在金屬加工領(lǐng)域，焊接作業(yè)產(chǎn)生的煙塵不僅影響車(chē)間環(huán)境，還會(huì)對(duì)操作人員的健康造成潛在威脅。多工位焊煙除塵設(shè)備作為應(yīng)對(duì)這類(lèi)問(wèn)題的關(guān)鍵設(shè)備，能同時(shí)處理多個(gè)焊接點(diǎn)位的煙塵污染，成為現(xiàn)代化工廠不可或缺的環(huán)保裝備。深入了解其工作原理、組件構(gòu)成及應(yīng)用要點(diǎn)，對(duì)提升除塵效率、保障生產(chǎn)安全具有重要意義。

　　In the field of metal processing, the smoke and dust generated by welding operations not only affect the workshop environment, but also pose a potential threat to the health of operators. Multi station welding smoke and dust removal equipment, as a key device to address such issues, can simultaneously handle smoke and dust pollution from multiple welding points, becoming an indispensable environmental protection equipment in modern factories. A deep understanding of its working principle, component composition, and application points is of great significance for improving dust removal efficiency and ensuring production safety.

　　設(shè)備工作原理與核心邏輯

　　Equipment working principle and core logic

　　多工位焊煙除塵設(shè)備的運(yùn)行基于負(fù)壓吸附與過(guò)濾分離的協(xié)同作用。設(shè)備啟動(dòng)后，主風(fēng)機(jī)產(chǎn)生的負(fù)壓通過(guò)分布在各焊接工位的吸氣臂或集氣罩形成氣流，將焊接過(guò)程中產(chǎn)生的煙塵、金屬顆粒等污染物吸入管道系統(tǒng)。這些含塵氣流首先進(jìn)入預(yù)處理裝置，通過(guò)重力沉降或慣性分離去除大顆粒雜質(zhì)，避免后續(xù)過(guò)濾組件被過(guò)快堵塞。

　　The operation of multi station welding smoke dust removal equipment is based on the synergistic effect of negative pressure adsorption and filtration separation. After the equipment is started, the negative pressure generated by the main fan forms an airflow through the suction arms or gas collection hoods distributed at each welding station, which sucks pollutants such as smoke and metal particles generated during the welding process into the pipeline system. These dusty airflows first enter the pretreatment device, where large particle impurities are removed through gravity settling or inertial separation to avoid rapid clogging of subsequent filtration components.

　　經(jīng)過(guò)預(yù)處理的氣流隨后進(jìn)入核心過(guò)濾單元，這里通常采用高效濾材制成的濾筒或?yàn)V袋。在過(guò)濾作用下，煙塵中的細(xì)微顆粒被截留附著在濾材表面，凈化后的潔凈空氣則通過(guò)風(fēng)機(jī)排出，部分設(shè)備還可將達(dá)標(biāo)空氣回送至車(chē)間，實(shí)現(xiàn)能源循環(huán)利用。為保證過(guò)濾效率的穩(wěn)定性，設(shè)備一般配備自動(dòng)清灰系統(tǒng)，通過(guò)脈沖噴吹、機(jī)械振動(dòng)等方式定期清除濾材表面的積塵，確保氣流阻力維持在合理范圍。

　　The preprocessed airflow then enters the core filtration unit, which typically uses filter cartridges or bags made of high-efficiency filter materials. Under the filtering effect, fine particles in the smoke and dust are trapped and attached to the surface of the filter material. The purified clean air is discharged through a fan, and some equipment can also send the standard air back to the workshop to achieve energy recycling. To ensure the stability of filtration efficiency, the equipment is generally equipped with an automatic dust cleaning system, which regularly removes the accumulated dust on the surface of the filter material through pulse blowing, mechanical vibration, and other methods to ensure that the airflow resistance is maintained within a reasonable range.

　　主要組件及功能特點(diǎn)

　　Main components and functional characteristics

　　吸氣裝置是設(shè)備與工位連接的關(guān)鍵部分，常見(jiàn)形式包括可伸縮吸氣臂、固定式集氣罩和柔性吸氣軟管?？缮炜s吸氣臂采用萬(wàn)向關(guān)節(jié)設(shè)計(jì)，能靈活調(diào)整吸氣口位置，貼近焊接點(diǎn)上方 15-30 厘米處，實(shí)現(xiàn)精準(zhǔn)捕集，特別適用于焊接位置不固定的工況；固定式集氣罩則適合流水線作業(yè)中的固定工位，通過(guò)合理設(shè)計(jì)罩口形狀與尺寸，可覆蓋較大范圍的煙塵擴(kuò)散區(qū)域。

　　The suction device is a key part connecting the equipment and the workstation, and common forms include retractable suction arms, fixed gas collection hoods, and flexible suction hoses. The retractable suction arm adopts a universal joint design, which can flexibly adjust the position of the suction port, close to 15-30 centimeters above the welding point, to achieve precise capture, especially suitable for working conditions where the welding position is not fixed; Fixed gas collection hood is suitable for fixed workstations in assembly line operations. By designing the hood mouth shape and size reasonably, it can cover a large range of smoke and dust diffusion areas.

　　管道系統(tǒng)承擔(dān)著氣流輸送的功能，其布局設(shè)計(jì)直接影響除塵效果。管道直徑需根據(jù)各工位的風(fēng)量需求計(jì)算確定，過(guò)大易導(dǎo)致流速不足、煙塵沉積，過(guò)小則會(huì)增加系統(tǒng)阻力。管道轉(zhuǎn)彎處通常采用大弧度彎頭，減少氣流擾動(dòng)和壓力損失，同時(shí)需在適當(dāng)位置設(shè)置檢修口，便于后期清理維護(hù)。

　　The pipeline system undertakes the function of airflow transportation, and its layout design directly affects the dust removal effect. The diameter of the pipeline needs to be calculated and determined based on the air flow requirements of each workstation. If it is too large, it can easily lead to insufficient flow velocity and smoke deposition, while if it is too small, it will increase system resistance. Large curvature elbows are usually used at pipeline bends to reduce airflow disturbance and pressure loss. At the same time, maintenance ports should be set up at appropriate locations for easy cleaning and maintenance in the later stage.

　　過(guò)濾單元的性能決定了最終的凈化效果，濾材選擇需結(jié)合焊接材料特性。針對(duì)碳鋼焊接產(chǎn)生的黑色煙塵，可選用聚酯纖維濾材；處理不銹鋼焊接時(shí)的金屬氧化物煙塵，建議采用抗靜電濾材，避免粉塵堆積引發(fā)安全隱患。濾筒或?yàn)V袋的使用壽命一般為 3000-5000 小時(shí)，具體需根據(jù)煙塵濃度和性質(zhì)定期更換。

　　The performance of the filtering unit determines the final purification effect, and the selection of filter materials should be combined with the characteristics of welding materials. Polyester fiber filter material can be selected for the black smoke generated during carbon steel welding; It is recommended to use anti-static filter materials to deal with metal oxide smoke and dust during stainless steel welding, in order to avoid safety hazards caused by dust accumulation. The service life of filter cartridges or filter bags is generally 3000-5000 hours, and they need to be replaced regularly according to the concentration and properties of smoke and dust.

　　風(fēng)機(jī)作為動(dòng)力源，其選型需匹配系統(tǒng)總阻力與所需風(fēng)量。多工位設(shè)備常采用離心式風(fēng)機(jī)，具有風(fēng)壓穩(wěn)定、適應(yīng)范圍廣的特點(diǎn)，安裝位置可分為內(nèi)置式和外置式，外置式風(fēng)機(jī)能減少設(shè)備內(nèi)部的粉塵污染，延長(zhǎng)使用壽命。

　　As a power source, the selection of a fan should match the total system resistance and the required air volume. Multi station equipment often uses centrifugal fans, which have the characteristics of stable air pressure and wide adaptability. The installation position can be divided into internal and external types. External fans can reduce dust pollution inside the equipment and extend its service life.

　　選型與安裝的關(guān)鍵要點(diǎn)

　　Key points of selection and installation

　　選型時(shí)需首先核算總風(fēng)量需求，單個(gè)焊接工位的風(fēng)量通常根據(jù)焊接電流確定：100-300A 的手工電弧焊需 800-1200m/h，300A 以上的埋弧焊則需 1500-2000m/h，總風(fēng)量為各工位風(fēng)量之和再附加 10%-15% 的余量。同時(shí)需考慮車(chē)間空間布局，若工位分散且距離較遠(yuǎn)，可采用分區(qū)式除塵系統(tǒng)，減少管道長(zhǎng)度和壓力損失。

　　When selecting, the total air volume requirement needs to be calculated first. The air volume of a single welding station is usually determined based on the welding current: manual arc welding with a current of 100-300A requires 800-1200m/h, while submerged arc welding with a current of over 300A requires 1500-2000m/h. The total air volume is the sum of the air volumes of each station, with an additional margin of 10% -15%. At the same time, the layout of the workshop space needs to be considered. If the workstations are scattered and far apart, a partitioned dust removal system can be used to reduce pipeline length and pressure loss.

　　安裝位置的選擇應(yīng)遵循 “就近處理、縮短管道” 的原則，主設(shè)備宜放置在車(chē)間外圍或?qū)Ｓ脵C(jī)房，避免占用生產(chǎn)空間。管道敷設(shè)需保持一定坡度，一般不小于 3°，防止粉塵在水平管道內(nèi)沉積；吸氣臂與地面的夾角建議在 45°-60° 之間，既便于操作又能保證捕集效率。

　　The selection of installation location should follow the principle of "processing nearby and shortening pipelines". The main equipment should be placed on the periphery of the workshop or in a dedicated computer room to avoid occupying production space. The pipeline laying should maintain a certain slope, generally not less than 3 °, to prevent dust from depositing in the horizontal pipeline; The recommended angle between the suction arm and the ground is between 45 ° -60 °, which is convenient for operation and ensures capture efficiency.

　　對(duì)于多工種混合作業(yè)的車(chē)間，需注意設(shè)備的兼容性。若同時(shí)存在焊接、打磨等工序，應(yīng)選用能處理多種粉塵的復(fù)合型過(guò)濾系統(tǒng)，并在管道入口處增設(shè)火花捕捉器，防止打磨產(chǎn)生的火星進(jìn)入濾材引發(fā)火災(zāi)。

　　For workshops with mixed operations of multiple trades, attention should be paid to equipment compatibility. If there are welding, grinding and other processes at the same time, a composite filtration system that can handle multiple types of dust should be selected, and a spark arrester should be added at the inlet of the pipeline to prevent sparks generated by grinding from entering the filter material and causing fires.

　　日常維護(hù)與效能提升

　　Daily maintenance and efficiency improvement

　　定期檢查是保證設(shè)備穩(wěn)定運(yùn)行的基礎(chǔ)，每日需觀察壓力表數(shù)值，若過(guò)濾前后的壓差超過(guò)設(shè)定值（通常為 1500Pa），應(yīng)啟動(dòng)清灰程序或手動(dòng)清理濾材；每周檢查吸氣臂的靈活性，對(duì)關(guān)節(jié)處加注潤(rùn)滑脂，確保定位準(zhǔn)確；每月清洗或更換預(yù)處理裝置中的擋塵板，防止雜質(zhì)堵塞管道。

　　Regular inspection is the foundation for ensuring stable operation of equipment. The pressure gauge value should be observed daily. If the pressure difference before and after filtration exceeds the set value (usually 1500Pa), the dust cleaning program should be initiated or the filter material should be manually cleaned; Check the flexibility of the suction arm weekly, add lubricating grease to the joints to ensure accurate positioning; Clean or replace the dust baffle in the pre-treatment device every month to prevent impurities from blocking the pipeline.

　　濾材維護(hù)需嚴(yán)格按照操作規(guī)程進(jìn)行，脈沖清灰的壓縮空氣壓力應(yīng)控制在 0.5-0.7MPa，每次噴吹時(shí)間 0.1-0.2 秒，間隔 30-60 秒，避免壓力過(guò)大損傷濾材。更換濾筒時(shí)需注意佩戴防護(hù)裝備，防止殘留粉塵吸入，同時(shí)檢查濾筒密封圈是否完好，確保安裝后無(wú)漏氣現(xiàn)象。

　　The maintenance of filter materials should be strictly carried out in accordance with the operating procedures. The compressed air pressure for pulse cleaning should be controlled at 0.5-0.7 MPa, with a spraying time of 0.1-0.2 seconds and an interval of 30-60 seconds to avoid damage to the filter materials caused by excessive pressure. When replacing the filter cartridge, it is necessary to wear protective equipment to prevent residual dust from being inhaled. At the same time, check whether the sealing ring of the filter cartridge is intact to ensure that there is no air leakage after installation.

　　為提升長(zhǎng)期使用效果，可結(jié)合車(chē)間生產(chǎn)計(jì)劃制定維護(hù)周期。在連續(xù)生產(chǎn)的情況下，建議每季度進(jìn)行一次全面檢修，包括風(fēng)機(jī)軸承潤(rùn)滑、電機(jī)絕緣檢測(cè)、管道密封性檢查等；每年對(duì)過(guò)濾效率進(jìn)行一次檢測(cè)，通過(guò)采樣分析確保排放濃度符合相關(guān)標(biāo)準(zhǔn)要求。

　　To improve long-term effectiveness, maintenance cycles can be developed in conjunction with workshop production plans. In the case of continuous production, it is recommended to conduct a comprehensive maintenance every quarter, including lubrication of fan bearings, insulation testing of motors, and inspection of pipeline sealing; The filtration efficiency is tested once a year to ensure that the emission concentration meets the relevant standard requirements through sampling analysis.

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