In the automotive manufacturing industry, the spray painting workshops have extremely high requirements for air quality. Pollutants such as dust and particles in the air, if attached to the vehicle body surface, will seriously affect the paint quality and reduce the product qualification rate. The self - cleaning air filters produced by Xinxiang Lifeierte Filter Corp.,LTD, with innovative technologies and excellent performance, have provided effective solutions for automotive manufacturing enterprises to solve air filtration problems. The following takes the actual project of a large - scale automotive manufacturing enterprise as an example to introduce the application of our company's self - cleaning air filters in detail.
I. Project Background
A large - scale automotive manufacturing enterprise has an annual production capacity of 500,000 vehicles, and its spray painting workshop originally used traditional bag - type air filters. In actual operation, traditional filters have many problems:
Low Filtration Efficiency
The filtration efficiency for particles with a size of 0.3 - 5 microns is only 85%, which is difficult to meet the demand for clean air in the spray painting process. A large number of fine particles entering the spray painting workshop result in about 5% of the vehicle body paint surfaces having defects such as particles and pitting. The annual rework cost caused by paint quality problems is as high as 8 million yuan.
Frequent Maintenance
The traditional bag - type filters need to replace the filter bags every 2 - 3 months. The replacement process is time - consuming and labor - intensive, and each filter bag replacement will cause the workshop to stop production for about 8 hours, affecting the production schedule. The total annual cost of filter bag consumables and labor costs is approximately 3 million yuan.
Inability to Adapt to Complex Working Conditions
During the automotive manufacturing process, special pollutants such as oily mist and metal debris are generated in the workshop. Traditional filters are easily blocked, and their filtration performance decreases significantly.
In order to improve product quality and reduce production costs, the enterprise decided to introduce advanced self - cleaning air filters. After comprehensive evaluation, it finally selected the products of our company.
II. Application and Implementation of Our Company's Self - Cleaning Air Filters
(I) Equipment Selection and Customization
The technical team of our company customized a set of self - cleaning air filtration system for the automotive manufacturing enterprise according to the size of the spray painting workshop (10,000 square meters in area and 12 meters in height), the demand for ventilation volume (60 air changes per hour, with a total ventilation volume of 600,000 cubic meters), and the characteristics of pollutants. The system is composed of multiple modular filter units. The core filter material uses nano - fiber composite filter media, and the filtration efficiency for 0.3 - micron particles can reach 99.97%, meeting the air quality requirements of ISO Class 6 cleanroom in ISO 14644 - 1 standard.
(II) System Installation and Debugging
Equipment Installation
A three - dimensional installation layout was adopted, and the filter units were installed at the inlet of the ventilation ducts on the top of the workshop. Each filter unit is equipped with an independent intelligent control module, which can real - time monitor parameters such as filtration resistance and operating status.
Configuration of Self - Cleaning System
The self - cleaning air filter is equipped with a pulse back - blowing system and an intelligent control system. The pulse back - blowing system uses compressed air to spray in the reverse direction instantaneously to remove pollutants attached to the surface of the filter media; the intelligent control system automatically determines the cleaning time according to the resistance change of the filter, achieving precise self - cleaning.
Debugging and Optimization
The professional technicians of our company conducted a one - week debugging of the system, adjusted parameters such as the pressure of the pulse back - blowing (set at 0.6 - 0.8MPa) and the frequency (automatically adjusted according to the pollution level, generally once every 2 - 4 hours), to ensure the stable and efficient operation of the equipment. In addition, operation training and maintenance guidance were provided for the enterprise's operators.
III. Application Effects
Effect Category | Specific Performance |
Significant Improvement in Filtration Efficiency | - The filtration efficiency for 0.3 - micron particles has increased from 85% to 99.97%, effectively ensuring the air quality in the spray painting workshop- The defect rate of the vehicle body paint surface has been reduced from 5% to below 0.5%, and the product qualification rate has been greatly improved. The annual rework cost has been reduced by about 7 million yuan |
Substantial Reduction in Maintenance Costs | - The service life of the filter media has been extended to 3 - 5 years. Compared with traditional filters, the replacement cycle of the filter media has been extended by 10 - 15 times- The self - cleaning function reduces manual maintenance workload, saving about 2.6 million yuan in annual filter media and labor maintenance costs- There is no need to stop production during equipment maintenance, ensuring production continuity |
Strong Adaptability to Complex Working Conditions | - Effectively filters special pollutants such as oily mist and metal debris, and the equipment has high operation stability- In a high - pollution environment, it can still maintain stable filtration performance, ensuring the normal progress of the spray painting process |
IV. Summary of Application Experience
Accurate Selection is the Foundation
The air filtration requirements of different industries and workshops vary greatly. Our company provides customized equipment selection solutions through on - site inspections, combined with factors such as the enterprise's ventilation volume, pollutant types, and cleanliness requirements, to ensure a high degree of matching between the filter performance and actual needs.
Intelligent Self - Cleaning Technology is the Key
The pulse back - blowing and intelligent control system of the self - cleaning air filter can timely remove pollutants on the surface of the filter media, maintain stable filtration efficiency, and reduce manual maintenance, which is the core advantage compared with traditional filters.
Complete After - Sales Service Guarantee
Our company provides comprehensive after - sales services for customers, including equipment installation and debugging, personnel training, regular inspections, 24 - hour technical support, etc., to promptly solve problems encountered by customers during the use process and ensure the long - term stable operation of the equipment.
The successful application of our company's self - cleaning air filters in this automotive manufacturing enterprise fully demonstrates the reliability and advancement of the products. In the future, [Company Name] will continue to focus on the research and development of air filtration technologies, providing more efficient and intelligent air filtration solutions for more industries.
