to reduce smoke and dust diffusion. Capture efficiency: The vacuum hood needs to form a negative pressure zone to ensure that smoke and dust are immediately sucked into the pipeline after production. When designing, it is necessary to meet the principle of "three sided enclosure+one side suction", and the recommended air speed for the suction port is ≥ 1.5m/s (manual welding) or ≥ 2.0m/s (robot welding).
2.管道系統設計：平衡風量與阻力管道布局：采用“樹枝狀”或“環狀”布局，主管道直徑需根據總風量計算（通常流速15~20m/s），分支管道逐步縮小，確保各工位風量均衡。阻力控制：管道轉彎處需加導流片，減少局部阻力；管道坡度≥2%以利冷凝水排放（尤其處理高溫煙塵時）；總阻力（管道+除塵器+風機）需控制在風機額定風壓范圍內（通常≤3000Pa）。防爆設計：若處理鋁鎂合金等可燃性粉塵，管道需采用防靜電材料（如不銹鋼），法蘭連接處跨接導線，并設置泄爆口（泄爆面積≥管道截面積的1/3）。
2. Pipeline system design: Balancing air volume and resistance Pipeline layout: Adopting a "tree branch" or "ring" layout, the diameter of the main pipeline needs to be calculated based on the total air volume (usually flow rate of 15-20 m/s), and the branch pipelines gradually decrease to ensure balanced air volume at each workstation. Resistance control: Flow deflectors need to be added at the turning point of the pipeline to reduce local resistance; Pipeline slope ≥ 2% to facilitate condensate discharge (especially when dealing with high-temperature smoke and dust); The total resistance (pipeline+dust collector+fan) needs to be controlled within the rated wind pressure range of the fan (usually ≤ 3000Pa). Explosion proof design: If dealing with combustible dust such as aluminum magnesium alloy, anti-static materials (such as stainless steel) should be used for the pipeline, wires should be bridged at the flange connection, and a venting port should be set up (venting area ≥ 1/3 of the pipeline cross-sectional area).
3.除塵器選型：高效凈化的核心袋式除塵器：原理：含塵氣體通過濾袋（材質為滌綸、芳綸或PTFE覆膜），顆粒物被攔截在濾袋表面，凈化氣體排出。優勢：處理風量大（可達10m/h以上），過濾效率高（對0.5μm以上顆粒物效率≥99%），適合中低濃度煙塵（通常≤500mg/m）。注意事項：需定期清灰（脈沖噴吹或機械振打），濾袋壽命2～3年；處理高溫煙塵（如不銹鋼焊接）時需預冷卻（<120℃）。濾筒除塵器：原理：采用褶皺式濾筒（材質為聚酯纖維+PTFE膜），表面積是同體積濾袋的3~5倍，過濾效率更高（對0.3μm顆粒物效率≥99.5%）。優勢：體積小（僅為袋式的1/3~1/2），清灰效率高（脈沖噴吹），適合空間有限的車間。注意事項：濾筒成本較高，需定期更換（壽命1～2年）；處理高濃度煙塵時需前置預處理器（如旋風除塵器）。
3. Selection of dust collector: the core of efficient purification Bag filter: Principle: Dust containing gas passes through a filter bag (made of polyester, aramid, or PTFE film), and particulate matter is intercepted on the surface of the filter bag, purifying the gas and discharging it. Advantages: High air volume processing (up to 10 μ m/h or more), high filtration efficiency (≥ 99% efficiency for particles larger than 0.5 μ m), suitable for medium and low concentration smoke and dust (usually ≤ 500mg/m) ）What. Attention: Regular dust cleaning (pulse blowing or mechanical vibration) is required, and the lifespan of the filter bag is 2-3 years; Pre cooling (<120 ℃) is required when dealing with high-temperature smoke and dust (such as stainless steel welding). Filter cartridge dust collector: Principle: Adopting a pleated filter cartridge (made of polyester fiber+PTFE membrane), the surface area is 3-5 times that of the same volume filter bag, and the filtration efficiency is higher (with an efficiency of ≥ 99.5% for 0.3 μ m particles). Advantages: Small size (only 1/3~1/2 of bag type), high dust cleaning efficiency (pulse blowing), suitable for workshops with limited space. Attention: The cost of the filter cartridge is relatively high and needs to be replaced regularly (with a lifespan of 1-2 years); A pre-processing unit (such as a cyclone dust collector) is required when dealing with high concentration smoke and dust.
4.風機與控制系統：節能與穩定運行的保障風機選型：根據系統總風量（Q）和總阻力（H）選擇離心式風機，需留10%～20%的余量（Q余量=1.1Q，H余量=1.2H）。例如：總風量50000m/h，總阻力2500Pa，可選風機參數為Q=55000m/h，H=3000Pa。變頻控制：通過PLC或DCS系統，根據焊接工位的開啟數量（如通過傳感器檢測工位電流或煙塵濃度）自動調節風機轉速，實現“按需供風”，降低能耗30%～50%。實時監測：安裝壓差傳感器（監測濾袋/濾筒阻力）、溫度傳感器（監測煙塵溫度）和顆粒物濃度傳感器（監測排放濃度），數據接入中控系統，異常時報警并聯動停機。
4. Fan and control system: guarantee of energy saving and stable operation Fan selection: Select a centrifugal fan based on the total air volume (Q) and total resistance (H) of the system, leaving a margin of 10% to 20% (Q margin=1.1Q, H margin=1.2H). For example, the total air volume is 50000m/h, the total resistance is 2500Pa, and the optional fan parameters are Q=5000m /h，H=3000Pa。 Variable frequency control: Through PLC or DCS system, the fan speed is automatically adjusted according to the number of welding stations opened (such as detecting station current or smoke concentration through sensors), achieving "on-demand air supply" and reducing energy consumption by 30% to 50%. Real time monitoring: Install differential pressure sensors (to monitor the resistance of filter bags/cartridges), temperature sensors (to monitor the temperature of smoke and dust), and particulate matter concentration sensors (to monitor the emission concentration). The data is connected to the central control system, and an alarm is triggered and the machine is shut down in case of abnormalities.
5.排放與安全：合規與風險防控排放達標：處理后的氣體需符合《大氣污染物綜合排放標準》（GB16297-1996）或地方更嚴標準（如京津冀地區顆粒物限值≤10mg/m）。可通過增加二級過濾（如活性炭吸附）進一步降低有害氣體（如臭氧、氮氧化物）濃度。
5. Emissions and Safety: Compliance and Risk Prevention Emission compliance: The treated gas must comply with the Comprehensive Emission Standards for Air Pollutants (GB16297-1996) or stricter local standards (such as the particulate matter limit of ≤ 10mg/m in the Beijing Tianjin Hebei region) ）. The concentration of harmful gases such as ozone and nitrogen oxides can be further reduced by adding secondary filtration (such as activated carbon adsorption).
防爆安全：針對可燃性粉塵（如鋁鎂合金），除塵器需采用防爆結構（如泄爆門、隔爆閥），風機需選用防爆電機，管道需設置靜電接地。灰渣處理：收集的煙塵（如鐵氧化物、鋁粉）需按《固體廢物污染環境防治法》分類處置，部分可回收利用（如鋁粉回爐重熔）。
Explosion proof safety: For combustible dust (such as aluminum magnesium alloy), the dust collector should adopt explosion-proof structure (such as explosion-proof door, explosion-proof valve), the fan should use explosion-proof motor, and the pipeline should be equipped with electrostatic grounding. Ash disposal: The collected smoke and dust (such as iron oxides and aluminum powder) need to be classified and disposed of according to the Solid Waste Pollution Prevention and Control Law, and some can be recycled (such as aluminum powder remelting).
總結車間焊接煙塵的集中式除塵系統通過科學設計吸塵罩、優化管道布局、選擇高效除塵器、配套智能控制，實現了煙塵的高效捕捉、凈化和資源化利用，既解決了焊接煙塵對環境和工人健康的危害，又通過節能降耗和資源回收創造了經濟價值，是規模化車間實現綠色生產的優選方案。
Summary The centralized dust removal system for welding fumes in the workshop achieves efficient capture, purification, and resource utilization of fumes through scientific design of dust hoods, optimization of pipeline layout, selection of high-efficiency dust collectors, and intelligent control. It not only solves the harm of welding fumes to the environment and workers' health, but also creates economic value through energy conservation, consumption reduction, and resource recovery. It is the preferred solution for achieving green production in large-scale workshops.
本文由 車間整體除塵設備 友情奉獻.更多有關的知識請點擊 http://www.9qmv.com/ 真誠的態度.為您提供為全面的服務.更多有關的知識我們將會陸續向大家奉獻.敬請期待.
This article is a friendly contribution from the overall dust removal equipment in the workshop For more related knowledge, please click http://www.9qmv.com/ Sincere attitude To provide you with comprehensive services We will gradually contribute more relevant knowledge to everyone Coming soon.
魯公網安備 37142502000144號