电泳培训资料.ppt

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1、PPG Confidential Material-E-Coat,1,PPG 电泳漆基础知识,PPG Confidential Material-E-Coat,2,使用电泳漆的原因?,质量-提高防腐和抗石击性能自动化-提高生产率不规则形状工件可操作性环保/安全水性涂料 可挥发溶剂非常低无火灾隐患(80%为水),膜厚均匀-泳透力提高漆膜外观-无流挂95%以上材料利用率单位面积低用量,PPG Confidential Material-E-Coat,3,电泳漆的局限性,-环氧链在紫外线照射下裂解-外表面要求涂漆,-特定漆膜颜色-要求占地面积-高初始投资,PPG Confidential Mater

2、ial-E-Coat,4,什么是电泳漆?,PPG Confidential Material-E-Coat,5,电泳产品和工艺阴极电泳漆,一种水性聚合物-酸极化 一种颜料浆 包含防腐颜料(为特定树脂所“包裹”),包含 多种溶剂 水溶性 包含DI水或RO水,PPG Confidential Material-E-Coat,6,一加伦电泳槽液,PPG Confidential Material-E-Coat,7,树脂,PPG Confidential Material-E-Coat,8,典型环氧树脂分子结构,环氧树脂形成电泳漆膜主框架,并提供:漆膜硬度,柔性,附着力;湿膜电阻,包裹颜料等性能.,P

3、PG Confidential Material-E-Coat,9,典型树脂混合,主树脂缩孔控制树脂流平控制树脂增塑剂溶剂,80-85%6-10%0-5%2-5%0-2%,PPG Confidential Material-E-Coat,10,成膜原理(阴极树脂),PPG Confidential Material-E-Coat,11,颜料浆,PPG Confidential Material-E-Coat,12,颜料浆组成,PPG Confidential Material-E-Coat,13,颜料组成,Titanium Dioxide 炭黑,DBTO(氧化二丁基锡)硅酸盐,PPG Conf

4、idential Material-E-Coat,14,循环系统的主要作用,搅拌 避免沉积过滤 除去灰粒,制冷 保持温度超滤 提供洗液阳极 保持电导,PPG Confidential Material-E-Coat,15,PPG Confidential Material-E-Coat,16,槽液循环,PPG Confidential Material-E-Coat,17,槽液循环,PPG Confidential Material-E-Coat,18,PPG Confidential Material-E-Coat,19,PPG Confidential Material-E-Coat,20

5、,PPG Confidential Material-E-Coat,21,槽液循环,PPG Confidential Material-E-Coat,22,置换槽,PPG Confidential Material-E-Coat,23,泵,过滤网,过滤器,PPG Confidential Material-E-Coat,24,热交换器,PPG Confidential Material-E-Coat,25,清洗系统,PPG Confidential Material-E-Coat,26,闭 环,PPG Confidential Material-E-Coat,27,循环喷淋,PPG Confi

6、dential Material-E-Coat,28,浸 洗,PPG Confidential Material-E-Coat,29,清洗系统,PPG Confidential Material-E-Coat,30,超滤系统主要作用,提供闭环清洗超滤液提供滤出水溶性污染物的方法,PPG Confidential Material-E-Coat,31,超滤膜功能,提取水及小分子保留大分子物质(树脂和颜料),PPG Confidential Material-E-Coat,32,超 滤 系 统,PPG Confidential Material-E-Coat,33,阳 极 系 统,PPG Conf

7、idential Material-E-Coat,34,阳 极 盒,PPG Confidential Material-E-Coat,35,板式阳极结构,PPG Confidential Material-E-Coat,36,阳极系统,PPG Confidential Material-E-Coat,37,供电系统,PPG Confidential Material-E-Coat,38,电泳基理,PPG Confidential Material-E-Coat,39,供 电 系 统,PPG Confidential Material-E-Coat,40,带 电 入 槽,PPG Confiden

8、tial Material-E-Coat,41,顶部阳极,PPG Confidential Material-E-Coat,42,泳 透 力,电泳漆在电场力的作用下到达复杂金属凹陷区域深处的实际效果,PPG Confidential Material-E-Coat,43,夹板泳透力,PPG Confidential Material-E-Coat,44,方箱泳透力,PPG Confidential Material-E-Coat,45,影响泳透力的因素,槽液电导 施工电压 槽液温度,槽液 P/B 通电时间,PPG Confidential Material-E-Coat,46,影响泳透力的因素

9、施工电压,PPG Confidential Material-E-Coat,47,影响泳透力的因素槽液电导,PPG Confidential Material-E-Coat,48,影响泳透力的因素槽液温度,PPG Confidential Material-E-Coat,49,影响泳透力的因素P/B,PPG Confidential Material-E-Coat,50,影响泳透力的因素通电时间,PPG Confidential Material-E-Coat,51,变化槽液电导提高槽液电导降低施工电压升高施工电压降低槽液温度升高槽液温度降低通电时间增加通电时间减少槽液固含增加槽液固含减少湿膜

10、电阻提高湿膜电阻降低槽液P/B 提高槽液P/B 降低,泳透力+-+-+-+-+-+-,外表面膜厚+-+-+-+-+-+-+,影响泳透力的因素,PPG Confidential Material-E-Coat,52,电 泳 烤 炉,PPG Confidential Material-E-Coat,53,基本设计,在烤炉入口1/3 处辐射墙其余 2/3 长度为对流保温段燃气 直燃式或间接式,5-8 分钟升温区20%-35%新鲜空气混合,PPG Confidential Material-E-Coat,54,漆膜烘烤要求,20 分钟 177C(金属),PPG Confidential Materia

11、l-E-Coat,55,PPG Confidential Material-E-Coat,56,常见缺陷,流挂水斑脏粒,缩孔重金属区欠烘烤-门柱-铰链-脚踏板 过烘烤,PPG Confidential Material-E-Coat,57,水 斑,不良导水出槽喷淋升温斜率,PPG Confidential Material-E-Coat,58,脏粒,从车身带入来自车身吊具输送链接油盘,槽液循环不良槽液过滤不充分来自烤炉环境空气,PPG Confidential Material-E-Coat,59,缩 孔,折边油输送链润滑油/脂低 P/B不兼容冲压油,PPG Confidential Mate

12、rial-E-Coat,60,PPG Confidential Material-E-Coat,61,PPG Confidential Material-E-Coat,62,PPG Confidential Material-E-Coat,63,PPG Confidential Material-E-Coat,64,PPG Confidential Material-E-Coat,65,问题解决,外观,PPG Confidential Material-E-Coat,66,问题解决,外观,PPG Confidential Material-E-Coat,67,问题解决,缩孔,PPG Confi

13、dential Material-E-Coat,68,问题解决,缩孔,PPG Confidential Material-E-Coat,69,问题解决,缩孔,PPG Confidential Material-E-Coat,70,问题解决,缩孔,PPG Confidential Material-E-Coat,71,问题解决,条纹,PPG Confidential Material-E-Coat,72,问题解决,条纹,PPG Confidential Material-E-Coat,73,电泳系统质量保证,现场取样SPC图表,检测实验结果反馈,PPG Confidential Material

14、-E-Coat,74,分析实验,BATHPANELS(83F-275V)PANELS(93F)RECIRC RINSEANOLYE,SOLIDSpHACID/BASE MEQCONDUCTIVITYPERCENT PIGMENTSOLVENT ANALYSISBACTERIAFILTER 200 MESHACID LEVELS(LACTIC)FILMTHROWPOWERAPPEARANCEAPPEARANCEPATCHY ROUGHNESSCRATERL-panelH-panelpHBACTERIACONDUCTIVITYpH,XXXXXXXXXXXXXXXXXXXXX,XXXXXXXX,PP

15、G LAB,CUSTOMERFACILITY,PPG Confidential Material-E-Coat,75,电泳漆操作规范,PPG Confidential Material-E-Coat,76,电泳前 需要,避免预处理皮膜外表面与外来材料接触,例如水,油滴,灰粒,手印,等.指导操作工从内表面打开车门.为所有操作人员提供手套.保证压缩空气无油干燥避免将水或者其他异物吹到车身外表面.避免缓存磷化车身,否则必须将车身从新磷化清洗或者用防水纸后塑料遮盖车身.确保小件安全稳固正确地付与车身之上.确保车身在进入电泳系统之前不带有任何异物,例如水,油滴,胶,溶剂,焊渣等.取保磷化车身外观均一,没

16、有蓝膜,条印,水斑等.确保车门掐具完好.,PPG Confidential Material-E-Coat,77,电泳前 不要,不得裸手触车.不得在前处理和电泳之间安排其他操作.不得打磨,擦刮磷化车身.槽液及阳极液液位不得低于最低标准.超滤流量不得过小.系统过滤不正常时超滤系统不得操作.过滤袋压差不得超过12 PSI.避免阳极液滞留时间过长.车身在槽液中停止时间不得过长.不得使过多工件掉入电泳槽.电泳/清洗系统中不得有过多泡沫.,PPG Confidential Material-E-Coat,78,电泳 需要,每班需要安排全职电泳操作工,电泳操作工至少需要提前半小时开始工作,同时允许提前半小

17、时下班.专人控制电泳参数.槽液分析实验设备必须完备.提供操作工记录报告单.建立工艺要求/问题解决档案.建立维修监控跟踪程序.确保备用电泳操作工和工程师.确保槽液/阳极液位得到监控.确保超滤液流量.确保正确槽液搅拌并且不产生泡沫.确保溢流槽起到驱除泡沫的作用.,PPG Confidential Material-E-Coat,79,电泳 需要,确保制冷系统正常工作.确保正常加料.确保记录参数正常.确保维修工作快速完成并记录.确保电泳系统员工培训.建立紧急事故临时措施.确保阳极液/阳极板得到定期检查.,PPG Confidential Material-E-Coat,80,电泳后 需要,确保喷嘴通畅,准确.合理安放车身工件,减少溢出.指导操作工从内表面打开车门.确保循环冲洗流量均衡分配.确保炉温正常.确保车身在烘烤后得到检查,如外观,固化,灰粒等.,PPG Confidential Material-E-Coat,81,电泳后 不要,不得裸手触车.电泳车身不得在冲洗工序停留过久.不得使过多工件掉入电泳冲洗槽/烤炉.避免过烘烤或欠烘烤.,