An excellent business solution is to paint cars at home. But in order to be able to paint cars, there is little experience and equipment for painting, you also need to have a room in which the painting will be done Vehicle. Organizations that paint cars have long carried out painting work in a chamber with a water curtain. It is no secret that such a device can be made with your own hands, only by making some effort and spending a small amount of money to purchase some equipment. You can buy a ready-made one, but its cost will be very high, and not everyone is ready to invest a large amount. In order to make a device with a water curtain with your own hands, you will also need some knowledge.
What does the camera consist of?
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A spray booth with a water curtain is a closed room that is made of stainless steel and has supply and exhaust ventilation. This ventilation is created using electric motors. The main part of the device is a heating element, which helps heat the room to the required temperature and maintain it during painting work. The chamber also includes lighting, which must be distributed evenly over the entire area and have sufficient luminous flux. It is best to place them not only on the ceiling of the room, but also on the side walls. The device also includes equipment for painting work and other auxiliary tools.
Layout of the painting booth
Knowing what the paint booth consists of, you need to decide on the location where the arrangement will be made, and make a project according to the location of the main structural elements. An excellent location for the construction of the device can be a garage, or build a new extension, which will take more time and, accordingly, finances.
Making a painting booth
Having made the layout, it is necessary to carry out all technical calculations and begin installation work.
First of all, a new room is built or a frame is assembled inside the garage. General dimensions should be: length 10 meters, width 8 meters, height 3.5 meters. The painting booth has the following dimensions: 4 meters wide and 6 meters long.
- Gate installation.
It is best to use insulated gates to avoid suction and loss of warm air; the outside is lined with corrugated sheeting. At the point of contact between the gates, it is insulated with a special adhesive tape. Places with cracks must be foamed with foam. - Floor construction. The base of the floor is made of concrete, inside which a hole is made, and a metal pipe with a diameter of 150 mm is led out onto the street for air outflow. A metal grate is placed on the floor over the entire surface of the room to a height of 15-20 cm.
- Walls. The walls are sheathed with corrugated sheets, and the inside is insulated; sandwich panels can be made.
- Air exchange system. Components: two electric motors and metal pipes with diameters of 100 mm and 150 mm, respectively. An electric motor with a power of 5 kW is used for supply ventilation, and at least 7 kW for exhaust ventilation.
- Ceiling. It is made of corrugated board, with insulation. Ceiling mounted metal carcass for air flow. An electric heater that will supply warm air indoors, installed outdoors.
- Air cleaning. It is carried out using filters and has three-level cleaning.
- Level 1 A frontal water curtain is created, which is carried out by flowing down uniform streams of water;
- Level 2. Cleaning the air inside the device. Promotes filtration and purification of air from paint waste;
- Level 3. Dry filtration. Helps completely clean the air from paint particles and protects the fan from paint sticking.
- Lighting. Mounted LED or fluorescent lamps along the ceiling and walls of the room.
Automatic control and monitoring sensors are also installed over the system of supply and exhaust fans and filters.
After installing everything necessary for the water chamber, painting equipment is installed.
How the work is carried out
An electric heater pumps air from the atmosphere into a confined space in a room. As the air passes through the system, it is purified by filters, each of which provides a specific purification.
The temperature in the room rises due to the work of the heating elements. The painting process begins. Down on the floor, air begins to be sucked out of the chamber using an exhaust fan. Water curtains are installed in front of the main line, which help retain paint particles. Here the air goes through all three levels of purification, if such are pre-installed. Cameras with a water curtain and factory production work on the same principle.
Positive aspects of a DIY device
- Free system planning.
- Big savings.
- Possibility to save on all components.
- Ability to use the main parts of the structure.
Disadvantages of the device
- There may be inaccuracies in calculations or imperfections in the installation of the device.
- It is not possible to completely automate the process, since the elements of the device consist of separate parts.
- There are no guarantees for the performance of such a device.
Price
The cost of constructing a chamber with a water curtain with your own hands may take long time, but its cost will be about $4,000. You can buy a factory one for $20,000 or more. To start a business, the best option There is a construction with your own hands, which is much more profitable for a start-up business.
Basic equipment:
- Prefabricated body and settling tank made of galvanized steel with a large number of longitudinal, transverse and vertical stiffeners.
- Double cascade of water curtains
The front curtains of both cascades (those through which water flows) have a quick-release design. This not only provides full access to the inside of the chamber for maintenance, but also makes it technically possible to narrow the gap between the bottom edge
curtains and water in the bathroom below. For the upper cascade, this is the bath of the lower cascade, and for the lower cascade, this is the settling bath.
This design has a number of advantages, the main ones being:
- due to the absence of long sections of free fall of water, the formation of splashes in both the upper and lower parts of the working area is eliminated;
- water rushing off the lower edge of the water curtain creates a dense flow that additionally cleans the air of suspended particles, which eliminates the need to install water sprinklers;
- the speed of air flow after entering the painting booth is reduced by 4-5 times, which allows suspensions to settle into the settling bath, increasing the degree of purification of the emitted air.
- The location of the bath for placing the pump is universal (to the left or to the right of the chamber). In this way, the service side can be selected during installation.
- The location of the service area outside the chamber allows for visual control of operation and avoids external contamination of the pump, which leads to its overheating and premature failure.
- Valves located outside make it easy to regulate the water flow in the water curtains, as well as to quickly drain water from the chamber using a standard pump during its scheduled maintenance.
- Stainless steel pump,pumps clots of coating sludge with a diameter of up to 35 mm, as well as a built-in overheating protection system.
- A system of circulation water lines, including a water circulation valve, an automatic water drain valve, all necessary hoses, passage units, flanges, clamps and other installation materials
- Mounting kit including bolts, nuts, washers, sealant, etc. according to camera configuration
- Packaging for transportation by road
- Passport and instruction manual
- CD with diagram and photo illustrations of the assembly
Additional options:
- Exhaust fan
- Labyrinth of barrier panels
- Control panel for placement outside the hazardous area
- Control panel in a plastic case
- Explosion-proof luminaires with lamps (2x36 W)
- Increasing the depth of the working area by 0.5 meters (roof panel and 2 side panels)
- Water floor
- Supply fan and set of filters for an “economy project”
- Placing the pump inside the chamber (to reduce the overall width of the chamber)
- The front curtains of both cascades are made of stainless steel instead of galvanized steel
Organizations that paint cars often use cameras with a water curtain. They represent one of the most advanced options, allowing you to create a coating for large-sized products, such as car bodies, their parts, furniture, etc. Their design as a whole is a stainless steel room with supply and exhaust ventilation, which operates on electric motors. The main working part is the heating element, which heats the box to the required temperature and maintains the heat level during work. Lighting also plays an important role, because it should create an even, intense light space without shadows.
Painting booths
What is the difference between painting chambers with a water curtain, and what is their advantage over traditional devices? Under specially created conditions, a mist of paint is formed, which then settles on the surface. But if in conventional options there is a danger that toxic substances or vapors will still leave the room, then in such devices they are retained with the help of water. In addition, the liquid binds volatile essential substances that are present in such a chamber. Of course, this type of filtration is not yet a guarantee of the final elimination of harmful emissions, but it is still a significant reduction in their number.
Outdoor spray booths
There are also painting booths that operate in a closed air flow cycle; in this case, the air moves in a circle and is returned for reuse. And if it is not very well cleaned before starting a new process, then small droplets of dye will enter the room, which will polymerize. This can deteriorate the properties of the enamel, however, the curtain of water traps these residues.
Painting booths with a water curtain: stages of operation
As already stated, this type cameras is similar to traditional devices. Air comes from the atmosphere into a confined space, and the suction is based on the operation of a fan. The air flow passes through many filters, and each of them performs a specific purification process. The quality of processing depends on the size of the holes in the filter material.
When the dyeing process begins, the air is heated using special heat elements. The temperature in the chamber increases. There are exit holes at the bottom of the device. They may be in different places. Through them, the air flow leaves the workspace, which is done with the help of fans. A water curtain is placed directly in front of the line, which removes the exhaust atmosphere from the chamber. Thus, before leaving the box, the air crosses a thin wall of water that traps dense particles - they settle as a suspension.
Actually, this design is a water filter. There are other possibilities when the air for cleaning is passed not through a wall of jets, but through a special container in which water is poured. In this case, dense particles accumulate at the bottom, which then form condensation. To ensure that all harmful substances precipitate faster, a reagent is added to such a container, which speeds up the processing processes.
The most advanced painting booths of this type have several levels of cleaning. The first of them is the passage of air through a continuous water curtain. In this case, a wall of water is created, and its speed of movement is always uniform. The second level provides better cleaning air masses from dye particles (internal cleaning). This is where complete liberation from impurities occurs. The third level is the completion of purification processes, which can be achieved through carbon-based filters or another type of dry-based filtration. At this stage, all paint particles disappear. Consequently, the fan will be protected from dye residues.
These are the main stages of operation of such cameras. This air purification system in spray booths with a water curtain helps reduce toxicity to a minimum, and therefore the use of this type of equipment is considered mandatory in those industries where the use of liquid paints and varnishes is required.
Paint booths with a water curtain are perhaps the most advanced design option for painting systems. Equipment of this type is used for painting large-sized products, including car bodies, or individual body parts, various furniture structures, etc.
Any spray booth is based on the fact that air moves inside the system, which carries with it mist from the paint, which evenly settles on the surface to be painted. And if in a traditional paint booth there is a possibility that harmful substances or paint particles will come out of the chamber, then in chambers with a water curtain the paint particles are retained by water. Moreover, water molecules bind molecules of harmful volatile substances, which are found in excess inside the paint booth.
Thus, the release of harmful substances into the surrounding atmosphere is sharply reduced. But it cannot be said that a water curtain provides a complete guarantee that the emission of harmful substances into the atmosphere is completely excluded.
In addition, there are chambers that operate in a partially closed air movement cycle. In this situation, it turns out that the air that has already been in the chamber enters it in the next cycle. And if it is not sufficiently cleaned before reuse, paint particles that have already begun to polymerize will enter the chamber along with the air. And this can significantly affect the final quality of the coating. And the water curtain, which can have a different design, traps paint residues.
How do water curtain spray booths work?
The principle of operation of a waterproof spray booth is very similar to traditional spray booths. Air is sucked from the atmosphere into the enclosed space of the chamber. Air is sucked in due to the operation of the fan. The air enters through a system of filters, each of which provides a certain level of purification. The smaller the holes in the filter material, the finer the cleaning.
During the painting stage, the air heats up when passing through special heating elements. The temperature in the chamber begins to rise.
There are exit holes at the bottom of the spray booth. Moreover, they can be located in different places in the chamber (depending on the hole). Through these openings, air leaves the enclosed space of the chamber due to the operation of suction fans. And it is in front of the main line, which works to remove air from the chamber, that water curtains are installed, which can also have a different design. Essentially, the air mixed with paint that comes out of the chamber passes through a thin wall of water. And all suspended particles remain in this water.
The water curtain can be considered as a water filter. Although there are options when the air does not pass through a wall of water, but through a special container with water. In this case, solid particles gradually accumulate at the bottom of the container, which then fall out as sediment to the bottom of the container.
In order to activate the process of binding harmful substances in the air with water, a special reagent is added to the container, which is a catalyst for chemical reaction cleaning.
The most advanced water curtain spray booths support multiple levels of air purification. The first level is when the air passes through the frontal water curtain. The water flows in a continuous wall, and the speed of water movement is the same all the time. Water covers the entire surface of the front part of the curtain.
At the second level, a more subtle cleaning of the air from paint particles occurs. This is the so-called internal cleaning level. According to experts, it is at this stage that the most complete purification of the air from paint impurities occurs.
The finest cleaning occurs on final filters, which can be made on the basis of hydrocarbon technologies ( carbon filters) or dry filters that are made on a different basis. Here literally all remaining paint particles are removed. This protects the fan blades from paint residues sticking to them.
How does a water curtain sprayer work?
The task of any paint booth is to ensure that the air in the spray zone is cleared of paint mist and solvent vapors.
Water spray booths have several levels of air purification from paint.
Level 1- frontal water curtain - this is the visible part of the spray booth with a water curtain. A stream of water flows down it in a continuous and continuous stream. It must be uniform and completely cover the entire front area (surface) of the curtain.
Level 2 -internal air purification - perhaps the main filtration and purification of air from paint waste is carried out here. Depending on the design of the spray booth and the manufacturer, there are various systems internal air purification.
Level 3 - dry filtration - carries out final cleaning of the air from remaining paint particles and protects the fan blades from paint sticking. Depending on the manufacturer, dry filtration is carried out in Italian painting booths with a water curtain, in Russian painting booths - in others, such as China, there is no filtration at all.
Below are diagrams of the structure of Italian and Russian paint booths:
1) Diagram of a water spray booth ZINCOVELO ZA Italy
2) Video of the painting booth in Italy
3) Scheme of a water spray booth made in Russia
4) Video of the Russia paint booth in operation (built into a clean room, overpressure chamber)
2
The operating principle of a spray booth with a water curtain is as follows.
When spraying the material, a paint mist is formed. The fan, which is installed on the roof of the spray booth, creates a vacuum and draws contaminated air through the opening in the paint booth at the bottom of the front curtain.
Also, particles of paint and dust are deposited on the front front surface, which are captured and carried away in a continuous stream into the bathtub of the paint booth and settle in the water.
Contaminated air, which entered the internal cavity of the painting water chamber with the air flow, is subject to additional cleaning. In Italian painting booths there are several water cascades, in Russian painting booths there is filtration by an irrigation system. The air is purified from spray waste.
Final cleaning - dry filtration installed in front of the fans (or)
Water spray booths can be of various modifications: with a floor, with side walls, without a floor and without walls. The choice of model depends on the painting technology and the product, as well as the requirements for the quality of the coating.
Painting booths perform the function of air extraction and purification.
When creating a painting area, it is very important to ensure the correct microclimate in the spray area (the required temperature regime), as well as the incoming air must be cleaned of dust and dirt, this allows us to achieve excellent conditions for obtaining High Quality coverings.