主要工藝環(huán)節(jié)應(yīng)用

Main process application

前處理工藝

Pre treatment process

脫脂：汽車車身在沖壓和焊接過程中會沾染油污等，涂裝流水線的脫脂環(huán)節(jié)通常采用堿性脫脂劑，通過噴淋或浸泡的方式，去除車身表面的油脂和污垢，為后續(xù)處理提供清潔表面。

Degreasing: During the stamping and welding process, the car body may be contaminated with oil stains. The degreasing process of the painting assembly line usually uses alkaline degreasing agents to remove grease and dirt from the surface of the car body through spraying or soaking, providing a clean surface for subsequent treatment.

磷化：經(jīng)脫脂后的車身進(jìn)入磷化槽，通過化學(xué)反應(yīng)在車身表面形成一層磷化膜，這層膜可以增強(qiáng)涂層與車身的附著力，提高耐腐蝕性，一般采用鋅系磷化工藝較多。

Phosphating: After degreasing, the car body enters the phosphating tank and forms a layer of phosphating film on the surface of the car body through chemical reaction. This film can enhance the adhesion between the coating and the car body, improve corrosion resistance, and generally use zinc based phosphating process.

鈍化：磷化后的鈍化處理可進(jìn)一步提高磷化膜的耐腐蝕性和穩(wěn)定性，通常使用含鉻或無鉻鈍化劑，在車身表面形成一層鈍化保護(hù)膜。

Passivation: Passivation treatment after phosphating can further improve the corrosion resistance and stability of the phosphating film. Usually, chromium containing or chromium free passivators are used to form a passivation protective film on the surface of the vehicle body.

噴漆工藝

Spray painting process

底漆噴涂：汽車車身進(jìn)入噴漆室，首先進(jìn)行底漆噴涂。底漆能夠為車身提供良好的防腐性能，并為面漆提供良好的附著基礎(chǔ)。一般采用電泳涂裝工藝，通過電場作用使涂料粒子均勻地沉積在車身表面，形成均勻的底漆涂層。

Primer spraying: When the car body enters the paint booth, the first step is to spray the primer. Primer can provide good anti-corrosion performance for the vehicle body and provide a good adhesion foundation for the topcoat. Generally, electrophoretic coating technology is used to uniformly deposit coating particles on the surface of the vehicle body through the action of an electric field, forming a uniform primer coating.

中涂噴涂：中涂漆主要起到填充和平整表面的作用，提高車身表面的平整度和光滑度，同時增強(qiáng)涂層的耐水性和耐石擊性。中涂漆通常采用自動噴涂設(shè)備，如機(jī)器人噴涂，以保證噴涂的均勻性和質(zhì)量。

Mid coat spraying: Mid coat paint mainly plays a role in filling and leveling the surface, improving the flatness and smoothness of the vehicle surface, while enhancing the water resistance and stone impact resistance of the coating. Automatic spraying equipment, such as robot spraying, is usually used for mid coat painting to ensure uniformity and quality of spraying.

面漆噴涂：面漆是汽車外觀的直接體現(xiàn)，其顏色和光澤度直接影響汽車的美觀度和市場競爭力。面漆噴涂一般采用靜電噴涂技術(shù)，利用靜電吸附原理使涂料更均勻地附著在車身表面，同時可以提高涂料的利用率。根據(jù)汽車的不同需求，面漆可分為素色漆、金屬漆和珠光漆等。

Topcoat spraying: Topcoat is a direct reflection of the appearance of a car, and its color and glossiness directly affect the beauty and market competitiveness of the car. The topcoat spraying generally adopts electrostatic spraying technology, which uses the principle of electrostatic adsorption to make the coating more evenly adhere to the surface of the vehicle, and can also improve the utilization rate of the coating. According to the different needs of automobiles, topcoats can be divided into plain paint, metallic paint, and pearl paint.

干燥固化工藝

Drying and curing process

烘干：每一層涂料噴涂后都需要進(jìn)行烘干處理，以去除涂料中的溶劑和水分，使涂料固化成膜。烘干過程通常在烘干室中進(jìn)行，采用熱風(fēng)循環(huán)或紅外線輻射等加熱方式，嚴(yán)格控制烘干溫度和時間，確保涂層的質(zhì)量和性能。一般底漆烘干溫度在 160 - 180℃，中涂和面漆烘干溫度在 140 - 160℃。

Drying: After each layer of coating is sprayed, it needs to be dried to remove solvents and moisture from the coating, so that the coating can solidify into a film. The drying process is usually carried out in a drying room, using heating methods such as hot air circulation or infrared radiation to strictly control the drying temperature and time, ensuring the quality and performance of the coating. The general drying temperature for primer is 160-180 ℃, while the drying temperature for intermediate and topcoat is 140-160 ℃.

冷卻：烘干后的車身需要進(jìn)行冷卻，使其溫度降至室溫，以便進(jìn)行后續(xù)的操作。冷卻方式一般采用自然冷卻或強(qiáng)制風(fēng)冷，確保車身溫度均勻下降，避免產(chǎn)生熱應(yīng)力和變形。

Cooling: The dried vehicle body needs to be cooled to room temperature for subsequent operations. The cooling method generally adopts natural cooling or forced air cooling to ensure a uniform decrease in body temperature and avoid thermal stress and deformation.

應(yīng)用優(yōu)勢

Application advantages

提高生產(chǎn)效率：涂裝流水線實現(xiàn)了汽車涂裝的自動化和連續(xù)化生產(chǎn)，各個工藝環(huán)節(jié)緊密銜接，大大縮短了汽車涂裝的生產(chǎn)周期，提高了生產(chǎn)效率。例如，一條先進(jìn)的汽車涂裝流水線每小時可完成數(shù)十輛汽車的涂裝作業(yè)。

Improving production efficiency: The painting assembly line has achieved automation and continuous production of automotive painting, with closely connected process links, greatly shortening the production cycle of automotive painting and improving production efficiency. For example, an advanced car painting assembly line can complete the painting operation of dozens of cars per hour.

保證涂裝質(zhì)量：通過精確控制涂裝工藝參數(shù)和采用先進(jìn)的涂裝設(shè)備，涂裝流水線能夠保證汽車涂層的均勻性、平整度和附著力等質(zhì)量指標(biāo)，提高汽車的外觀質(zhì)量和耐腐蝕性。機(jī)器人噴涂和自動輸送系統(tǒng)可以減少人為因素對涂裝質(zhì)量的影響，使每輛車的涂裝質(zhì)量都能達(dá)到較高的標(biāo)準(zhǔn)。

Ensuring coating quality: By precisely controlling coating process parameters and using advanced coating equipment, the coating assembly line can ensure the uniformity, flatness, and adhesion of automotive coatings, improving the appearance quality and corrosion resistance of automobiles. The robot spraying and automatic conveying system can reduce the influence of human factors on the painting quality, so that the painting quality of each vehicle can reach a high standard.

降低生產(chǎn)成本：自動化的涂裝流水線減少了人工操作，降低了人工成本。同時，通過優(yōu)化涂料供應(yīng)系統(tǒng)和回收利用技術(shù)，提高了涂料的利用率，減少了涂料的浪費(fèi)，降低了材料成本。此外，高效的生產(chǎn)和穩(wěn)定的質(zhì)量也有助于降低整體的生產(chǎn)成本。

Reduce production costs: Automated painting assembly lines reduce manual operations and lower labor costs. Meanwhile, by optimizing the coating supply system and recycling technology, the utilization rate of coatings has been improved, waste of coatings has been reduced, and material costs have been lowered. In addition, efficient production and stable quality also contribute to reducing overall production costs.

提升環(huán)保水平：現(xiàn)代涂裝流水線配備了先進(jìn)的廢氣處理、廢水處理和廢渣處理系統(tǒng)，能夠有效減少涂裝過程中污染物的排放，降低對環(huán)境的影響。例如，采用活性炭吸附、催化燃燒等技術(shù)處理噴漆廢氣，使廢氣中的 VOCs 含量達(dá)到環(huán)保排放標(biāo)準(zhǔn)。

Improving environmental protection level: Modern painting assembly lines are equipped with advanced exhaust gas treatment, wastewater treatment, and waste residue treatment systems, which can effectively reduce the emission of pollutants during the painting process and reduce the impact on the environment. For example, technologies such as activated carbon adsorption and catalytic combustion are used to treat paint exhaust gas, so that the VOCs content in the exhaust gas meets environmental emission standards.

發(fā)展趨勢

Development Trends

智能化：隨著人工智能和物聯(lián)網(wǎng)技術(shù)的發(fā)展，涂裝流水線將更加智能化。通過安裝傳感器和監(jiān)控設(shè)備，實現(xiàn)對涂裝過程的實時監(jiān)控和數(shù)據(jù)分析，自動調(diào)整工藝參數(shù)，提高涂裝質(zhì)量和生產(chǎn)效率。同時，智能機(jī)器人將在涂裝流水線中得到更廣泛的應(yīng)用，實現(xiàn)更加復(fù)雜和精細(xì)的涂裝操作。

Intelligence: With the development of artificial intelligence and Internet of Things technology, painting assembly lines will become more intelligent. By installing sensors and monitoring equipment, real-time monitoring and data analysis of the painting process can be achieved, automatic adjustment of process parameters can be made, and painting quality and production efficiency can be improved. At the same time, intelligent robots will be widely used in painting assembly lines to achieve more complex and precise painting operations.

綠色化：環(huán)保要求的不斷提高將推動涂裝流水線向綠色化方向發(fā)展。一方面，將采用更加環(huán)保的涂料，如水性涂料、高固體分涂料和粉末涂料等，減少 VOCs 的排放；另一方面，將進(jìn)一步優(yōu)化廢氣、廢水和廢渣處理技術(shù)，實現(xiàn)污染物的零排放或超低排放。

Greening: The continuous improvement of environmental protection requirements will drive the development of coating assembly lines towards greening. On the one hand, more environmentally friendly coatings such as water-based coatings, high solid coatings, and powder coatings will be used to reduce VOC emissions; On the other hand, further optimization of waste gas, wastewater, and waste residue treatment technologies will be carried out to achieve zero or ultra-low emissions of pollutants.

集成化：未來的涂裝流水線將更加注重與汽車制造其他工藝環(huán)節(jié)的集成化，實現(xiàn)從車身焊接到涂裝再到總裝的無縫銜接，提高整個汽車制造過程的協(xié)同性和效率。同時，涂裝設(shè)備制造商也將提供更加集成化的解決方案，將涂裝設(shè)備、輸送設(shè)備、環(huán)保設(shè)備等進(jìn)行一體化設(shè)計和制造，為汽車制造商提供更加便捷和高效的服務(wù)。

Integration: In the future, the painting assembly line will pay more attention to the integration with other process links in automobile manufacturing, achieving seamless connection from body welding to painting and final assembly, and improving the synergy and efficiency of the entire automobile manufacturing process. At the same time, coating equipment manufacturers will also provide more integrated solutions, integrating the design and manufacturing of coating equipment, conveying equipment, environmental protection equipment, etc., to provide more convenient and efficient services for automobile manufacturers.

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