Steel structure product spraying system and machining method

Abstract

The invention is suitable for the technical field of steel structure product machining, and provides a steel structure product spraying system and a machining method.The steel structure product spraying system comprises a circulating rail mechanism, a spraying device, a waste gas treatment system, an air energy heat pump and a control system; the circulating track mechanism circularly transfers workpieces in the feeding bin, the spraying bin, the paint baking bin and the discharging bin; the spraying device is arranged in the spraying bin; the waste gas treatment system communicates with the exhaust end of the spraying bin and comprises a dry type filtering unit, catalytic combustion equipment and an adsorption purification unit which communicate in sequence. The air energy heat pump is communicated with the paint baking bin; and the control system is connected with the circulating track mechanism, the spraying device, the waste gas treatment system and the air energy heat pump to coordinate the continuous operation of the transferring, spraying and drying procedures.

Description

Technical Field

[0001] The present invention is applicable to the technical field of steel structure product processing, and in particular relates to a steel structure product spraying system and a processing method. Background Art

[0002] In existing technologies, the spray coating process for steel structures typically involves multiple independent steps, including workpiece handling, spraying, and drying. Traditional processing methods often rely on manual operation or semi-automated equipment, resulting in inefficiency and difficulty in ensuring consistency throughout the production process. For example, in the spraying process, manual spraying is not only labor-intensive, but the spraying quality is also significantly affected by the operator's skills. In addition, traditional spraying systems lack effective exhaust gas treatment mechanisms, and the volatile organic compounds (VOCs) generated during the spraying process are directly discharged into the atmosphere without adequate treatment, causing environmental pollution.

[0003] Furthermore, existing steel structure spraying production lines also have shortcomings in workpiece transfer. Typically, workpieces are moved from one process step to the next using forklifts or manual handling. This not only increases worker workload but can also damage the workpiece due to improper handling. Furthermore, the lack of close integration between processes results in extended production cycles, failing to meet the modern industry's pursuit of efficient production.

[0004] In order to solve the above technical problems, the present invention designs a steel structure product spraying system and processing method. Summary of the Invention

[0005] The present invention provides a steel structure product spraying system, which aims to solve the technical problems of high labor intensity, low production efficiency and environmental pollution in traditional spraying processes.

[0006] A steel structure product spraying system, comprising a circulating track mechanism, a spraying device, an exhaust gas treatment system, an air energy heat pump and a control system; The circulating track mechanism circulates and transfers the workpieces among the feeding bin, spraying bin, paint baking bin and discharging bin; the spraying device is arranged in the spraying bin; the exhaust gas treatment system is connected to the exhaust end of the spraying bin, and includes a dry filter unit, catalytic combustion equipment and adsorption purification unit connected in sequence; the air energy heat pump is connected to the paint baking bin; the control system connects the circulating track mechanism, spraying device, exhaust gas treatment system and air energy heat pump to coordinate the continuous operation of the transfer, spraying and drying processes.

[0007] Based on the above technical solution, the circulating track mechanism is a hanging rail mechanism, including a frame and a circular track. The hanging rail mechanism is slidingly connected to the transfer unit, and the transfer unit is an electric hoist and a detachable hook. The steel structure product is hung on the detachable hook.

[0008] Based on the above technical solution, the circulating track mechanism is a ground rail mechanism, including a ground rail transfer rail and a ground rail return rail arranged in parallel, a sliding transfer unit on the ground rail mechanism, and the transfer unit is a carrier frame; the two ends of the ground rail transfer rail are connected to the ground rail return rail through a ground rail connecting rail, and the ground rail connecting rail is slidably connected to the sliding frame, and the carrier frame can be movably set on the sliding frame.

[0009] Based on the above technical solution, the circulating track mechanism is a segmented composite track, including at least one hanging rail segment and at least one ground rail segment; the hanging rail segment is equipped with an electric hoist, and the ground rail segment is equipped with a carrying trolley.

[0010] A method for processing steel structure products, using the above-mentioned spraying system, specifically comprises the following steps: S1: The steel structure products are transferred from the feeding bin to the spraying bin through the circulating track mechanism; S2: In the spraying chamber, the spraying device sprays the surface of the steel structure product transferred to the spraying chamber; S3: In the spray booth, the exhaust gas treatment system treats the exhaust gas in the spray booth; S4: The sprayed steel structure products are transferred from the spraying chamber to the paint chamber through the circulating track mechanism; S5: In the paint baking chamber, the air energy heat pump bakes the steel structure products transferred to the paint baking chamber; S6: The painted steel structure products are transferred from the paint storage bin to the discharge bin via a circulating track mechanism.

[0011] Beneficial effects Compared with existing technologies, this invention offers the following benefits: 1. Improved production efficiency and consistency: Through an automated circulating track mechanism and the implementation of spraying, drying, and exhaust gas treatment systems for steel structure products, workpiece transfer is automated, significantly improving production efficiency. 2. A multi-level exhaust gas treatment system, combined with waste heat recovery and condensate reuse technologies, effectively removes volatile organic compounds (VOCs), reduces environmental pollution, and improves energy efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] To more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only one embodiment of the present invention. Those skilled in the art can also derive other implementation drawings based on the provided drawings without inventive effort.

[0013] Figure 1: Schematic diagram of the processing system structure when the circulating track mechanism of the present invention is a segmented composite track; Figure 2 : A schematic diagram of the processing system structure when the circulating track mechanism of the present invention is a ground track mechanism; Figure 3 : A schematic structural diagram of the hanging rail mechanism of the present invention; Figure 4 : The circulating track mechanism of the present invention is a schematic structural diagram of the transfer unit of the hanging rail mechanism; Figure 5 : The circulating track mechanism of the present invention is a schematic structural diagram of a ground track mechanism; Figure 6 : Positional relationship diagram of the ground rail connecting rail and the sliding frame of the present invention; Figure 7 : A schematic structural diagram of the segmented composite track of the present invention; Figure 8 : Position relationship diagram of the electric hoist of the present invention; Figure 9 : A schematic structural diagram of the exhaust gas treatment system of the present invention; Figure 10 : A schematic structural diagram of the spraying device of the present invention; Figure 11 : Position relationship diagram of the spraying chamber of the present invention; Figure 12 : Principle connection diagram of the air energy heat pump of the present invention. DETAILED DESCRIPTION

[0014] The present invention will be further described below with reference to the accompanying drawings and examples: The following describes embodiments of the present invention in detail. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended only to explain the present invention and are not to be construed as limiting the present invention.

[0015] In the description of the present invention, it should be noted that, unless otherwise specified or limited, the terms "mounted," "connected," and "connected" should be understood broadly. For example, they may refer to fixed connections, detachable connections, or integral connections; they may refer to direct connections or indirect connections through an intermediary. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0016] In the description of the present invention, it should be understood that the terms "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention. A steel structure product spraying system, comprising a circulating track mechanism 1, a spraying device, an exhaust gas treatment system 3, an air energy heat pump 4 and a control system; The circulating track mechanism 1 includes a product transfer section and an empty return section. The product transfer section sequentially passes through the feed bin 51, the spray bin 52, the paint bin 53, and the discharge bin 54. The circulating track mechanism is movably connected to a transfer unit, which is used to carry the steel structure product 9 and circulate along the product transfer section. like Figure 10 As shown, the spraying device is disposed within the spraying chamber 52 and includes a guide rail 201 and a spraying robot 202 slidably connected to the guide rail. A rack is provided on the guide rail 201, and a motor is mounted on the mounting base of the spraying robot 202. The motor output is connected to a gear that meshes with the rack on the guide rail to achieve movement of the spraying robot. The precise coordination of the gear and rack enables high-precision movement and positioning of the spraying robot 202. Compared to other drive methods such as belt drive, rack and pinion drive provides higher position control accuracy, ensuring consistency and accuracy in spraying operations.

[0017] The control system connects the circulating track mechanism 1, the spraying robot 202, the exhaust gas treatment system 3 and the air energy heat pump 4 to coordinate the continuous operation of the transfer, spraying and drying processes.

[0018] Preferably, the end of the spray robot 202 is integrated with a UV-LED curing module, enabling "spraying and local curing." This allows for localized curing of the coating while spraying, significantly shortening the overall process time. The UV-LED curing module precisely controls the curing location and timing based on the spray robot's programming, ensuring that each sprayed area is uniformly and fully cured, avoiding the unevenness that can occur with traditional curing methods.

[0019] The circulating track mechanism 1 can be a hanging rail mechanism, a ground rail mechanism or a segmented composite track.

[0020] like Figure 3 and Figure 4As shown, the circulating track mechanism 1 is a hanging rail mechanism, which includes a frame 11 and a circular track 12 arranged on the frame 11, and the transfer unit is slidably connected to the circular track 12, as shown in FIG. Figure 3 As shown, the transfer unit is an electric hoist 21 and a detachable hook 22 suspended below it, and the steel structure product 9 is hung on the detachable hook 22. The electric hoist 21 and the detachable hook 22 can easily hang, transfer or unload the steel structure product, and are suitable for handling products of different sizes and weights.

[0021] The electric hoist can be composed of a motor, a reducer, a drum, a wire rope or a chain, etc. In the present invention, the electric hoist not only has the ability to lift vertically, but also can move horizontally along the circular track 12. The electric hoist is a device well known to those skilled in the art and will not be described in detail here.

[0022] The hanging rail mechanism moves the steel structure product 9 by suspending it, effectively utilizing the space above the factory building and reducing the floor space occupied by ground equipment. This helps optimize the workshop layout and leaves more floor space for other operations.

[0023] The tops of the feed bin 51, spray bin 52, paint bin 53, and discharge bin 54 are each provided with chutes, to which the electric hoist 21 is slidably connected. The chute design allows the electric hoist 21 to move precisely laterally within the multiple functional bins. This allows steel structure products to be accurately positioned at the specific location where they require processing or handling. The chute provides a stable guide path for the electric hoist 21, avoiding safety hazards caused by track deviation or instability.

[0024] During operation, at the starting point of the production line, the unprocessed steel structure product 9 is loaded onto the transfer unit through the workpiece transfer station. Specifically, a worker or automated equipment hangs the steel structure product 9 on a detachable hook 22 below an electric hoist 21, such as an electric hoist.

[0025] After the steel structure product 9 is hung, the electric hoist starts to move along the ring track 12 provided on the frame 11. This track is designed as a closed ring to ensure that the product can pass through each functional warehouse according to the predetermined path.

[0026] The steel structure product 9 is moved along the product transfer section of the circular track by an electric hoist, passing through several functional bins (feed bin 51, spray bin 52, paint bin 53, and discharge bin 54). A chute is provided at the top of each functional bin to ensure the electric hoist can stably enter and exit the bin and process the steel structure product accordingly. Once the steel structure product 9 has completed all necessary processing steps, the electric hoist transports it to the workpiece transfer station on the production line, transferring it to the external unloading process for the next production stage or direct shipment. The electric hoist then returns to its original position along the unloaded return section, allowing it to be reused within the circular track.

[0027] like Figure 5 and Figure 6 As shown, the circulating track mechanism 1 can be a ground rail mechanism, including a ground rail transfer rail 16 and a ground rail return rail 17 arranged in parallel. By setting two parallel tracks, one for forward transport of steel structure products 9 and the other for empty return, continuous material flow is achieved, thereby improving the efficiency of the entire production line.

[0028] The two ends of the ground rail transfer rail 16 are provided with ground rail connecting rails 18, and a sliding frame 181 is slidably connected to the ground rail connecting rail 18. The transfer unit is a carrier frame 182, and the carrier frame 182 is slidably connected to the sliding frame 181; the sliding frame 181 moves on the ground rail connecting rail 18 to realize the switching of the steel structure product 9 between the ground rail transfer rail 16 and the ground rail return rail 17; The ground rail transfer rail 16, ground rail return rail 17, and ground rail connecting rail 18 are all equipped with conveyor rollers, and the carrier frame 182 is placed on the conveyor rollers and moves along the conveyor rollers. Each conveyor roller or a group of conveyor rollers is connected to one or more drive motors. These motors provide power to enable the conveyor rollers to rotate. The conveyor rollers are also equipped with a control system that coordinates the operation of the various drive motors to ensure that the conveyor rollers can operate at a predetermined speed and direction.

[0029] The sliding frame can move on the ground rail connecting rail 18, so that the carrier can smoothly switch between the ground rail transfer rail 16 and the ground rail return rail 17. This design reduces waiting time and ensures efficient material handling.

[0030] The carrier 182 includes a frame structure and bottom rollers. The bottom rollers cooperate with conveying rollers to enable the carrier 182 to move on the ground rail transfer rail 16, the ground rail return rail 17 and the ground rail connecting rail 18.

[0031] Preferably, a transition plate or transition wheel is installed in the gap between the ground rail transfer rail 16 and the ground rail connecting rail 18. These devices can fill the gap so that the bottom roller on the carrier 182 can smoothly move from one track to another track.

[0032] During operation, the unprocessed steel structure product is loaded onto the carrier 182 through the workpiece handover station through the external loading process. The staff or automated equipment places the steel structure product 9 on the carrier and prepares to enter the next process.

[0033] After the control system is activated, the drive motor rotates the conveyor rollers, causing the carrier 182 and the steel structure product 9 on it to begin moving along the ground rail transfer rail 16. The steel structure product 9, along with the carrier 182, passes through multiple functional storage locations, undergoing various processing operations. The conveyor rollers in each functional location ensure smooth passage of the carrier, allowing specific operations to be performed as needed.

[0034] When carrier 182 reaches the end of the floor rail transfer rail 16, the steel structure product is unloaded from carrier 182 and transferred to the external unloading process. Carrier 182 then enters the floor rail connecting rail 18. At this point, the sliding frame 181 moves along the floor rail connecting rail 18, transferring carrier 182 from the floor rail transfer rail to the floor rail return rail 17. Carrier 182 returns to its starting position along the floor rail return rail 17, ready for the next loading task. During this process, the carrier is also driven by conveyor rollers to ensure smooth movement.

[0035] like Figure 7 and Figure 8 As shown, in order to adapt to different process requirements, the circulating track mechanism is a segmented composite track, including at least one hanging rail segment 13 and at least one ground rail segment 14, the hanging rail segment 13 is slidingly connected to the electric hoist 21, and the ground rail segment 14 is slidingly connected to the carrying trolley 23.

[0036] There are two ground rail sections 14 and two supporting trolleys 23, each slidably connected to the ground rail sections 14. The trolleys 23 are mounted on the feed and discharge bins, respectively, and are equipped with ground rail transfer units. The trolleys 23 are equipped with rollers at their bases, designed to mate with the tracks on the ground rail sections 14. Each trolley or group of trolleys is typically connected to one or more drive motors. These motors provide power, enabling the trolleys to move along the tracks.

[0037] The feed bin and discharge bin are equipped with ground rail sections 14, while the spray bin 52 and paint bin 53 are equipped with hanging rail sections 13. Different functional bins may require different types of transportation methods. For example, the spray bin 52 and paint bin 53 are suitable for suspended operation using hanging rail sections 13 to avoid interference from ground equipment and ensure uniform processing; while the feed bin 51 and discharge bin 54 are more suitable for ground rail sections because they usually need to carry a larger weight. The design of the segmented composite track allows for flexible selection of the appropriate transportation method according to specific needs.

[0038] Segmented composite rails allow steel structure products to switch between hanging rail sections and ground rail sections according to actual needs, reducing unnecessary handling steps and time and improving the logistics efficiency of the entire system.

[0039] During use, the unprocessed steel structure product 9 is loaded onto the carrying trolley 23 from the workpiece transfer station through the external loading process. The staff or automated equipment places the steel structure product on the carrying trolley, ready to enter the next process.

[0040] The ground rail section 14 is equipped with a separate control system, drive motor, and conveyor rollers. When activated, the drive motor drives the conveyor rollers to rotate, causing the carrier trolley 23 and the steel structure product 9 on it to begin moving along the ground rail section 14. A transition device (such as a lifting platform or transfer robot) is installed in front of certain functional chambers (such as the spray chamber 52 and the drying chamber 53) to transfer the steel structure product 9 from the ground rail section 14 to the hanging rail section 13. The transition device transfers the steel structure product 9 from the carrier trolley 23 to the detachable hook 22 of the electric hoist 21. The steel structure product 9 is suspended from the electric hoist 21 and moves along the hanging rail section 13, passing through the spray chamber 52, the paint chamber 53, and other functional chambers in sequence.

[0041] At this point, the trolley 23, located on the ground rail section of the feed bin 51, returns to its initial position to receive the next steel structure product 9. After completing all necessary steps, the steel structure product 9 returns to the ground rail section of the discharge bin 54. At this point, it is transferred from the hanging rail section 13 to the trolley 23 via a transition device, and then travels along the ground rail section to the final workpiece handover station.

[0042] like Figure 9 As shown, the exhaust gas treatment system 3 is connected to the exhaust end of the spray chamber 52, and includes a dry filter unit 31, a catalytic combustion device 33 and an adsorption purification unit connected in sequence; In the exhaust gas treatment system 3, the dry filter unit 31 is a multi-stage filtration structure, including at least one primary filter cotton or cartridge filter. This effectively removes large particulate matter and some volatile organic compounds (VOCs) from the exhaust gas. Multi-stage filtration not only improves the capture efficiency of pollutants of varying particle sizes but also extends the service life of subsequent treatment equipment.

[0043] The catalytic combustion equipment 33 includes a heat exchanger, an electric heating assembly, and a catalytic reaction chamber. The heat exchanger's inlet is connected to the outlet of the dry filter unit 31. The adsorption purification unit comprises a first adsorption tank 321 and a second adsorption tank 322, which are used to alternately perform adsorption and desorption regeneration operations. By configuring two adsorption tanks, one can perform adsorption while the other performs desorption and regeneration. The system can continuously process exhaust gas without requiring downtime for adsorbent regeneration or replacement, thus ensuring continuous and stable production.

[0044] In the adsorption purification unit, a VOCs concentration sensor is also provided for real-time monitoring of data to predict VOCs peaks and activate the standby adsorption tank in advance. When low-concentration exhaust gas is detected, the system automatically switches to energy-saving mode (dry filtration only) to achieve optimal exhaust gas treatment while saving energy.

[0045] Specifically, a high-precision VOCs concentration sensor is installed inside the adsorption purification unit or in the pipeline before and after it. The sensor transmits the detected data to the central control system in real time. This system is responsible for collecting, analyzing, and processing these data and making decisions based on pre-set algorithms. The central control system uses machine learning or statistical models to analyze incoming VOCs concentration data. By analyzing historical data and current trends, it predicts upcoming VOCs peaks. When a high-concentration VOCs is predicted, the system activates the standby adsorption tank in advance. The first adsorption tank 321 and the second adsorption tank 322 serve as the main and backup adsorption tanks, respectively. This means that if the currently used adsorption tank is close to saturation, the system will switch to the standby adsorption tank before it is needed, ensuring that the treatment efficiency will not be reduced due to adsorbent saturation. When the sensor detects low VOCs concentration in the exhaust gas, the system automatically switches to energy-saving mode. In this mode, only the dry filtration unit is used for preliminary purification, while the adsorption purification unit is turned off to save energy and prolong the service life of the adsorbent.

[0046] The catalytic combustion device 33 includes a heat exchanger, a catalytic reaction chamber, and an electric heating assembly. The inlet of the heat exchanger is connected to the exhaust end of the dry filtration unit 31, the outlet of the heat exchanger is connected to the electric heating assembly, and the end of the electric heating assembly away from the heat exchanger is connected to the catalytic reaction chamber. The heat exchanger in the catalytic combustion device 33 can use the high-temperature purified gas discharged from the catalytic reaction chamber to preheat the incoming low-temperature exhaust gas, thereby reducing the energy consumption of the electric heating assembly. This way, energy is effectively recycled, reducing overall energy consumption and meeting energy-saving and environmental protection requirements.

[0047] During exhaust gas treatment, the exhaust gas first undergoes preliminary purification through a dry filtration unit 31 to remove large particulate pollutants and other impurities. The pre-purified exhaust gas then enters the heat exchanger portion of the catalytic combustion equipment 33. The exhaust gas then comes into contact with the high-temperature purified gas discharged from the catalytic reaction chamber, using the heat carried by the gas to preheat the exhaust gas and raise its temperature. After leaving the heat exchanger, the preheated exhaust gas enters the electric heating assembly. If the exhaust gas temperature has not yet reached the catalyst's activation temperature, the electric heating assembly further heats the exhaust gas to ensure it reaches the appropriate reaction temperature. Once the exhaust gas reaches the reaction temperature, it then enters the catalytic reaction chamber and comes into contact with the catalyst surface. The catalyst reduces the activation energy of the reaction, allowing the VOCs in the exhaust gas to be rapidly oxidized and decomposed into carbon dioxide and water vapor at a relatively low temperature. The purified gas after treatment in the catalytic reaction chamber contains little or no harmful substances. This gas can be recycled back to the heat exchanger as part of the heat source to recover waste heat. It is then further treated by the adsorption purification unit before being safely discharged into the atmosphere via the fan 34 and the overhead exhaust pipe 35.

[0048] The spray booth 52 includes a room body 521, an air filtration system 522, an air supply device and an electronic control system; the room body 521 is composed of a frame, wall panels and a safety door welded from galvanized square tubes; the air supply device is arranged in the spray booth 52 and is connected to the air filtration system 522 and the exhaust gas treatment system.

[0049] The frame of chamber 521 is welded from 80*80*2mm square tubes, meeting the load-bearing requirements of the chamber and its workpieces. The wall panels are 100mm thick rock wool composite panels with a bulk density of 100 kg. The inner iron plate is 0.4mm thick, while the outer iron plate is 0.4mm thick, made of color-coated steel. This welded galvanized square tube frame ensures the overall strength and stability of the spray chamber 52. The thick rock wool and color-coated steel composite panels offer excellent thermal insulation and fire resistance, while effectively isolating the interior from external noise and temperature fluctuations, providing a relatively stable working environment. An air-energy electric heating enclosure is installed on the side of the chamber, housing a heat conversion device and a hot air circulation fan.

[0050] The chamber's frame is welded from 80*80*2mm square tubes, with a bridge-like structure supporting the weight of the curing chamber. Air curtains are installed above the entrance and exit doors. When the circulating track mechanism 1 is configured as a hanging track, the gutter is 150mm wide to facilitate the travel of the wire rope. A soft and durable silicone baffle is installed to prevent the escape of high-temperature gases and paint mist.

[0051] Two spray chambers 52 and spraying devices are provided, one on each side of the circulating track mechanism 1. This allows for double-sided spray coating of steel structures in a single pass. This significantly reduces the time required to flip the workpiece or perform secondary processing, thereby significantly improving spraying efficiency. The two spray chambers 52 are connected to the exhaust gas treatment system 3 via a pipeline.

[0052] The spraying chamber 52 is a functional chamber, which may need to be replaced by a functional chamber (e.g. replacing the spraying chamber 52 with a phosphating chamber, a shot blasting chamber or a spraying chamber of a different form, or adjusting the baking chamber 53 according to different heating requirements).

[0053] Preferably, the spraying chamber 52 and the baking chamber 53 are designed as two parts: a fixed bottom and a variable chamber. The fixed bottom and the variable chamber are connected by a locking device. The locking device can be a pneumatic or hydraulic locking mechanism, which is a prior art known to those skilled in the art and will not be described here. The fixed bottom is the basic part of the entire chamber body, which contains the necessary support structure, air inlet and outlet, pipe interface, etc. The variable chamber can be quickly replaced according to actual needs, for example, from a spraying chamber to a phosphating chamber or a shot blasting chamber, or adjusting the configuration of the baking chamber according to different heating methods.

[0054] In some embodiments, in order to replace the functional chamber, a guide rail is installed on the ground, and pulleys or ball bearings are arranged on the bottom of the functional chamber module and the spraying chamber 52 and the baking chamber 53, so that the chamber module can be easily pushed in and out along the guide rail, improving the efficiency of loading and unloading.

[0055] When the chamber needs to be replaced, the operator first releases the locking device of the existing spraying chamber. The original functional chamber is removed, a new functional chamber is replaced, and the locking device is fixed.

[0056] As shown in Figure 11 In some embodiments, the air filtration system 522 and the house body 521 are arranged on the two sides of the circulating track mechanism 1, respectively. The air inlet and outlet paths can be better planned to ensure uniform distribution of air flow in the spraying chamber 52. This helps to form a stable laminar flow environment, reduces paint mist diffusion and deposition, and improves the spraying quality.

[0057] The air filtration system and the air supply device arranged in the spraying chamber ensure good air quality during spraying and prevent paint mist diffusion from affecting the environment. The exhaust gas treatment system is connected to the spraying chamber. The exhaust gas first enters the dry filtration unit 31 for preliminary purification to remove large particle impurities. The air supply device includes a centrifugal fan and an air duct system connected thereto. The air duct system is arranged at the top of the spraying chamber and is provided with a plurality of air outlets. The air filtration system is a prior art available to those skilled in the art and will not be described here.

[0058] As shown in Figure 12 The air-to-air heat pump 4 is in communication with the baking chamber 53. The air-to-air heat pump 4 includes a refrigerant circulation channel, which includes a compressor 41, a condenser 42, an outdoor evaporator 43, an expansion valve 455 and an indoor evaporator 44. Among them, the evaporator: the air energy heat pump drying room first absorbs low-temperature and low-pressure heat from the surrounding air, causing the moisture in the air to evaporate.

[0059] Compressor 41: The absorbed low-temperature, low-pressure refrigerant is compressed by the compressor. This process compresses the gas into a high-temperature, high-pressure state.

[0060] Condenser 42: High-temperature, high-pressure refrigerant gas passes through the condenser, releasing heat. This causes the refrigerant gas to condense into a liquid state, releasing a large amount of heat energy.

[0061] Expansion valve 455: The high-temperature and high-pressure liquid refrigerant rapidly expands through the expansion valve, and the temperature and pressure decrease as it returns to its original low-temperature and low-pressure state. The outlet of the compressor 41 is respectively connected to the inlet of the first throttle valve 451 and the inlet of the second throttle valve 452; the outlet of the second throttle valve 452 is connected to the inlet of the condenser 42, and a fourth throttle valve 454 is connected in parallel on the connecting pipeline to connect to the inlet of the compressor 41; the outlet of the condenser 42 is connected to the bypass pipeline via the expansion valve 455; the bypass pipeline includes a first channel and a second channel, the first channel is connected to the inlet of the indoor evaporator 44 via the outdoor evaporator 43 and the seventh throttle valve 457 in sequence; the second channel is directly connected to the inlet of the indoor evaporator 44 via the sixth throttle valve 456; the outlet of the indoor evaporator 44 and the outlet of the first throttle valve 451 are respectively connected to the inlet of the third throttle valve 453; the outlet of the third throttle valve 453 is connected to the inlet of the compressor 41.

[0062] It also includes an air circulation channel, which includes a sealed air duct that connects the paint storage bin 53, the indoor evaporator 44, the condenser, and the fan in sequence. The fan is used to drive the air to flow through the paint storage bin 53, the indoor evaporator 44, the condenser 42 in the sealed air duct in sequence, and then return to the paint storage bin 53 to form a closed air circulation path.

[0063] High temperature drying process: Open the second throttle valve 452, the expansion valve 455, and the seventh throttle valve 457, and close the remaining throttle valves; allow the refrigerant to flow through the compressor 41, the second throttle valve 452, the condenser 42, the expansion valve 455, the outdoor evaporator 43, the seventh throttle valve 457, the indoor evaporator 44, the third throttle valve 453 in sequence, and then return to the compressor 41.

[0064] Refrigerant flow: compressor 41 - a - second throttle valve 452 - b - condenser 42 - c - expansion valve 455 - d - outdoor evaporator 43 - e - seventh throttle valve 457 - f - indoor evaporator 44 - g - third throttle valve 453 - h - compressor 41 .

[0065] At the outlet of compressor 41, the refrigerant is compressed into a high-temperature, high-pressure gas. Due to the compression, both the temperature and pressure of the refrigerant increase significantly. The high-temperature, high-pressure refrigerant gas passes through the second throttle valve 452 and enters the condenser 42. In the condenser 42, the refrigerant releases heat to the surrounding air or water, cooling and partially liquefying. During this process, the refrigerant's temperature decreases, while its pressure remains relatively high. After passing through the expansion valve 455, the refrigerant's pressure rapidly drops, further lowering its temperature and transforming it into a low-temperature, low-pressure liquid. In the high-temperature drying mode, the refrigerant flows through the seventh throttle valve 457 to the outdoor evaporator 43 and then into the indoor evaporator 44. The outdoor evaporator 43 absorbs heat from the ambient air, converting the refrigerant back into a gas. The gaseous refrigerant then enters the indoor evaporator 44, where it absorbs heat from the indoor air, further heating it. Finally, the refrigerant returns to the compressor 41 through the third throttle valve 453, completing the cycle.

[0066] In high-temperature drying mode, air is drawn from the paint baking chamber 53 and heated as it passes through the indoor evaporator 44, which acts as a heater during this stage, absorbing heat from the refrigerant. The heated air then passes through the condenser 42, where it may experience further temperature increase or decrease, depending on the specific requirements of the system design. The treated air ultimately returns to the paint baking chamber 53, forming a closed air circulation path that maintains optimal temperature and humidity conditions within the chamber for an efficient drying process.

[0067] High temperature is suitable for intelligent mode, which is used when the temperature is greater than 25 degrees.

[0068] The working process of open and closed drying mode: Open the second throttle valve 452, the expansion valve 455, and the sixth throttle valve 456, and close the remaining throttle valves; allow the refrigerant to flow through the compressor 41, the second throttle valve 452, the condenser 42, the expansion valve 455, the sixth throttle valve 456, the indoor evaporator 44, the third throttle valve 453 in sequence, and then return to the compressor 41.

[0069] The open and closed drying mode is suitable for use between 10 and 25 degrees Celsius.

[0070] Refrigerant flow direction: compressor 41 - a - second throttle valve 452 - b - condenser 42 - c - expansion valve 455 - d - sixth throttle valve 456 - f - indoor evaporator 44 - g - third throttle valve 453 - h - compressor 41 .

[0071] The refrigerant is compressed into a high-temperature, high-pressure gas at the outlet of compressor 41. Due to the compression, both the temperature and pressure of the refrigerant increase significantly. The high-temperature, high-pressure refrigerant gas passes through the second throttle valve 452 and enters the condenser 42. In the condenser 42, the refrigerant releases heat to the surrounding air or water, cooling it and partially liquefying it. The refrigerant's temperature decreases, but its pressure remains relatively high. After passing through the expansion valve 455, the refrigerant's pressure drops rapidly, further lowering its temperature and transforming it into a low-temperature, low-pressure liquid. The low-temperature, low-pressure refrigerant liquid then passes through the sixth throttle valve 456 and flows to the indoor evaporator 44. In the indoor evaporator 44, the refrigerant absorbs heat from the surrounding air, evaporating and transforming into a gas. This process cools the indoor air for dehumidification or heating, depending on the specific application scenario. Finally, the refrigerant returns to the compressor 41 through the third throttle valve 453, completing the cycle.

[0072] Air is drawn from the paint chamber 53 and passes through the indoor evaporator 44. At this stage, the air is heated. The treated air then flows to the condenser 42, where it is further heated to achieve ideal drying conditions. The treated air ultimately returns to the paint chamber 53, forming a closed air circulation path.

[0073] The compressor is controlled by the drive controller to set the drying temperature value.

[0074] Low temperature drying process: Open the first throttle valve 451, the fourth throttle valve 454, and the sixth throttle valve 456, and close the remaining throttle valves; allow the refrigerant to flow through the compressor 41, the first throttle valve 451, the indoor evaporator 44, the sixth throttle valve 456, the expansion valve 455, the condenser 42, the fourth throttle valve 454 in sequence, and then return to the compressor 41.

[0075] Refrigerant flow direction: compressor 41 - a - first throttle valve 451 - g - indoor evaporator 44 - f - sixth throttle valve 456 - d - expansion valve 455 - c - condenser 42 - b - fourth throttle valve 454 - h - compressor 41 .

[0076] The refrigerant at the outlet of compressor 41 is compressed into a high-temperature, high-pressure gas. Due to the compression, both the temperature and pressure of the refrigerant increase significantly. The high-temperature, high-pressure refrigerant gas passes through the first throttle valve 451 and enters the indoor evaporator 44. This step differs from the high-temperature or open-close drying mode in that the high-temperature, high-pressure refrigerant is directed directly to the indoor evaporator 44 to heat the air. In the indoor evaporator 44, the refrigerant releases heat to the surrounding air, thereby heating the air for drying. During this process, the refrigerant cools and partially liquefies, but the pressure remains high. The refrigerant then passes through the sixth throttle valve 456 before flowing to the expansion valve 455, preparing for the expansion phase. After passing through the expansion valve 455, the refrigerant's pressure drops rapidly, further lowering its temperature and transforming it into a low-temperature, low-pressure liquid. The low-temperature, low-pressure refrigerant liquid then flows into the condenser 42, where it absorbs heat from the ambient air. If the ambient temperature is low, additional auxiliary heating may be required to return the refrigerant to a gaseous state and restore it to a desired temperature and pressure. Finally, the refrigerant returns to the compressor 41 through the fourth throttle valve 454, completing a cycle.

[0077] Air is drawn from the paint baking chamber 53 and enters the air circulation system. It flows through the indoor evaporator 44, where it is heated, releasing heat from the refrigerant. The heated air then flows to the condenser 42. Finally, the heated air returns to the paint baking chamber 53, providing a suitable drying environment for the products.

[0078] Low-temperature drying is suitable for certain specific application scenarios where the material needs to be dried at a temperature lower than the ambient temperature. The second throttle valve 452 and the third throttle valve 453 are four-way throttle valves.

[0079] The air-source heat pump 4 also includes a temperature sensor located within the paint baking chamber 53 and a central controller. The central controller connects the temperature sensor to the air-source heat pump 4. The temperature sensor monitors the temperature within the paint baking chamber 53 in real time and provides feedback to the central controller, which dynamically adjusts the heat output of the air-source heat pump 4. By monitoring the temperature at the outlet of the compressor 41, the controller can precisely adjust the direction and flow rate of the refrigerant. This enables the system to dynamically adjust operating parameters based on actual needs, thereby improving overall energy conversion efficiency. When external environmental conditions (such as temperature or humidity) change, the system can quickly respond and make corresponding adjustments, ensuring high energy efficiency under all operating conditions.

[0080] In order to improve energy efficiency, the exhaust gas treatment system 3 includes a waste heat recovery system. The exhaust end of the catalytic combustion equipment 33 is connected to the preheating section heat exchanger arranged at the inlet end of the paint storage bin 53 through a heat pipe; the indoor evaporator 44 of the air energy heat pump 4 is provided with a water collection tray at the bottom to collect condensed water, and the outlet of the water collection tray is connected to the top nozzle of the spray tower through a drainage pipe.

[0081] It includes the following two types of recovery: catalytic combustion waste heat recovery: the high-temperature exhaust gas discharged by the catalytic combustion equipment 33 is introduced into the preheating section heat exchanger at the inlet end of the paint storage bin 53 through a heat pipe; Air-to-energy heat pump condensate reuse: A condensate collection tray is provided at the bottom of the indoor evaporator 44 of the air-to-energy heat pump 4; the condensate is transported to the nozzle at the top of the spray tower through a drain pipe for cooling and pre-treatment of the exhaust gas.

[0082] Among them, the preheating section is used to heat the air or workpiece that is about to enter the paint baking chamber to improve heating efficiency.

[0083] A method for processing steel structure products, using the above-mentioned spraying system, specifically comprises the following steps: S1: The steel structure product 9 is transferred from the feeding bin 51 to the spraying bin 52 via the circulating track mechanism 1; S2: In the spraying chamber 52, the spraying device sprays the surface of the steel structure product 9 transferred to the spraying chamber 52; S3: In the spraying chamber 52, the exhaust gas treatment system 3 treats the exhaust gas in the spraying chamber 52; S4: The spray-coated steel structure product 9 is transferred from the spraying chamber 52 to the paint-baking chamber 53 via the circulating track mechanism 1; S5: In the paint baking chamber 53, the air energy heat pump 4 performs paint baking treatment on the steel structure product 9 transferred to the paint baking chamber 53; S6: The painted steel structure product 9 is transferred from the paint storage bin 53 to the discharge bin 54 via the circulating track mechanism 1 .

[0084] In step S3, the exhaust gas treatment system 3 processes the exhaust gas by: The exhaust gas first passes through a dry filter unit 31 for preliminary purification, removing large particulate pollutants and other impurities. The preliminarily purified exhaust gas then enters the heat exchanger portion of the catalytic combustion device 33. There, it comes into contact with the high-temperature purified gas exhausted from the catalytic reaction chamber, using the heat carried by the high-temperature purified gas to preheat the exhaust gas, raising its temperature.

[0085] After leaving the heat exchanger, the preheated exhaust gas enters the electric heating assembly. If the exhaust gas temperature has not yet reached the catalyst's activation temperature, the electric heating assembly further heats the exhaust gas to ensure it reaches the appropriate reaction temperature. Once the exhaust gas reaches the reaction temperature, it enters the catalytic reaction chamber, where it comes into contact with the catalyst surface, rapidly oxidizing and decomposing the VOCs in the exhaust gas into carbon dioxide and water vapor.

[0086] The high-temperature exhaust gas discharged by the catalytic combustion device 33 is transferred to the preheating section heat exchanger at the inlet end of the paint baking chamber 53 through the heat pipe to preheat the fresh air or workpieces that are about to enter the paint baking chamber.

[0087] The sodium-potassium alloy phase change material filled in the heat pipe absorbs the heat of the high-temperature exhaust gas and liquefies, then flows into the preheating section at the inlet end of the paint storage bin 53, releasing latent heat to heat the fresh air; When the air energy heat pump 4 is running, the dehumidified condensed water collected in the water collecting tray at the bottom of the indoor evaporator 44 is transported to the nozzle at the top of the spray tower 332 of the exhaust gas treatment system 3 through the drain pipe to spray and cool the exhaust gas before catalytic combustion.

[0088] The high-temperature exhaust gas from the catalytic combustion device 33 transfers heat through a heat pipe filled with a sodium-potassium alloy phase change material. This material liquefies after absorbing heat and releases latent heat in the preheating section at the inlet of the paint baking chamber 53, heating the fresh air. This method not only efficiently transfers waste heat but also enhances heat storage and release through the high latent heat properties of the phase change material. This significantly reduces the external energy required to heat the paint baking chamber, such as electricity or gas, thereby reducing operating costs.

[0089] Dehumidified condensate collected in the water collection tray at the bottom of the indoor evaporator 44 of the air-source heat pump 4 is transported via a drainpipe to the nozzles at the top of the exhaust gas treatment system's spray tower, where it is sprayed to cool the exhaust gas before catalytic combustion. This step helps lower the exhaust gas temperature and reduces the load on subsequent treatment equipment. The low-temperature condensate spray not only effectively lowers the exhaust gas temperature but also captures fine particulate matter and some volatile organic compounds (VOCs) in the exhaust gas, further improving the overall efficiency of the exhaust gas treatment.

[0090] This design achieves dual recycling of exhaust heat and condensed water, creating a closed-loop energy network. The heat from the exhaust is used to preheat the fresh air in the paint booth, while the condensed water is used for spray cooling, reducing the need for external resources and aligning with green manufacturing principles.

[0091] It should be noted that the control system, spray device, and drive mechanism of this embodiment are all commonly used standard components or components known to those skilled in the art. Their structures and principles can be learned by those skilled in the art from technical manuals or through routine experimental methods. The "inlet" and "outlet" in this embodiment should be determined in conjunction with the system operating mode and are not strictly single directions.

[0092] The present invention has been described above by way of examples, but the present invention is not limited to the above specific embodiments. Any changes or modifications based on the present invention fall within the scope of protection claimed by the present invention.

Claims

1. A steel structure product spraying system, characterized by: It includes a circulating track mechanism (1), a spraying device, an exhaust gas treatment system (3), an air energy heat pump (4) and a control system; The circulating track mechanism (1) circulates and transfers the workpieces among the feeding bin (51), the spraying bin (52), the baking paint bin (53) and the discharging bin (54); the spraying device is arranged in the spraying bin (52); the exhaust gas treatment system (3) is connected to the exhaust end of the spraying bin (52), and includes a dry filter unit (31), a catalytic combustion device (33) and an adsorption purification unit connected in sequence; the air energy heat pump (4) is connected to the baking paint bin (53); the control system is connected to the circulating track mechanism (1), the spraying device, the exhaust gas treatment system (3) and the air energy heat pump (4), and coordinates the continuous operation of the transfer, spraying and drying processes.

2. A steel structure product spraying system according to claim 1, characterized in that: The circulating track mechanism (1) is a hanging rail mechanism, comprising a frame (11) and a circular track (12); a transfer unit is slidably connected to the hanging rail mechanism; the transfer unit is an electric hoist (21) and a detachable hook (22); and the steel structure product (9) is hung on the detachable hook (22).

3. A steel structure product spraying system according to claim 1, characterized in that: The circulating track mechanism (1) is a ground rail mechanism, comprising a ground rail transfer rail (16) and a ground rail return rail (17) arranged in parallel, a sliding transfer unit on the ground rail mechanism, and the transfer unit is a carrier frame (182); both ends of the ground rail transfer rail (16) are connected to the ground rail return rail (17) through a ground rail connecting rail (18), and the ground rail connecting rail (18) is slidably connected to a sliding frame (181), and the carrier frame (182) is movably arranged on the sliding frame (181).

4. A steel structure product spraying system according to claim 1, characterized in that The circulating track mechanism (1) is a segmented composite track, comprising at least one hanging rail segment (13) and at least one ground rail segment (14); the hanging rail segment (13) is equipped with an electric hoist (21), and the ground rail segment (14) is equipped with a carrying trolley (23).

5. A steel structure product spraying system according to claim 1, characterized in that: In the exhaust gas treatment system (3), the dry filter unit (31) is a multi-stage filter structure, the catalytic combustion device (33) includes a heat exchanger, an electric heating component and a catalytic reaction chamber, and the inlet of the heat exchanger is connected to the outlet of the dry filter unit (31); the adsorption purification unit includes a first adsorption box (321) and a second adsorption box (322).

6. A steel structure product spraying system according to claim 1, characterized in that: The spraying chamber (52) comprises a chamber body (521), an air filtration system (522), an air supply device, and an electric control system; the chamber body (521) is composed of a frame, wall panels, and a safety door formed by welding galvanized square tubes; the air supply device is arranged in the spraying chamber (52) and is connected to the air filtration system (522) and the exhaust gas treatment system.

7. A steel structure product spraying system according to claim 5, characterized in that: The air energy heat pump (4) includes a refrigerant circulation channel, which includes a compressor (41), a condenser (42), an outdoor evaporator (43) and an indoor evaporator (44); the outlet of the compressor (41) is connected to a first throttle valve (451) and a second throttle valve (452); the outlet of the second throttle valve (452) is connected to the inlet of the condenser (42), and a fourth throttle valve (454) is connected in parallel on the pipeline to the inlet of the compressor (41); the outlet of the condenser (42) is divided into two paths through an expansion valve (455): the first path is connected to the inlet of the indoor evaporator (44) through the outdoor evaporator (43) and the seventh throttle valve (457) in sequence, and the second path is directly connected to the inlet of the indoor evaporator (44) through the sixth throttle valve (456); the outlet of the indoor evaporator (44) and the outlet of the first throttle valve (451) are merged to the third throttle valve (453) and then return to the compressor (41).

8. A steel structure product spraying system according to claim 7, characterized in that: The exhaust gas treatment system (3) includes a waste heat recovery system. The exhaust end of the catalytic combustion device (33) is connected to the preheating section heat exchanger at the inlet end of the paint storage bin (53) through a heat pipe. A water collecting pan for collecting condensed water is provided at the bottom of the indoor evaporator (44) of the air energy heat pump (4). The outlet of the water collecting pan is connected to the top nozzle of the spray tower through a drainage pipe.

9. A method for processing a steel structure product, using a spraying system according to any one of claims 1 to 8, characterized in that: The specific steps include: S1: The steel structure product (9) is transferred from the feeding bin (51) to the spraying bin (52) via the circulating track mechanism (1); S2: In the spraying chamber (52), the spraying device sprays the surface of the steel structure product (9) transferred to the spraying chamber (52); S3: In the spraying chamber (52), the exhaust gas treatment system (3) treats the exhaust gas in the spraying chamber (52); S4: The spray-coated steel structure product (9) is transferred from the spraying chamber (52) to the paint-baking chamber (53) via the circulating track mechanism (1); S5: In the paint baking bin (53), the air energy heat pump (4) performs paint baking treatment on the steel structure product (9) transferred to the paint baking bin (53); S6: The painted steel structure product (9) is transferred from the paint storage bin (53) to the discharge bin (54) via the circulating track mechanism (1).

10. A method for processing a steel structure product according to claim 9, characterized in that: In step S3, the exhaust gas treatment system (3) processes the exhaust gas by: Passing high-temperature exhaust gas discharged from the catalytic combustion device (33) into the heat pipe; The sodium-potassium alloy phase change material filled in the heat pipe absorbs the heat of the high-temperature exhaust gas and liquefies, and flows into the preheating section at the inlet end of the paint baking chamber (53), releasing latent heat to heat the fresh air; When the air energy heat pump (4) is in operation, the dehumidified condensed water collected by the water collecting tray at the bottom of the indoor evaporator (44) is transported to the top nozzle of the spray tower (332) of the exhaust gas treatment system (3) through the drainage pipe to spray and cool the exhaust gas before catalytic combustion.

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