Ultra-large industrial welding dust collection system with 960m2 filtering area
During operation, harmful fumes enter the purification system through the suction pipe. The filtration material near the air inlet within the purification system is stainless steel mesh sintered with PTFE membrane which is a patented product of our company. This filter can intercept large particles of spark and flammable substances and make them fall into the dust collector below, which greatly elongate the filter cartridge’s life span.
After first filtration, fine dusts’ moving speed are slowed down, the deflector ramify the air flow to make a even air distribution into the main filter cartridge. World's leading PTFE membrane micro-filtration technology is adopted on this product, and the filtration efficiency (0.1μm) reaches 99.9%, meanwhile maintains a high air flow. The dusts that are filtered out accumulate on the surface of filter cartridge continuously, this is monitored by differential pressure sensor, when the air flow resistance reach a certain degree, namely air flow is affected, the control system automatically open solenoid valves in turn to implement a thorough reverse blow cleaning, thus guarantee a steady air flow. The blown-off dusts fall into dust collector.
Central fume filtration system advantages
Reverse blow cleaning
Rotary dust blowing device is inserted inside the filter cartridge and very close to the cartridge’s inner wall. When the solenoid valve opens, compressed air rush into two pipes drilled with nozzles, implementing rotary blowing to clean every part of the filter cartridge. Compared with externally placed blowing nozzles, rotary dust blowing nozzles’ blow force is even on every part of the cartridge, and have a thorough cleaning to avoid big noise and damage to the cartridge caused by instant huge blow impact of the externally placed blowing method.
Dusts fall directly into the dust collector below after treated by central fume extractor. Kaisen central fume extractor adopts pneumatic or mechanical lifting. Stop the machine to remove dusts regularly, open pneumatic control valve or wind the mechanical handle, dust collector will fall slowly to carry or pull it outside to dump the dusts. If the machine can’t stop, a flash board can be inserted on the dust collector, to avoid dust escape while removing dusts. To prevent dusts secondary pollution, Kaisen dust collector is complete with flame-retardant garage bag, to make dust removing easier.
The central fume purification system is controlled by PLC control system. All of operations control and information display are on the control panel with control button and display screen, the operation screen is humanization design and the operating is very convenient.
Our engineers can set the running program according to the requirement of different working conditions, for instance the automatically cleaning ash times after starting and stopping the equipment. Setting up the reverse blow cleaning’s technical parameters according to the on-site air environment, fume & dust characters and compressed air supplying.
The controlling system implements real time monitoring and analyzes on a number of important parameters of the equipment in operation, and show them on the display screen. It has automatically self-diagnosis function to show the equipment’s abnormal and error conditions in operation. These functions can make the equipment in good working condition and extend the usage life of the equipment.
Automatic frequency converter
As an optional function, automatically frequency converter can be configured to the central fume purification system.
Through automatic frequency converter, the purification system can adjust fan’s speed depending on actual air flow needs, thus it will reduce electrical energy consumption.
Built-in pressure sensor can sensitively monitor the air flow needs of any of the multiple fume inlets connected to the central purification system. When any fume inlet is closed or opened, the system will reduce or speed up the fan speed automatically to meet different air flow needs.
Frequency converter’s functions: always provide adequate but not surplus air flow, thus reduce both energy consumption and filter element’s wear and tear, and elongate filter element’s life span. Therefore, the investment on frequency converter will reduce energy consumption & save costs in the long run.
Surface filtration precision
The functionality of an extractor lies in the filter cartridge’s material, Kaisen has been dedicating to upgrading filter cartridge.
Kaisen filter element is specially developed for the purification of fume and tiny particles generated in welding and cutting, which solved this industry’s problem of low filtration precision and filter element’s blocking. Kaisen filter cartridge uses polyester fibers (glass fiber) material, and with a special heat process the outer surface of the cartridge is covered with a layer of PTFE (polytetrafluorethylene) membrane. The filter cartridge’s interior wall is thin and firm, the surface membrane has very even pores, and form a network of pores’ of diameter less than 0.1μm.
In order to increase filtration area, all of filters are folded in “v” shape, the folding angle is sharp, so no dusts will be retained in the “V” shaped folds when the vertically placed filter cartridge is blow-cleaned. Dusts directly fall into the dust collector below and won’t cause interactive pollution.
Split type central dust collector with large airflow is not suitable for the collector integration of design due to the fan and moter measurement is larger.Therefroe we use the design of split type. Seperated the fan and motor sound proof box with silencer makes the noise decline greatly. Inside the dust collector adopts multiple fire-proof steps,to make sure that it is more safe and reliable in the processing of operating.
Split Type Central Control system implements real-time monitoring and analysis on a number of important parameter of equipments in the operation and show them in the display, and it has self- diagnosis function, showing abnormal and error conditions in the operation of the equipment automatically.The central dust & fume purification system' s performance is controlled by PLC controlling system.
Split Type Central fume&dust purifier is a series product researched, developed and designed by
the company based on the requirements of different site conditions.The structure of split type units is designed to large and reasonable. A complete series of specifications has been developed to meet the on-site different work-in-conditions, whether large-scale welding or grinding shop, or welding
centers, robotic welding production lines, plasma, or laser cutting blanking production lines, you can find suitable product model.
Rotary dust blowing device is inserted inside the filter cartridge, and very close to the cartridge's inner wall.When the solenoid valve opens, compressed air enter into two pipes drilled with nozzles,
implementing rotary blowing to clean every part of the filter cartridge. Compared with externally placed
blowing nozzles, rotary dust blowing "nozzles" blow force is even on every part of the cartridge, and have a thorough cleaning, avoid big noise and damage to the cartridge caused by instant huge blow impact of the externally placed blowing method.
To the position polluted by a little oil mist, the company's special spray powder device not only dilutes oil
mistand prevents the dust from attaching to the filter surface to reduce its service life, but also plays a role in fire prevention.
We can customize to design the device of dust caputuring according to the workpieces size, shape,
welding position,welding craft, welding fume nature, and on-site environment etc integrated factor. Also
we provide the common mass production kinds of suction arm, suction nozzle,suctin welding cap, suction
welding guns etc. Meanwhile, to point some special requirement of work units, we also design the
different size welding house, manual/air/electric suction hood and the other types fume captureing device
1. CE certification is available.
2. It has adjustable air flow function though frequency converter.
3. Application for 40-50 welding units fume disposal, big plasma cutting fume disposal and robot welding
housing fume disposal and so on.
4. Large air flow, automatically cleaning, maintaining easy, preprocessor to intercept the spark, filter
quickly installation design.
5. Good parts make sure the qualilty, for example, Schneider,CHNT electrics, Siemens PLC and montoring
screen, USA gas-pressure switch, Japan Toray filtering material, AKZO Nobel spraying powder etc.
6. Exellent housing and structure design makes sure the machine is durable.
|1||Fan type||centrifugal fan|
|2||Treatment of air flow||96000±100 m3/h|
|3||Motor power||132 kW|
|4||Power supply||3×380 or 415V/50Hz|
|6||Number of cartridge filters||48 pieces|
|7||Filter medium||PTFE coated filter element|
|9||Solenoid valve||48 pieces|
|10||Compressed air||5～6 bar|
|11||Ash hopper volume||225L|
|13||Weight||3x1980±20kg (Not fan)|