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PPGConfidentialMaterial-E-Coat1PPG电泳漆基础知识Mar,2012PPGConfidentialMaterial-E-Coat2使用电泳漆的原因?•质量-提高防腐和抗石击性能•自动化-提高生产率•不规则形状工件可操作性•环保/安全•水性涂料可挥发溶剂非常低•无火灾隐患(80%为水)•膜厚均匀-泳透力•提高漆膜外观-无流挂•95%以上材料利用率•单位面积低用量PPGConfidentialMaterial-E-Coat3电泳漆的局限性-环氧链在紫外线照射下裂解-外表面要求涂漆-特定漆膜颜色-要求占地面积-高初始投资PPGConfidentialMaterial-E-Coat4什么是电泳漆?PPGConfidentialMaterial-E-Coat5电泳产品和工艺阴极电泳漆•一种水性聚合物-酸极化•一种颜料浆–包含防腐颜料(为特定树脂所“包裹”)•包含多种溶剂–水溶性•包含DI水或RO水PPGConfidentialMaterial-E-Coat6一加伦电泳槽液PPGConfidentialMaterial-E-Coat7树脂PPGConfidentialMaterial-E-Coat8典型环氧树脂分子结构环氧树脂形成电泳漆膜主框架,并提供:漆膜硬度,柔性,附着力;湿膜电阻,包裹颜料等性能.PPGConfidentialMaterial-E-Coat9典型树脂混合•主树脂•缩孔控制树脂•流平控制树脂•增塑剂•溶剂•80-85%•6-10%•0-5%•2-5%•0-2%PPGConfidentialMaterial-E-Coat10成膜原理(阴极树脂)(-)cathode(+)anodeHOeOH12H2--2HOH12O+2e22-2cations-anions+OHsolubleinsolubleprecipitatesoncathodeNHNPPGConfidentialMaterial-E-Coat11颜料浆PPGConfidentialMaterial-E-Coat12颜料浆组成PPGConfidentialMaterial-E-Coat13颜料组成•TitaniumDioxide•炭黑•DBTO(氧化二丁基锡)•硅酸盐PPGConfidentialMaterial-E-Coat14循环系统的主要作用•搅拌–避免沉积•过滤–除去灰粒•制冷–保持温度•超滤–提供洗液•阳极–保持电导PPGConfidentialMaterial-E-Coat15PPGConfidentialMaterial-E-Coat16槽液循环PPGConfidentialMaterial-E-Coat17槽液循环PPGConfidentialMaterial-E-Coat18PPGConfidentialMaterial-E-Coat19PPGConfidentialMaterial-E-Coat20PPGConfidentialMaterial-E-Coat21槽液循环PPGConfidentialMaterial-E-Coat22置换槽PPGConfidentialMaterial-E-Coat23泵,过滤网,过滤器PPGConfidentialMaterial-E-Coat24热交换器PPGConfidentialMaterial-E-Coat25清洗系统PPGConfidentialMaterial-E-Coat26闭环PPGConfidentialMaterial-E-Coat27循环喷淋PPGConfidentialMaterial-E-Coat28浸洗PPGConfidentialMaterial-E-Coat29清洗系统PPGConfidentialMaterial-E-Coat30超滤系统主要作用•提供闭环清洗超滤液•提供滤出水溶性污染物的方法PPGConfidentialMaterial-E-Coat31超滤膜功能•提取水及小分子•保留大分子物质(树脂和颜料)PPGConfidentialMaterial-E-Coat32超滤系统PPGConfidentialMaterial-E-Coat33阳极系统PPGConfidentialMaterial-E-Coat34阳极盒PPGConfidentialMaterial-E-Coat35板式阳极结构PPGConfidentialMaterial-E-Coat36阳极系统PPGConfidentialMaterial-E-Coat37供电系统PPGConfidentialMaterial-E-Coat38电泳基理PPGConfidentialMaterial-E-Coat39供电系统PPGConfidentialMaterial-E-Coat40带电入槽PPGConfidentialMaterial-E-Coat41顶部阳极PPGConfidentialMaterial-E-Coat42泳透力电泳漆在电场力的作用下到达复杂金属凹陷区域深处的实际效果PPGConfidentialMaterial-E-Coat43夹板泳透力PPGConfidentialMaterial-E-Coat44方箱泳透力PPGConfidentialMaterial-E-Coat45影响泳透力的因素槽液电导•施工电压•槽液温度槽液P/B•通电时间PPGConfidentialMaterial-E-Coat46影响泳透力的因素施工电压PPGConfidentialMaterial-E-Coat47影响泳透力的因素槽液电导PPGConfidentialMaterial-E-Coat48影响泳透力的因素槽液温度PPGConfidentialMaterial-E-Coat49影响泳透力的因素P/BPPGConfidentialMaterial-E-Coat50影响泳透力的因素通电时间PPGConfidentialMaterial-E-Coat51变化槽液电导提高槽液电导降低施工电压升高施工电压降低槽液温度升高槽液温度降低通电时间增加通电时间减少槽液固含增加槽液固含减少湿膜电阻提高湿膜电阻降低槽液P/B提高槽液P/B降低泳透力+-+--++-+-+-+-外表面膜厚+-+-+-+-+--+-+影响泳透力的因素PPGConfidentialMaterial-E-Coat52电泳烤炉PPGConfidentialMaterial-E-Coat53基本设计•在烤炉入口1/3处辐射墙•其余2/3长度为对流保温段•燃气–直燃式或间接式•5-8分钟升温区•20%-35%新鲜空气混合PPGConfidentialMaterial-E-Coat54漆膜烘烤要求20分钟@177°C(金属)PPGConfidentialMaterial-E-Coat55PPGConfidentialMaterial-E-Coat56常见缺陷•流挂•水斑•脏粒•缩孔•重金属区欠烘烤-门柱-铰链-脚踏板过烘烤PPGConfidentialMaterial-E-Coat57水斑•不良导水•出槽喷淋•升温斜率PPGConfidentialMaterial-E-Coat58脏粒•从车身带入•来自车身吊具•输送链•接油盘•槽液循环不良•槽液过滤不充分•来自烤炉•环境空气PPGConfidentialMaterial-E-Coat59缩孔•折边油•输送链润滑油/脂•低P/B•不兼容冲压油PPGConfidentialMaterial-E-Coat60问题解决问题原因解决方案主槽脏粒细菌环境杀菌剂适量补加酸金属颗粒从车身车间带入加强内部清洗加强前处理过滤在前处理电泳系统安放磁棒电火花清洁铜排清洁触头加宽接油盘PPGConfidentialMaterial-E-Coat61问题解决问题原因解决方案主槽脏粒颜料颜料沉积加料前搅拌搅拌前加10%水低槽液转换率加料过快2-3GPM齿轮泵/叶片泵柱塞泵/隔膜泵颜料加料系统加酸专用加料系统加料加料线太长加入循环管路加料槽停止搅拌加料槽为电泳漆/水所稀释置换新鲜颜料PPGConfidentialMaterial-E-Coat62问题解决问题原因解决方案主槽脏粒树脂变性树脂清洁树脂储存槽树脂加料系统加酸专用加料系统加料泡沫泡沫吸附颗粒查明泡沫来源离析碱性D.I水控制水源电导小于25微欧主槽加入浓缩的杀菌剂将杀菌剂加入超滤系统B20加入浓缩的杀菌剂事先稀释机械剪切提高流量更换过滤袋主槽金属去除金属修补槽衬主槽PH值太高加酸PPGConfidentialMaterial-E-Coat63问题解决问题原因解决方案主槽脏粒过滤过滤袋尺寸太大减少尺寸过滤袋破裂适时更换过滤袋过滤网错位清理设备提高设备强度PPGConfidentialMaterial-E-Coat64问题解决问题原因解决方案最后一道清洗后的松散脏粒水平面灰粒浸槽太赃置换清洁改良循环改良过滤停止循环去除灰粒出口洁净喷淋D.I.循环喷淋泥浆D.I.循环槽杀菌UF液太赃清洁槽壁和蓬顶改良超滤细菌控制PPGConfidentialMaterial-E-Coat65问题解决问题原因解决方案外观橘皮膜厚太高降低膜厚核查槽温核查链速核对膜厚仪核对校正零板过超滤减少超滤流失补加新漆槽液更新率太低补加新漆减少超滤流失主槽可溶性离子停止阳极泄漏提高主槽pH板材粗糙改良板材主槽电导太高降低主槽电导PPGConfidentialMaterial-E-Coat66问题解决问题原因解决方案外观局部粗糙主槽可溶性离子排放超滤液磷化代入改良D.I.水洗改良浸洗增加驼峰D.I.水系统D.I.水系统检查不良镀锌板降低主槽电导提高主槽温度降低电压改良金属板材电泳烤炉降低升温区温度紧P/B过高降低P/B板材粗糙改良金属板材PPGConfidentialMaterial-E-Coat67问题解决问题原因解决方案缩孔常见缩孔P/B过低板材油污提高P/B提高除油效果(前处理)安装除油过滤袋人员/环境污染化妆品禁止在工作区使用化妆品前处理化学品排除化学泄露停止污染化学品加药面漆漆渣系统安装隔离墙门窗关闭门窗维修工作区安装隔离墙PPGConfidentialMaterial-E-Coat68问题解决问题原因解决方案缩孔新设备安装泵,管路,阀门事先用溶剂清洁在前处理系统清洁手工清洁强碱清洁顶部输送链接油盘泄漏清洁修复喷嘴异位正位链条油油品不合格更换油品用油过量检测加油器泵润滑脂油品不合格更换油品用油过量减少用油量PPGConfidentialMaterial-E-Coat69问题解决问题原因解决方案缩孔开门器润滑脂油品不合格更换油品减少用油量用油过量冲压油油品不兼容更换油品增强前处理除油效能先进先出防锈油防锈油干渍预先打磨加强前处理清洁效果PPGConfidentialMaterial-E-Coat70问题解决问题原因解决方案缩孔传输设备使用不兼容油品更换油品链条松弛调整档板安装档板过滤器密封圈使用凡士林禁用凡士林过滤袋不兼容缝纫油选用合格产品去掉标签PPGConfidentialMaterial-E-Coat71问题解决问题原因解决方案条纹条纹钝化铬浓度过高降低钝化后冲洗为钝化液污染排空清洁工件半干半湿吹干工件保持全湿磷化冲洗加入表面活性剂阳极过于靠前渐次关闭入槽阳极降低一段电压前处理清洁不良强化清洁效能预擦净使用“SCOTCHBRITE”预擦净干化保持湿润预擦净浓度过高降低浓度PPGConfidentialMaterial-E-Coat72问题解决问题原因解决方案条纹条纹在前处理各工段间干化清洁喷嘴降低温度安装润湿喷嘴磷化过喷至表调喷嘴定位降低喷淋压力表调喷嘴堵塞清洁喷嘴表调参数控制调整参数表调加药至表调槽加药至表调出槽喷淋D.I.水不合格重新制备PPGConfidentialMaterial-E-Coat73电泳系统质量保证现场取样SPC图表检测实验结果反馈PPGConfidentialMaterial-E-Coat74分析实验ßßßßßßßßßßßßßßßßßß