POWDER COATING APPLICATION,Process Control & The Big Five,Training Objectives,Gain a better understanding of . . .The powder coating application process 粉末喷涂过程Process monitoring and control 过程监督和控制The most common causes of application problems 问题发生的主要原因How to recognize an application problem 怎样识别问题How to prevent the most common problems 怎样防止常见问题,Monitor & Control,The Process Must be Constantly MONITORED and CONTROLLED,MONITOR: Observation, Measurement and Testing监督：观察，测量和试验Process Control Engineer 控制过程的工程师Team Leader 领导者Process / Chemical Techs 技术/化学技术人员Operators 操作工CONTROL: Adjustment and Maintenance控制：调整和维护Team Leader 领导者Process / Chemical Techs技术/化学技术人员Maintenance Personnel 维护工,The Big Five,The Five Critical Aspects of the Powder Coating Process . . .,COMPRESSED AIR QUALITY 压缩空气质量 PARTS CLEANING AND PRETREATMENT 工件的清洁和预处理 PARTS GROUNDING 工件接地 POWDER CHARGING 粉末充电 POWDER CURING 粉末烘干,1. Compressed Air Quality 压缩空气质量,Compressed Air Quality Definition,NO Oil: 0.1 PPM (0.1 mg/m3)油 百万分之0.1NO Water: 38F dew point (1.3 g/m3)水 露点NO Particulates: 0.3 microns颗粒 ：0.3微米,“CLEAN AIR” 干净的空气,. . . Compressed Air Must Be Clean And Dry压缩空气必须干净和干燥,Compressed Air Quality Potential Problems,Coating Defects 涂层缺陷Craters and fisheyes 裂纹Pinholes 小孔Adhesion failure 吸附性差Powder agglomerations 粉末结块Equipment Damage设备问题Impact fusion in pumps, hoses and nozzles 泵，软管和喷嘴连接效果差 Blinding of primary filter cartridges 初级烧结板堵塞Blinding of fluidizing membranes in hopper/collector流化膜堵塞Obscured view of UV fire detection sensors紫外线感应装置被挡,Compressed Air Quality Monitor and Control,MonitorOil or water vapor visible from blow-guns喷枪上可看见油和水蒸汽Oil or water present at drains and drip legs near booth 监测粉房旁边的排水管和水过滤器Oil or water residue visible in air-flow meters 气流计上能看见油和水的残留物Gummy powder residue on UV Detector windows 紫外线探测仪玻璃上有粘性粉末残留物Difficult to fluidize powder 流化粉末Poor powder containment by booth 被粉房污染粉末ControlDrain filters, traps and drip-legs regularly 排水管，存水杯，水过滤器Replace coalescing and particulate filter elements更换过滤器部件Maintain the compressor and air-dryer保持空气压缩器和空气干燥器,Parts Cleaning & Pretreatment 工件清洁和预处理,Parts Cleaning & Pretreatment Definition,No Oily or Powdery Residues 没有油性或者粉末状残留物No Polishing Compound 没有光亮剂混合物No Metal Chips 没有金属碎片,Effective De-Oxidizing去除氧化物Adequate Phosphate (or Chromate) Deposition 适当酸洗处理Thorough Rinsing 彻底清洗,“CLEAN PART” “干净的工件”,“PROPER PRETREATMENT”,Parts Cleaning & Pretreatment Potential Problems,Appearance Defects 外表缺陷Craters and fisheyes 裂痕Pinholes 针眼Poor Smoothness不光滑Performance DeficienciesAdhesion failure吸附性差Reduced corrosion protection抗腐蚀性降低Pull-away (In corners or in spots),Parts Cleaning & Pretreatment Monitor and Control,MonitorWater-Break free surface 没有水痕的表面Uniform chromate color 统一的颜色White towel wipe 白色纸巾擦拭没有脏物Titration 滴定试验ControlAdjust concentrations 调整浓度Dump and recharge 清槽,Parts Grounding 工件接地,Part,Hanger,PARTS GROUNDING,Track,Rotator,Trolly,Conveyor,Parts Grounding Definition,No electrical resistance - Between the part and earth ground 没有电阻工件和地面之间Zero ohms at 1000v DC Measured 1000V直流电0欧姆测量的数据. . . At each contact point between part and conveyor在每一个工件和输送链接触点. . . Through the powder application zone粉末喷涂区,“GROUNDED PART”,Parts Grounding Potential Problems,Coating Efficiency 涂层效率Poor transfer 输送缓慢Slow film build 涂层达不到要求Light coverage overall 涂层薄 Difficult to coat Faraday Cage areas 法拉第效应Excessive powder usage in spray-to-waste situations 粉末浪费Safety 安全Ignition source 点火源Shock hazard 触电,Parts Grounding Monitor and Control,MonitorMeasure resistance to ground 测量接地电阻Fire detection system displays alert or alarm 防火系统显示和警报Hear or see arcing at contact points 接触点有打火现象Operators getting shocked 操作者被电Poor transfer efficiency, slow film build and light coverage Difficulty coating Faraday Cage areasBack-ionization电离 ControlProper design of contact points on racks and hangers钩子，架子上接触点有着适当的设计Effective hanger and rack burn-off or stripping procedures,Powder Charging 粉末充电,H/V CONTROLLER,EARTH GROUND,CABLE,110 VAC,GUN,CONVEYOR,PART,HANGER,LOAD The Electrostatic Charge On The Powder Particles,ELECTRODE,The “ELECTROSTATIC CIRCUIT”,CURRENT FLOW,CURRENT FLOW,Powder Charging Definition,“CHARGED POWDER”Adequate electrostatic charge on the powder particles 适当地对粉末颗粒施以静电Sufficient volume of charged powder particles 足够的静电颗粒,Powder Charging Potential Problems,Coating Efficiency 涂层效率Poor transfer 输送缓慢Slow film build 涂层形成缓慢Light coverage overall 整体涂层 Difficulty coating Faraday Cage areasExcessive powder usage in spray-to-waste situations 过多的粉末,Powder Charging Monitor and Control,MonitorReduced E.S. wrapPoor transfer efficiency, slow film build and light coverageDifficulty coating Faraday Cage areasMeasure E.S. output of the guns regularly 检查出粉量ControlRepair or replace guns, cables and power supplies as necessary 必要时修理，更换枪，线路，和电源,FARADAY CAGE PHENOMENON,