Air Supersonic Turnkey

The HA-3000 supersonic flame spraying system developed by Zhengzhou Lijia is a new type of HVAF system. It uses compressed air and propane fuel to generate high-speed airflow, igniting it to heat the powder, accelerating the powder to over 700 m/s to impact the substrate, forming a low oxygen content, high density coating, which has a low impact on the thermal degradation of the sprayed material, and the coating exhibits excellent wear resistance and corrosion resistance.

This system was carefully developed by several engineers in the company based on the introduction, absorption, and digestion of internationally advanced technology. The equipment is operated via a touchscreen and features internationally leading process settings, spraying monitoring, and other functions, with complete operation, display, and alarm functions that conform to user habits, making it simple to use and of stable quality.

The HA-3000 system has many advantages:
1. It uses a touchscreen and a fully closed-loop automatic control structure, with gas controlled by imported pressure sensors from the USA and pressure regulators from Japan, allowing real-time pressure monitoring and automatic achievement of set values.
2. Using propane as fuel and air as an oxidizer, it is the safest combustion mode among market gas models.
3. The spray gun is designed based on the principle of rocket generators, with flame flow speeds exceeding 2000 m/s, high output power, and stepless adjustment.
4. The spray gun delivers powder axially to the center, allowing better melting of the powder and uniform distribution in the flame, improving coverage efficiency and coating quality.
5. It has a process formula storage and retrieval function, allowing for the addition, modification, and saving of parameters.
6. The system features a fully closed-loop, modular design for fuel, with high-performance PLC control, ensuring safe and easy operation.
7. The coating has high bonding strength, with porosity ≤ 1%, reaching internationally leading levels, and high spraying efficiency (up to 30 kg of powder delivered per hour).
8. It can be connected to the LA2 series spray guns.

Sound insulation spraying room

• Noise control

Set up a spray painted soundproof room. According to the principle of acoustics, the noise generated during spraying is controlled inside the room to prevent outdoor workers from being contaminated by noise and damaging the nervous system. The sound insulation room is composed of four angle steel columns, wall panels, top plates, upper and lower grooves, corner wrapping, and special sealing components for gaps, which not only ensure the sound insulation and overall rigidity of the room, but also pay special attention to the appearance and thoughtful detail treatment. Each completed project has received unanimous praise and praise from domestic and foreign users.

• Soundproof board

The structure of the panel group is as follows: the outer wall is made of 2.0mm thick white spray coated steel plate, filled with a damping layer, asbestos board, double-layer 100Kg/m3 high solubility weight sound-absorbing cotton, waterproof and dustproof sound-absorbing film, and the inner wall is made of metal porous sound-absorbing plate (with a punching rate of 25%). The soundproof panel is supported by welded steel frames arranged in a zigzag pattern, which are then pressed into shape. The soundproof panel is smooth and scratch resistant both inside and outside, with a bright and beautiful surface.

The standard W of the soundproof board is 970mm, the thickness is 210mm, and the L can be determined by the required H of the room. The sound insulation board has undergone noise testing (with no gypsum board placed on the tested sample), and the air sound insulation in the frequency range of 125-4000Hz is 42dB (A). At present, the soundproof board added with PDF fiberglass board has a greater sound insulation capacity in practical applications. The soundproof board is assembled with specially made and thickened steel plates, and the gaps are filled with glue to prevent sound leakage;

Multi-layer soundproof panel structure

• Soundproof door

We have designed the soundproof door for the entry and exit of the workpiece as a stepped sealing structure, which achieves noise reduction through a stepped structure. At the same time, a sealing strip is used on the door for sealing. When the door is opened and closed, the sealing strip plays a sealing role, reducing sound leakage.

• Soundproof window

Observation windows are installed on soundproof wall panels and doors, using transparent tempered glass. The number of observation windows on soundproof panels is specified by the owner. Air intake and exhaust muffler

To meet the needs of indoor dust extraction and ventilation, the spraying room is equipped with inlet and exhaust silencers to maintain a balanced negative pressure inside the room. As the airflow passes through the muffler, indoor noise is absorbed by the muffler. Prevent noise from spreading outward through the air inlet.

• Adjustable suction box

There is a suction box installed in the room that can adjust the air volume and regional wind direction. The L of the suction box is 2 m and it is divided into two areas. The left and right sides can be adjusted with louvers for air volume and wind speed adjustment.

Adjustable suction box

• Sand-blasting room

It is used to isolate the noise and dust generated during the sandblasting operation of the workpiece. It has: beautiful and atmospheric purification board facade, steel structure strengthening structure, anti-wear rubber lining board, observation window, double door, single opening work door, dustproof lighting, dust suction port and fresh air intake port.

Sand blasting system

Turntable

Zhengzhou Lijia ZC series horizontal turntable is a special equipment designed and manufactured for thermal spraying shafts, rollers and ball valve parts, shaped like a lathe, and its function is mainly to load and rotate the parts transversely during the spraying process, so it is called "horizontal turntable". This series of products are customized according to the different loads of the clamped workpiece, and the mechanical structure of the horizontal turntable is reasonably designed, which not only effectively blocks the impact of dust on the transmission part, but also ensures the durability of the equipment due to the use of high-quality materials and component assembly.

Figure--Horizontal turntable (with battery automatic walking function)

• 6+1 axis robotic axis  (2 sets)

• Features of the six-axis manipulator:

1. High-strength arm and six-axis servo technology effectively improve the speed of each axis and acceleration and deceleration performance.

2. An independent drive mechanism is designed in the wrist shaft to achieve a delicate and compact mechanical arm with built-in cables. The operation of the robot in the narrow space and the high-density environment can be effectively realized.

3. The front cantilever to achieve excellent cable integration capabilities, to keep the hand cable path smooth, easier maintenance. Hand cable inserts are also available as an option.

4. The front end of the manipulator has been reformed, the gun frame is added, and the spray gun can be quickly added.

• Pulse ventilation and dust removal system

In order to make the free dust in the spraying room can be captured and purified, spraying heat quickly distributed, the spraying room set up a ventilation dust removal system.

Pulse dust removal system

Air compressor system configuration:

Air compressor

• Sand-blasting machine

The main engine of the sandblasting machine is the core unit of the sandblasting system, and the performance of the main engine directly affects whether the sandblasting system can carry out the sandblasting operation normally and efficiently. This sandblasting system adopts the high-efficiency and large-capacity sandblasting machine as the main engine of the system, and the sandblasting machine is a pressure-maintaining working principle, with a sand control valve and a high-speed spray gun for sandblasting operation.   

• Gas supply system

The system provides oxygen gas and nitrogen gas to the equipment, which have undergone airtightness tests and are safe and reliable.

• Centralized control system

This system is a turnkey project that involves a wide range of equipment. Through a centralized control system, customers can easily control various facilities of the spraying system. Can achieve online monitoring, switch of various devices, motion control, and safety interlock control; Helping users achieve efficient spraying operations, ensuring the quality of coatings, while also improving usage efficiency, and ensuring the safety of operators.

Centralized control system

Zhengzhou Lijia HA-3000 air supersonic spraying system turnkey project has a wide range of application fields, mainly including the following aspects:

1.Aerospace field: It can be used for wear-resistant and high-temperature coating spraying of aircraft engine blades, combustion chambers and other parts, improve the corrosion resistance and thermal shock resistance of parts, prolong the service life, and ensure flight safety; It can also be used to strengthen the surface of aerostructures to enhance their strength and durability.

2.Automobile manufacturing field: suitable for the spraying of automobile engine blocks, piston rings, valves and other parts to form anti-friction and wear-resistant coatings, reduce friction loss, and improve engine efficiency and reliability; It can also be used for anti-corrosion coating spraying of automobile body chassis to enhance the corrosion resistance of the body and extend the overall service life of the car.

3.Energy and power: In thermal power, hydropower, nuclear power and other power generation equipment, steam turbine blades, boiler pipes and other components can be sprayed to prevent erosion and corrosion of components, and improve the operation efficiency and stability of equipment; For the blades and towers of wind power equipment, protective coatings can be sprayed to resist the erosion of natural environments such as wind and sand, rain, etc.

4.Machining field: all kinds of molds and tools can be coated to improve the hardness, wear resistance and lubrication of molds and tools, reduce the friction coefficient in the processing process, improve the machining accuracy and surface quality, prolong the service life of molds and tools, and reduce production costs.

5.Petrochemical field: It is used to spray corrosion-resistant and wear-resistant coatings on the inner surface of petroleum pipelines, chemical reactors, pumps and valves to prevent equipment from being corroded and washed out by petroleum and chemical media, reduce the risk of equipment leakage, and ensure production safety and stable operation.

6.Medical device field: It can spray biocompatible coatings on the surface of medical devices such as artificial joints and dental implants to improve the binding force between devices and human tissues, reduce rejection reactions, promote tissue healing, and improve the performance and safety of medical devices.

7.Electronic industry: Functional coatings such as insulation, moisture-proof, and anti-static can be sprayed on the surface of electronic components and circuit boards to protect electronic equipment from the external environment, improve the stability and reliability of electronic equipment, and ensure its normal operation.

Product Operate Guide     

1.Clear requirements: At the start of the project, the team communicates with you to understand the product material, size, output, coating requirements, and survey the site area, layout, electricity, ventilation and other conditions.

2.Site adaptation: According to the site plan, the installation system and supporting facilities are reserved for no less than [X] square meters, ventilation per hour [X] cubic meters, and stable power supply [X] kilowatts.

3. Installation sequence: After the equipment arrives, the engineer installs the host and spray gun according to the drawing, the position error of the parts is ± [X] mm, the levelness of the host is ± [X] degree, and the appropriate accessories are selected to fasten the pipes and lines.

4.Commissioning tips: After installation, the engineer turns on the power supply and sets the parameters of the control cabinet, such as the air supply pressure of the spray gun [X] - [X] MPa, the powder feeding rate [X] - [X] g/min, start the spray gun to check the air flow, send the powder to see the powder deposition, and fine-tune it to the best. 

5.Fault insight: the operator is familiar with the fault performance, the coating is rough or due to powder, powder feeding, and airflow problems; Shutdown and overcurrent alarm, mostly due to electrical or spray gun short circuit, overload; Poor adhesion of coatings involves substrate and parameter issues.

6.Emergency treatment: When the fault occurs, according to the process, the power is cut off before the shutdown and the indicator light is used to judge the fault; Suspend parameter tuning for quality problems; The powder feeding pipe is blocked and blown with compressed air, and the spray gun is faulty and the after-sales service is contacted.

Q: What information do you need to provide in the early stage? 

A: Product material, size, output, coating performance requirements, as well as the situation of infrastructure such as site area, layout, electricity, and ventilation. 

Q: Can employees operate independently after training, or is there guidance? 

A: Most can operate independently, but if there are issues in the initial stage, they can contact after-sales support for guidance via phone or remote assistance.

Q: Can simple faults be resolved by ourselves, or should we wait for after-sales? 

A: Simple faults like powder delivery pipe blockage can be handled independently, but for complex faults such as spray gun or electrical system issues, contact after-sales and do not disassemble it yourself.