Plasma Turnkey

The LBP100 plasma spraying equipment is a new type of plasma spraying system. It uses a mass flow controller and a new - generation fiber - controlled inverter power supply as its core configuration. It is also one of the most popular plasma spraying equipment in the world currently. Plasma spraying is a technology for material surface strengthening and surface modification, which can endow the substrate surface with properties such as wear resistance, corrosion resistance, high - temperature oxidation resistance, electrical insulation, heat insulation, radiation protection, anti - friction, and sealing. The basic principle of the plasma spraying technology is to use a direct - current - driven plasma arc as the heat source to heat materials such as ceramics, alloys, and metals to a molten or semi - molten state, and then spray them at high speed onto the pre - treated surface of the workpiece to form a firmly adhered surface layer.

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

The turnkey project of Zhengzhou Lijia LBP-100 plasma spraying system has a wide range of applications:

1.Aerospace: used in aircraft engines, such as combustion chambers and turbine blades, thermal barrier coatings can be sprayed to block high temperatures, wear-resistant coatings to resist wear, ensure excellent mechanical properties of components in high temperature and harsh environments, and improve engine thermal efficiency and reliability; After the landing gear and transmission parts are treated with wear-resistant coating, the surface hardness and wear resistance are greatly increased, the loss is reduced, and the take-off and landing flight safety of the aircraft is escorted.

2.Automobile manufacturing: In the engine, pistons, cylinder liners and other parts are coated with ceramic or metal alloys, which improves high temperature resistance, wear resistance and corrosion resistance, reduces friction loss, and makes fuel economy and power performance better; In the automobile exhaust system, the thermal insulation and anti-corrosion coating of the three-way catalytic converter and exhaust pipe can effectively prevent heat loss, resist corrosion, and prolong the service life.

3.Energy and power: The heating surface pipes of power station boilers rely on wear-resistant and corrosion-resistant coatings to resist fly ash erosion and high-temperature corrosion to ensure safe and economical operation; The turbine blades and runners are repaired and protected by spraying, the anti-cavitation and anti-wear capabilities are upgraded, and the efficiency and stability of hydropower equipment are improved.

4.Machining: Injection molding, die-casting and other molds form high-hardness and wear-resistant coatings after surface spraying, which makes the demoulding smoother, reduces wear and strain, and improves both life and production efficiency; Worn shaft parts are repaired with plasma spraying to restore dimensional accuracy, and metal or alloy coatings help them get back to the production line and save repair costs.

5.Biomedical: bioactive coatings on the surface of implants such as artificial joints and bone nails, such as hydroxyapatite coating, can improve the compatibility with human tissue, osseointegration ability, promote the growth of bone tissue, and reduce the risk of loose infection; Antibacterial and lubricating coatings for surgical instruments and medical catheters prevent bacterial growth and optimize performance and safety.

6.Electronic information: electronic components such as resistors, capacitors, inductors, surface insulation coatings to enhance insulation, moisture-proof performance, resist external interference, and ensure the stability and reliability of electronic equipment; The conformal coating of the printed circuit board is moisture-proof, mildew-proof, and salt-spray-proof, which improves the electrical performance and service life to ensure the normal operation of electronic equipment in harsh environments.

Product Operate Guide     

1.Demand communication: At the start of the project, we communicate with you to understand the product, production, coating expectations, site and other information. For example, spraying of auto parts will ask about the material, size, output, power supply and ventilation of the workshop, etc., to lay the foundation for planning.

2.Site preparation: According to the communication results, it is recommended to the site to install the LBP-100 system and set aside at least [X] square meters, and the site ventilation should be [X] cubic meters per hour, and the power supply should be stable to meet the demand of [X] kilowatts. 

3.Installation process: the equipment to the site, the engineer according to the layout of the main machine, spray gun and other components, the positioning error of ± [X] mm, the levelness of the host ± [X] degrees, fastened with bolts, the powder feeding pipeline should be well sealed, and the PTFE sealing tape is used to prevent leakage.

4.Debugging points: After installation and commissioning, first turn on the power supply and set the electrical parameters of the control cabinet, such as plasma current [X] - [X] amperes, voltage [X] - [X] volts, start the spray gun to see the flame flow, it should be blue and white, send powder to check the powder dispersion and melting, and fine-tune the parameters to the best.

5. Identification of common faults: Operators are familiar with the fault manifestations, such as rough coatings that may be due to powder, powder feeding, or flame flow problems; Shutdown and overcurrent alarm, possible electrical short circuit, etc.; The poor adhesion of the coating involves the problem of substrate and parameters, and measures are taken accordingly.

6.Emergency measures: Operate according to the process when the fault occurs, cut off the power before shutting down, and judge the fault by looking at the indicator light of the control cabinet; Suspend the adjustment of parameters for coating problems; Simple faults such as blocked powder feeding pipes are blown with compressed air, and complex faults are contacted after sales.

Q: What details do you have to supply at the commencement stage?

A: The material of the product, its dimensions, production volume, coating performance prerequisites, along with the particulars of infrastructure like the site area, layout, power supply, and ventilation conditions.

Q: Will the employees be capable of operating autonomously post-training, or will there be any follow-up guidance?

A: Generally, they can function independently. However, should any problems crop up during the initial period, they can reach out to the after-sales service for counsel either over the phone or through remote assistance.

Q: Can we take care of straightforward malfunctions on our own, or must we await the arrival of the after-sales team?

A: Minor glitches such as a clogged powder feeding pipe can be sorted out by ourselves. But in the case of intricate faults involving the spray gun or electrical system, get in touch with the after-sales and refrain from dismantling it unaided.