PAINTING COMPLEX FOR GENERAL ELECTRIC DIESEL LOCOMOTIVES AT KRYUKOVSKY RAILWAY CAR BUILDING PLANT
February 23 announced the signing of a framework agreement between JSC “Ukrzaliznytsia” and American Corporation General Electric for the purchase and modernization of 225 locomotives until 2034. General Electric will supply Ukrzaliznytsia with 5th generation Evolution TE33A series freight diesel locomotives with an asynchronous traction drive. This is the most modern platform for GE lineup.
In April 2018, we were approached by representatives of the Kryukovsky railway car building plant with a request for the production of a painting complex for diesel locomotives, which, as part of an agreement with GE, will be assembled at the Kryukovsky railway car building plant production facilities. After conducting a detailed analysis of the technical specifications, we developed a concept for the future painting complex, which included: a degreasing chamber, a preparation chamber, a painting and drying chamber. All three cameras are combined into one complex and have common walls with a hinged gate so that the product does not leave the limits of the zone of the complex during various stages of processing. The paint complex is located on a flat concrete site, and the preparation chamber and the drying chamber are designed for installation without filling the foundation, with ejection of the exhaust air side by means of ventilation channels, and the painting chamber, in addition to the side ventilation ducts, has underground ones, which made it possible to improve aerodynamic performance in the working area. The use of the combined method of exhaust air removal allowed to do without labor-intensive preparatory construction work on the arrangement of underground ventilation ducts and significantly reduced the duration of the project as a whole.
The training chamber has a working area of 6’880×6’700×4’000mm. The thermo-ventilation group is represented by one supply and exhaust thermo-ventilation cabinet and a set of bypass air channels. The thermal ventilation cabinet has two centrifugal ventilation units, each with a productivity of up to 30,000 m3 / h, one works to supply air to the chamber, and the other to outward air. The chamber has one own entrance gate, as well as one gate to go to the painting chamber.
The paint coating chamber has a working area of 12’920×6’700×4’000mm. The thermal ventilation group consists of four thermal ventilation cabinets and a set of bypass air ducts. A total of 8 highly productive centrifugal ventilation units with a productivity of up to 30,000 m3 / h each are involved in the thermal ventilation group, which ensures a constant and uniform air flow inside the chamber, with a speed of at least 0.3 m / s. The chamber has one own entrance gate and two gates that connect it to the preparation and drying chambers.
The drying chamber has a working area of 9’880×6’700×2’700mm. The thermal ventilation group includes one supply and exhaust thermal ventilation cabinet with one centrifugal ventilation unit, which circulates the air flows in the chamber, with partial air renewal, within 10-15%, which prevents the formation of an explosive atmosphere inside the chamber, with minimal loss of warm air. The drying chamber, like the preparation chamber, has one gate of its own and one gate connecting it to the painting chamber.
The thermal ventilation group of the entire painting complex for diesel locomotives uses gas burners and stainless steel heat exchangers to heat the air, in total 6 burners are used in the complex, manufactured by CIB Unigas, Italy, with a capacity of up to 300 kW. All thermal ventilation cabinets are located outside the premises, at a distance of 2.5 meters from the cabin of the complex.
MOBILE PAINTING AND DRYING CHAMBER – «VERTYKAL» SCIENTIFIC AND PRODUCTION ASSOCIATION
To improve the quality of painting and reduce the timing of finished products, «VERTYKAL» scientific and production association and the «TWEKO» plant developed and manufactured a mobile spray booth for painting complex large-sized metal structures with the proper quality of paintwork.
The peculiarity of the project on creation of the camera in this series has become a transforming working area – chamber cabin. The supply and exhaust thermo-ventilation group is mounted permanently on the foundation, and the chamber cabin is in the folded position (when it is not necessary) and moves apart after the product has been placed for applying the paintwork.
Difficulties for the realization of the project implementation has added two camera modes – «painting» and «drying». As an enclosing structure applied flame retardant fabric with a silicone coating that resists high thermal and mechanical loads.
The sliding cabin of the chamber when folded occupies 1850 mm in length, while in the unfolded state the working area is 15180 x 5000 x 5000 mm. The appearance of the transformed painting and drying chamber for the enterprise has reduced the time available for painting works – from 2 – 3 days (each layer paint had to dry naturally) to 1-night shift (up to 8 hours).
PAINTING CHAMBER FOR CARS – MPM MOTORS COMPANY
In 2016, representatives of the MPM Motors company, which are engaged in the production of sports cars in the suburbs of Paris, approached us with a request for the reconstruction of the existing painting area. Previously purchased and installed equipment from China suppliers did not meet the high requirements for the quality of the paintwork.
The first stage of the reconstruction was the modernization of the existing painting chamber. We supplied a set of equipment to improve ventilation and air filtration systems, a set of wall and ceiling lamps, as well as service doors. This set of equipment made it possible to create the necessary air exchange and ensure an acceptable air velocity in the working area, at the level of 0.2 m / s, and also significantly improve the quality of air purification in the chamber and lighting in the working area.
The second stage in the reconstruction of the painting area was the development, manufacture and supply of a new painting and drying chamber for automobiles. This chamber has an internal size of 9 x 6 x 4 meters, it is installed on the existing floor of the paint shop without foundation work using a metal podium, which allows you to remove the exhaust air according to the scheme “top-to-bottom”. The whole-grating steel floor provides a straight-line and even distribution of air flows throughout the chamber, which allows to achieve the best quality paintwork on products.
The thermal ventilation group consists of two supply and exhaust thermal ventilation cabinets with electric heat exchangers. Four powerful centrifugal ventilation units, with a capacity of up to 30 thousand cubic meters per hour each, provide a constant and uniform air flow inside the chamber, with an air velocity of at least 0.3 m / s. Electric heat exchangers consume from 22 to 90 kW / h of electricity and heat the entire volume of supplied air to the required delta of 35 °C (“delta” is the difference in air temperature between the inlet to the heat exchanger and the exit to the working area), thus providing optimal conditions for application paints and varnishes at an external temperature of air to -15 °C.
The delivered set of work equipment allowed to increase the productivity of the painting area by more than three times and to ensure the proper quality of the paintwork for automobile production.
PAINTING CHAMBER FOR AGRICULTURAL MACHINERY — OLIS COMPANY
The painting chamber for agricultural machinery was manufactured on the order of «Olis» LLC, the largest producer of agricultural machinery, production facilities of which are located in Odessa.
The camera is equipped with a two-level exhaust air filtration system, the first level is cardboard labyrinth filters with high cumulative ability, which trap most of the paint and varnish materials, the second level is fiberglass filters, filter class EU3. In this configuration, the storage capacity increases significantly, and the amount of paint and varnish particles in the discharged air is less by 35-40%, but the main advantage is that the service life of fiberglass filters is increased by 3 times, and the total cost of filter materials of emission is reduced by 30%.
A feature of this camera is the highway, which is integrated into the ceiling structure. A monorail is integrated into the center of the painting chamber in the ceiling, which allows you to suspend painted items in the cabin and freely rotate them around its axis. The maximum permissible load on the monorail is 1,000 kg, but at the buyer’s request the figure may be several times higher and the chamber may be parallel to up to 3 monorails.
The thermal ventilation group of the chamber consists of 2 supply and exhaust cabinets with a capacity of up to 56 m. cube/hour. Air heating is carried out using electric heat exchangers of our own design, the maximum power consumption of each of them reaches 84 kW / h, and in nominal mode, when the air temperature is about 0 ° C, the consumption will be ~ 45 kW / h.
PAINTING CHAMBER FOR CAR TRAWLS – PP «Trans Auto D»
The painting chamber for car trawls was developed and manufactured by us for the «Trans Auto D» company, which is involved in the transportation of oversized cargo in Ukraine and abroad, as well as the production of automobile trailers – trawls.
This painting chamber was built in the premises of the customer in such a way to maximize the usable space. The camera’s cabin has internal dimensions of 24’000×5’000×4’100 mm, it is made of sandwich panels with 80 mm thick mineral wool filler. The painting and drying chamber has 3 inlet-exhaust heat-expansion cabinets with powerful centrifugal ventilation units, with a total capacity of up to 100,000 m³/h.
Air heating in the cold season is carried out using electric heat exchangers of our own design. These heat exchangers consume a total of up to 270 kW / h in acceleration mode while giving a delta of ~ 35 ° C for all 100,000 m³/hour, which is 50-70% less than the closest analogues from competitors.
In addition to the standard equipment set consisting of two-row lighting, a three-level air filtration system, three-wing swing gates, automation and control systems, this chamber also has a central ventilated pit that allows the operator to paint trawls from the bottom without having to turn or lift the product.
PAINTING CHAMBER FOR ARMORED VEHICLES – REFORM COMPANY
The painting chamber for armored vehicles was created by order of Reform LLC, an enterprise engaged in the production of armored vehicles in the Kyiv region.
One of the main tasks of any enterprise in Ukraine that produces products, whether it is engineering or agricultural machinery, or any other products, is to give it a beautiful appearance, and it is possible only when you not only found a good artist and a painting area but also provide it high-quality abrasive blasting, painting and drying chambers, which are produced by our Joint Ukrainian-German company «Techservice VEKO».
An example of equipping the engineering enterprises of Ukraine with our equipment is the «Reform» enterprise. In 2016-2017, for «Reform», our company successfully developed, manufactured and commissioned a set of equipment for painting for heavy equipment. The painting chamber for armored vehicles has a twin-engine supply and exhaust ventilation circuit, effective air filtration. The ergonomic cabin, which is located inside the production hall, has a couple of service doors, double-row lighting creates illumination in the chamber at the level of 1000 lux. A thermo-ventilation cabinet with supply and exhaust ventilation is located on the street and is equipped with a diesel burner and an automatic fuel heating system developed by our specialists, which allows uninterrupted operation in the winter time.
MODERNIZATION OF THE PAINTING CHAMBER OF THE BELOTSERKOVMAZ COMPANY
The modernization of the painting chamber for the for agricultural machinery in order to equip the active floor begins with our designers calculating the size of the air ducts of the floor, or what depth to make a pit for a particular configuration of the painting chamber. Due to these calculations, a technical task is drawn up, which indicates what the exhaust channels should be, their shape and depth. We also calculate the cross-section of the air ducts. Sometimes the existing ducts before modernization are not enough for the productive work of the new active floor. Calculated power and performance exhaust hood, which is already available, namely whether it will cope with its new tasks.
Every floor modernization is made individually for the customer. We take into account all the nuances in the production of this type of exhaust hood, such as:
• The number, depth and location of the exhaust ducts (if large objects are placed in your painting chamber that are located in the center of the chamber, then a design with two exhaust ducts on the sides of the chamber is suitable for you, and if you have many parts located throughout the chamber, then you’ll need more a shallow pit which will work across the entire area of your active floor);
• The direction of the floor grates (the direction of the grates plays an important role, if trolleys or supports with small wheels are used in your painting chamber, they can get stuck in the grate, respectively, the direction of the grate should be perpendicular to the route of the trolley);
• Additional exhaust equipment or modernization of the existing one (in order for your active floor to work as expected, it will need an exhaust system that can extract paint particles and spray mist from a large surface of floor filters, it will also be necessary to overcome the resistance of these filters);
• Additional supply equipment or modernization of the existing one (by making the active floor of the painting chamber we also take into account the fact that the extraction of your chamber becomes more and more productive, and at the same time it is not possible to leave the dispensing equipment the same, because the pressure in your chamber will be insufficient. In order to stabilize the pressure and improve the frequency of air exchange, we replace the intake fan and, if necessary, the inlet cabinet engine).
• The active paint floor allows you to remove fog from paint materials such as paint, primer, varnish, etc. The main objective of this design is not to allow the fog to rise up to the respiratory tract of the painter, but to be immediately absorbed into the active floor. This allows you to make the paint coating better and cleaner. Working conditions of the painter become safer and this allows him to work much more efficiently.
With the modernization of the floor of your paint chamber, you get an extraction hood which will provide you with safe working conditions and better work quality.
The active paint floor can be used as a hood for the painting chamber in your garage. You get a hood that will not be inferior to a professional hood in the spray booth for a small cost. To do this, just need to calculate the fresh air plenum that will deliver air in a painting chamber in your garage and air changes in the chamber, which you would like to have.
PAINTING COMPLEX OF «TWEKO» PRODUCTION FOR «POLYMER» COMPANY
The painting complex consists of a painting chamber with dry filtration 5x4x4.4 m, a drying chamber measuring 6x4x4.4 m and one adjacent door, air heating – electricity. The thermal ventilation group is located on a special platform, above the cameras to save space. This painting complex is designed for painting furniture products.
COMPLEX OF EQUIPMENT FOR PAINTING
In 2015, we received a request for the development of a complex of equipment for painting and shot blasting cleaning of large-sized metal products. The complex should provide a full cycle of work on preparing products for painting – cleaning from scale, rust and other contaminants, followed by applying and drying the paintwork. We proposed to equip the painting area with an abrasive blasting chamber with systems for automatic collection, regeneration of shots and dust removals such as a filtering and ventilation unit.
In the process of manufacturing, the technical task for the complex of equipment for painting was also supplemented by the need to move products between the chambers, as well as to lift the products in the chambers for painting the bottom. To meet this request, we have developed and manufactured self-propelled rail trolleys with a built-in hydraulic lift. Rail trolleys have an overall size of 6×2 m and allow you to move products weighing up to 10 tons between the painting, drying and shot blasting chambers. As trolleys are used in the painting area they are explosion-proof and are driven by a low-voltage gear motor powered by built-in rechargeable batteries. Two out of five bogies have hydraulic lifts built-in, which allow you to lift the product to a height of 2 meters so that the operator can paint the bottom of the products.
The abrasive blasting chamber has internal dimensions of 12.5x6x5 m, the cabin is made of a steel framework with galvanized steel panels, on the inner side is coated with a protective rubber sheet which prevents the ricochet of the shot in the operator during cleaning, and the deformation of the chamber. The fraction collection system is implemented as an automatic scraper floor, which collects the fraction over the entire area of the chamber and supplies it to the fraction regeneration system. The regeneration system first raises the shot with the bucket elevator to a height of up to 6 meters, and then purifies it from large particles and dust which are not suitable for further use, and then supplies the purified shot to the bunker storage device which is connected to the shot blasting machine. The enclosure is thus provided with a closed fraction cycle, thereby significantly increasing the blast cleaning efficiency.
The painting chamber has internal dimensions of 12x6x5 m, and the drying chamber of – 10х4х4.3 m, which makes it possible to apply high-quality paint coating to the products and to dry them effectively, with minimal energy input. The drying chamber has two thermal ventilation cabinets with high-efficiency ventilation units, productivity up to 25,000 m³ each, air heating is carried out with the aid of electric heat exchangers, the total power consumed is 45-135 kW/h. The painting chamber has two inlet thermal ventilation cabinets and one dual exhaust ventilation cabinet, which provide an air flow of 70,000 m³ / h. Air heating is performed using two electric heat exchangers, the total energy consumption is 60-180 kW/h. Both chambers are equipped with multi-level filtration air treatment systems (cleaning class EU5), which, together with the supply and heating systems, provide intensive and uniform blowing of products, with clean, heated air to a predetermined temperature, which creates an optimal microclimate for applying and drying paintwork coverings inside the chambers.
BOSH SERVICE – PAINTING AND DRYING CHAMBER FOR TRUCK CARS
Freestanding painting and drying chamber for trucks and vans designed and manufactured by us for Bosch service in the city of Bila Tserkva, the Kyiv region.
Since the chamber is located in the open air, outdoors, the sandwich panels of the chamber cabin and thermal ventilation group have improved thermal insulation, their thickness is 100 mm, as well as additional hydraulic protection and improved sealing of all camera components. The internal size of the camera is 8100x4500x3500, which allows you to paint both cars and vans. The ceiling plenum has a size of 8000x4000x500, the area of the ceiling filter material is 32 m². The lighting in the chamber is two-level, consists of two upper rows located at an angle of 45º to the ceiling, and two side rows of sealed fluorescent lamps.
The thermal ventilation group of the painting and drying chamber will consist of one, combined – supply and exhaust, thermal ventilation cabinet (TVC). TVC will be located at the back of the chamber cabin. The air handling unit capacity will be 26,000 m3/h, an electric motor with a capacity of 15 kW at 1,500 rpm. TVС provides an air exchange rate of at least 200 times/hour in the painting mode and at least 50 times/hour in the drying mode, which ensures uniform blowing and quick drying of the painted product, as well as acceptable conditions for the operator to work during painting (comply with EU labor protection standards). TVС has three gate devices: a supply, discharge and recirculation gate, which direct air flows in accordance with the selected chamber operation mode. The thermal ventilation cabinet uses a heat exchanger made of heat-resistant steel with a diesel burner with thermal power of 300 kW as a heat-generating installation.
The control panel (СР) with automation and control systems sets the modes and algorithms of the equipment: painting-blowing-drying. Management of all chamber nodes is carried out using one central CP, it controls and coordinates the operation of all camera nodes for trucks.