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In the electrostatic powder spraying
process, the pretreatment of the workpiece is a key step that directly affects
the quality and adhesion of the final coating. In order to ensure the
effectiveness and stability of the pretreatment, multiple key parameters need
to be monitored in real time. This not only helps to improve the quality of the
coating, but also reduces resource waste and reduces production costs. This
article will introduce the parameters that need to be monitored in pretreatment
and commonly used sensors.
1.1 Temperature
Monitoring function: Temperature is a key
parameter that affects the speed of chemical reactions and the effect of
treatment. During treatments such as degreasing, phosphating and passivation,
temperature fluctuations will directly affect the efficiency and quality of
chemical reactions.
Common sensors:
• Thermocouple: It can respond quickly to temperature changes and is
suitable for high temperature environments.
• Thermal resistor (RTD): It has high accuracy and stability and is
suitable for occasions where precise temperature control is required.
• Infrared temperature sensor (Infrared Thermometer): Non-contact
measurement, suitable for measuring the temperature of surfaces that are not
easy to touch.
1.2 pH value
Monitoring function: In chemical treatment
processes such as phosphating and pickling, the pH value of the solution has a
significant impact on the process effect. Maintaining an appropriate pH value
can ensure the stability and consistency of the treatment effect.
Common sensors:
• pH electrode: used to continuously monitor the pH value of the
solution, often used in conjunction with a pH meter.
• Digital pH sensor: provides higher accuracy and data processing
capabilities, suitable for complex automation systems.
1.3 Conductivity
Monitoring function: Conductivity reflects
the change in ion concentration in the solution, and can indirectly reflect the
concentration and state of chemicals such as degreasing agents, acids or
phosphating solutions.
Common sensors:
• Conductivity sensor: By measuring the conductivity of the solution,
monitor the change in chemical concentration and adjust the addition amount in
time.
1.4 Liquid level
Monitoring function: In chemical treatment
tanks and cleaning tanks, the stability of the liquid level affects the
treatment effect and the recycling efficiency of the solution. Low liquid level
may cause the solution to fail to cover the surface of the workpiece, while too
high a liquid level may increase overflow and waste.
Commonly used sensors:
• Ultrasonic Level Sensor: Non-contact measurement, suitable for
measuring the level of corrosive liquids.
• Float Level Sensor: Detects level changes by moving the float up
and down, suitable for simple and economical measurement.
• Capacitive Level Sensor: Suitable for a variety of liquids and
complex environments, providing accurate level measurement.
1.5 Flow
Monitoring function: During cleaning,
flushing and chemical treatment, the flow of the solution affects the
processing time and effect. Accurate flow control can optimize resource usage
and avoid excessive or insufficient solution.
Commonly used sensors:
• Turbine Flow Meter: Provides high-precision flow data by measuring
the speed of the fluid passing through the turbine blades.
• Ultrasonic Flow Meter: Uses the propagation speed of sound waves in
the liquid to measure the flow, suitable for non-contact measurement.
• Electromagnetic Flow Meter: By measuring the electromotive force of
the conductive fluid in the magnetic field, it is suitable for measuring the
flow of a variety of liquids.
2.1 Data acquisition and analysis
The data of various parameters are
collected in real time through sensors, and the data is transmitted to the
control system for analysis and processing. Modern monitoring systems usually
integrate artificial intelligence and big data analysis technology, which can
realize predictive adjustment of parameters and abnormal warning.
2.2 Automated control system
Combining monitoring data with automated
control system can realize precise control of pretreatment process. For
example, the system can automatically adjust the heating device according to
the data of temperature sensor, or adjust the amount of acid and alkali
solution added according to the data of pH sensor.
2.3 Remote monitoring and maintenance
Through network connection, the monitoring
system can realize remote monitoring and data access. This enables factory
managers and technicians to understand the production status at any time,
perform maintenance and adjustments in time, and reduce downtime and production
losses.
In the pretreatment process of
electrostatic powder spraying, accurate monitoring of various parameters is
crucial to ensure treatment quality and process efficiency. By using
appropriate sensors and monitoring systems, enterprises can optimize pretreatment
processes, reduce resource waste, and improve product quality and production
efficiency.
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