WO2011006343A1 - 大型钢管防腐涂层自动涂装工艺及其生产线 - Google Patents

大型钢管防腐涂层自动涂装工艺及其生产线 Download PDF

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Publication number
WO2011006343A1
WO2011006343A1 PCT/CN2010/000147 CN2010000147W WO2011006343A1 WO 2011006343 A1 WO2011006343 A1 WO 2011006343A1 CN 2010000147 W CN2010000147 W CN 2010000147W WO 2011006343 A1 WO2011006343 A1 WO 2011006343A1
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WO
WIPO (PCT)
Prior art keywords
steel pipe
coating
paint
curing
automatic
Prior art date
Application number
PCT/CN2010/000147
Other languages
English (en)
French (fr)
Inventor
史岳明
熊信勇
Original Assignee
Shi Yueming
Xiong Xinyong
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Shi Yueming, Xiong Xinyong filed Critical Shi Yueming
Priority to KR2020117000027U priority Critical patent/KR20110010571U/ko
Priority to DE212010000102U priority patent/DE212010000102U1/de
Priority to JP2011600063U priority patent/JP3173913U/ja
Publication of WO2011006343A1 publication Critical patent/WO2011006343A1/zh

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/14—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to metal, e.g. car bodies
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L58/00—Protection of pipes or pipe fittings against corrosion or incrustation
    • F16L58/02—Protection of pipes or pipe fittings against corrosion or incrustation by means of internal or external coatings
    • F16L58/04—Coatings characterised by the materials used
    • F16L58/10—Coatings characterised by the materials used by rubber or plastics
    • F16L58/1009—Coatings characterised by the materials used by rubber or plastics the coating being placed inside the pipe
    • F16L58/1027—Coatings characterised by the materials used by rubber or plastics the coating being placed inside the pipe the coating being a sprayed layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
    • B05B7/16—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B9/00—Spraying apparatus for discharge of liquids or other fluent material, without essentially mixing with gas or vapour
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L58/00—Protection of pipes or pipe fittings against corrosion or incrustation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2202/00—Metallic substrate
    • B05D2202/10—Metallic substrate based on Fe
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2254/00—Tubes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/02—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
    • B05D3/0218—Pretreatment, e.g. heating the substrate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/02—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
    • B05D3/0254—After-treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/10—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by other chemical means
    • B05D3/102—Pretreatment of metallic substrates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/12—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by mechanical means

Definitions

  • the invention relates to an anticorrosive treatment process for a pipe material and a production line thereof, and more particularly to an automatic coating process for a large-scale steel pipe anticorrosive coating and a production line thereof.
  • Large steel pipes usually refer to steel pipes with a diameter of 0.5 to 2.4 meters and a length of 12 to 90 meters.
  • more and more large-scale steel pipes are used in port terminals, marine engineering and municipal engineering.
  • the most commonly used method of preservative treatment is to apply an anticorrosive coating to the surface of a steel pipe.
  • the anti-corrosion coating of large-scale steel pipes at home and abroad mainly adopts three methods: manual coating, automatic coating of molten epoxy powder and three-layer PE coating.
  • the manual coating method mainly uses a solvent-based paint to coat a large-sized steel pipe, and the surface of the steel pipe is first subjected to manual blasting or mechanical shot blasting, and then the paint is applied on the surface of the steel pipe by manual roll coating or spraying.
  • the above-mentioned manual coating method can achieve the anticorrosion treatment of the steel pipe, the following defects exist: (1) Due to the high content of the organic solvent in the coating, the organic solvent of the coating will be volatilized during the drying process, which will not only pollute Environment, and the working environment is poor, the work intensity is high, and there is a hidden danger to the health of the operator; (2) At the same time, because the large steel pipe cannot be rolled in place during manual painting, the viscosity of the coating required for construction cannot be too high, usually The content of the organic solvent in the coating is sometimes as high as 15% or more, which causes the paint film to sag after painting, resulting in unevenness in thickness and thickness, which greatly reduces the overall corrosion resistance of the steel tube coating.
  • the automatic coating process of molten epoxy powder is done automatically on the mechanical line.
  • the surface of the steel pipe is rusted by a shot blasting machine, and then the steel pipe is heated to a certain high temperature by medium frequency induction, and then the epoxy resin powder is quickly applied to the steel pipe by electrostatic spraying.
  • the epoxy powder melts into a film immediately after contact with the high-temperature steel pipe and adheres to the surface of the steel pipe, and finally the coating is rapidly cooled and solidified by rapid water cooling.
  • the degree of automation is obviously improved, and the construction and curing of the coating are not affected by the surrounding environment and weather, and the labor intensity of the workers is low and the work efficiency is high.
  • the degree of automation is obviously improved, and the construction and curing of the coating are not affected by the surrounding environment and weather, and the labor intensity of the workers is low and the work efficiency is high.
  • its application examples are rarely seen abroad, mainly because the temperature change during the construction of the coating is too large, and the expansion system of the steel pipe and the coating is
  • the three-layer PE coating automatic coating production line is mainly used for anti-corrosion coating of buried steel pipes.
  • the length of the processed steel pipes can only be more than ten meters, and it cannot be processed for longer steel pipes. Therefore, the three-layer PE cannot be applied to the construction of anti-corrosion coatings for large steel pipes, and the three-layer PE coating is rarely used in port terminals and marine engineering.
  • a large-scale steel pipe automatic coating production line which has been disclosed, for example, in Chinese Patent Publication No. CN1673604A, CN1672809A and Chinese Patent Publication No. CNU22772C, discloses the use of a primer with tape winding or PE as a coating material. There are few reports on automatic coating lines using high solids coatings. Summary of the invention
  • the technical problem to be solved by the present invention is to provide an automatic coating process for a large-scale steel pipe anticorrosive coating using a high solid content coating and having high coating production efficiency, small environmental pollution, and good impact resistance of the coating. .
  • Another technical problem to be solved by the present invention is to provide an automatic coating of a large-scale steel pipe anticorrosive coating using a high solid content coating and having high coating production efficiency, low environmental pollution, and good impact strength of the coating. production line.
  • the technical solution adopted by the present invention to solve the above technical problems is as follows:
  • the large-scale steel pipe anti-corrosion coating automatic coating process is characterized in that it comprises the following steps:
  • the steel pipe is first dehumidified and decontaminated to remove the oil and moisture on the surface of the steel pipe;
  • the steel pipe after dehumidification and decontamination enters the automatic shot blasting machine to remove the rust layer and the oxide layer on the surface of the steel pipe, so that the surface of the steel pipe meets the requirements of cleanliness and roughness before painting;
  • the steel pipe enters the preheating drying room, and the steel pipe to be painted is heated to a first temperature value, and the first temperature value ranges from 40 ° C to the curing temperature of the used paint to the curing temperature of the used paint.
  • Minus between 20 ⁇ ;
  • the heated steel pipe enters the spray booth, and the sprayer sprays the paint with the second temperature value onto the surface of the steel pipe.
  • the second temperature value ranges from 40 ° C to the curing temperature of the used paint to the paint used. Curing temperature minus 20 ° C;
  • the steel pipe sprayed with the paint enters the curing room of the paint film, and the hot air circulation system installed in the curing room of the paint film sends hot air to heat the steel pipe to the curing temperature range of the used paint;
  • the steel pipe enters the cooling room for rapid cooling;
  • the cooling room can be cooled by air cooling, water cooling and other cooling methods;
  • the air cooling can be cooled by natural air or cold air;
  • the method sets the first temperature value in the preheating drying room, that is, the preheating temperature of the steel pipe and the temperature of the paint spraying, that is, the second temperature value, according to the curing temperature of the coating used, so that the steel pipe and the coating are simultaneously heated to greatly accelerate the paint film.
  • the curing speed reduces the curing time of the coating.
  • the solvent content in the coating may be less than 10%.
  • the lacquer film curing chamber adopts a hot air circulation heating process, which is low in cost, safe and improves the curing environment of the coating.
  • the spraying machine can adopt a high-pressure airless spraying machine, and the coating enters the coating inlet of the high-pressure airless spraying machine after being heated by the automatic heating mechanism paint, and the time used for the high-pressure airless spraying machine to be ejected after the heating of the coating is controlled
  • the high-pressure airless sprayer allows easy control of the spray temperature of the coating, the mixing time of the curing agent and the coating, and the time from the heating of the coating to the ejection.
  • the large-scale steel pipe anti-corrosion coating automatic coating production line includes a steel pipe conveying mechanism that drives the steel pipe to rotate and moves horizontally along the center of the steel pipe, a dehumidifying and decontaminating machine for removing oil stains and moisture on the surface of the steel pipe, and is used for removing the rust layer and oxidation of the steel pipe surface.
  • the preheating drying room is further provided with a painting curing unit, which is composed of a spray booth, a paint curing chamber and a cooling room which are arranged in a straight line before and after, wherein the spray booth is provided with an anti-corrosion coating on the surface of the steel pipe.
  • the sprayer, and the paint film curing room is provided with a hot air circulation system.
  • the coating, curing and cooling of the paint layer are replaced by manual painting in the traditional process, and the natural environment is solidified and cooled in the natural environment, and the painting work is highly efficient, especially
  • the curing time of the paint film is greatly shortened, shortened from 24 hours in the conventional method to 20 minutes in the patented method, and the coating work efficiency is increased by more than 10 times; and the adverse effects of natural environmental factors on the curing and cooling of the paint film are avoided.
  • the impact strength of the coating is greatly improved; at the same time, the pollution caused by the evaporation of the solvent to the environment and the operator is also avoided.
  • the steel pipe conveying mechanism may comprise a plurality of roller sets arranged at intervals and equal heights, each roller set being composed of two rollers arranged side by side and rotating in the same direction, and the distance between the adjacent two roller groups It is satisfied that the steel pipes are placed at least on the two roller groups at the same time during transportation.
  • roller sets arranged at intervals and equal heights, each roller set being composed of two rollers arranged side by side and rotating in the same direction, and the distance between the adjacent two roller groups It is satisfied that the steel pipes are placed at least on the two roller groups at the same time during transportation.
  • other conveying mechanisms in the prior art can also be used.
  • the preheating drying chamber may be provided with nozzles disposed on opposite sides of the steel pipe and disposed obliquely to the steel pipe, the nozzle being connected to a source of hot air.
  • the heating method has a fast heating speed, and the required equipment and heating source are easily available.
  • the spraying machine can adopt a high-pressure airless spraying machine, and the high-pressure airless spraying machine is connected to the automatic heating device for coating; the automatic heating device for the coating can be connected to the inlet of the high-pressure airless spraying machine, or Connection In the middle of the high-pressure airless spraying machine, that is, between the pump of the high-pressure airless spraying machine and the paint spraying channel; by using the characteristics of the high-pressure airless spraying machine, the coating can be heated and sprayed in a mist, thereby greatly reducing the coating.
  • the content of the solvent which in turn accelerates the curing of the paint film.
  • the paint curing unit may be provided in plurality according to the paint layer.
  • the spray paint solid unit may have three lines, which are sequentially distributed in a straight line;
  • the coating of steel pipes usually requires special design of three coats of primer, intermediate paint and top coat.
  • the automatic coating process and the production line of the large-scale steel pipe anti-corrosion coating are continuous automation of dehumidification, surface treatment, pre-heating, painting and the like of the steel pipe in one production line.
  • the operation combined with the preheating of the steel pipe and the high-pressure airless automatic heating spraying technology, realizes the continuous painting and continuous operation of the large steel pipe, so the invention greatly reduces the labor intensity of the worker compared with the conventional manual painting operation mode.
  • Increased production efficiency (its coating efficiency can be increased by more than 10 times); the solvent content in the coating can be reduced from the traditional 40 ⁇ 60% to less than 10%, and the organic solvent is reduced by 4-6 times.
  • the invention greatly shortens the working time, reduces the production cost, and ensures
  • the anti-corrosion construction quality and anti-corrosion performance of large-scale steel pipe coatings have achieved unexpected technical effects in actual trial production, so it is worthy of promotion and application in existing large steel pipes.
  • FIG. 1 is a flow chart of a production line in the present invention
  • Figure 2 is a schematic cross-sectional view of the A-A direction of Figure 1;
  • Figure 3 is a schematic cross-sectional view of the B-B direction of Figure 1;
  • Figure 4 is a schematic cross-sectional view of the C-C direction of Figure 1. detailed description
  • the large-scale steel pipe anti-corrosion coating automatic coating production line includes: steel pipe conveying mechanism 1, dehumidification decontamination machine 2, automatic shot blasting machine 3, preheating drying room 4 and curing by paint booth 5, paint film
  • the spray curing unit composed of the room 6 and the cooling room 7 needs to be coated with the primer, the intermediate paint and the top paint in the embodiment. Therefore, three curing units are arranged in a straight line in front and rear, that is, the first painting curing unit, a second paint curing unit and a third paint curing unit.
  • the steel pipe conveying mechanism 1 includes a plurality of roller sets arranged at intervals and equal heights, and each roller set is composed of two rollers arranged side by side and rotating in the same direction, and the axial center of the rollers in each group of roller sets
  • the line is inclined to the horizontal plane so that the steel pipe can be spirally advanced thereon; and the steel pipe 8 is at least simultaneously placed on two adjacent sets of rollers when transporting, and only two roller sets are provided in each of the paint curing units, and the two The roller sets are located in front of the spray booth 5 and cooled
  • the dehumidifying and decontaminating machine 2 adopts a diesel burner for a gas boiler, and may also adopt other existing equipment; the automatic shot blasting machine 3 adopts conventional equipment; the preheating drying room 4 is inside the lower side of the steel pipe 8,
  • the oblique steel pipe 8 is provided with two nozzles. Referring to Fig. 2, each nozzle is connected to a hot air source, and hot air is sprayed from the lower side of the steel
  • Each spray booth 5 is provided with a high-pressure airless sprayer 9, and the nozzle of the high-pressure airless sprayer is located above the steel pipe 8 and obliquely to the steel pipe 8, see Fig. 3, the inlet and the coating of the paint in the high-pressure airless sprayer
  • the outlet of the automatic heating device is connected, wherein the automatic heating device of the paint adopts a conventional paint heating device; each of the paint film curing chambers 6 is provided with a hot air circulation system, and the hot air circulation system also adopts a conventional technology;
  • the cooling room 7 is cooled by natural air (air conditioning and cold air can also be used if necessary).
  • the steel pipe 8 in this embodiment needs to be sprayed with three paint layers, that is, the primer is epoxy resin, the solvent content is about 8%, the curing temperature is 90 ⁇ 10° C., the intermediate paint is epoxy resin, and the solvent content thereof. It is about 6%, the curing temperature is 90 ⁇ 10 °C, and the topcoat is made of epoxy resin. The solvent content is 1% and the curing temperature is 90 ⁇ 10°C.
  • the large steel pipe 8 with a diameter of 1.8 m and a length of 60 m to be sprayed is hoisted to the steel pipe conveying mechanism 1 by a suitable crane structure, and the steel pipe conveying mechanism is opened, and the two rollers of each group of rollers are rotated in the same direction. , the steel pipe 8 is spirally advanced between the roller sets; when the steel pipe 8 passes through the dehumidification and decontamination machine 2, the combustion flame generated by the diesel burner is sprayed toward the surface of the steel pipe to remove the moisture and oil on the surface of the steel pipe 8;
  • the steel pipe 8 enters the preheating drying room 4, as shown in Fig. 2, the two nozzles blow the hot air flow from the obliquely downward direction of the steel pipe 8 to the steel pipe 8, and heat the steel pipe 8 to the first temperature value of 50-70 °C. And then delivered to the spray booth 5;
  • the automatic heating mechanism heats the paint to a second temperature value of 50-70 ° C and then feeds it into a high-pressure airless spray machine, which is uniformly mixed with the curing agent in a mist form, and is sprayed from the obliquely upper side of the steel pipe 8 to the surface of the steel pipe 8; Shown; control the time from the entry of the paint into the high pressure airless sprayer to the discharge within 3 minutes;
  • the steel pipe enters the paint curing chamber 6 and the hot air circulation system disposed in the curing chamber of the paint film sends out the hot air.
  • the hot air is blown from the opposite sides of the steel pipe 8 to the spray.
  • a primer steel tube the steel tube 8 is heated to 90 ⁇ 10 ° C, so that the paint film of the primer is quickly solidified, and the hot air circulation takes away the solvent volatilized in the primer;
  • the two roller sets are arranged only in front of the spray booth 5 and after the cooling chamber 7 in the paint curing unit, the sprayed paragraph does not touch the roller during the entire process from the start of the primer coating to the curing and cooling of the paint film. A lacquer layer that is not cooled will not damage the paint film by contact with the rollers.
  • the temperature in the curing room of the paint film is 90 ⁇ 10°C ; the temperature of the topcoat entering the high-pressure airless spraying machine in the spray booth of the third painting curing unit is 50- At 70 ° C, the temperature in the cured film room is 90 ⁇ 10 ° C.
  • the above-mentioned automated production line is sprayed with three layers of anti-corrosion coating on the large steel pipe.
  • Each paint is cooled in 20 minutes from the time of spraying to curing. Therefore, it takes only one hour to complete the three-way paint, which greatly shortens the working time. , to improve production efficiency, and because of the entire process of automation, the paint quality of the paint layer is greatly improved.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Coating Apparatus (AREA)
  • Spray Control Apparatus (AREA)

Description

大型钢管防腐涂层自动涂装工艺及其生产线
技术领域
本发明涉及一种管材的防腐处理工艺及其生产线，更具体地说是指一种大型钢管防 腐涂层自动涂装工艺及其生产线。 背景技术
大型钢管通常是指直径在 0.5~2.4米、 长度为 12~90米的钢质管道。 近年来， 随着 我国国民经济的快速发展，越来越多的大型钢管应用于港口码头、海洋工程和市政工程。 为了有效地控制大型钢管的腐蚀，延长大型钢管的使用寿命，保证基础设施的安全运行， 需要对钢管进行表面防腐处理。 最常使用的防腐处理方法是在钢管的表面涂装防腐涂 料。 目前国内外大型钢管的防腐涂装主要采用人工涂装、 熔融环氧粉末自动涂装和三层 PE涂装等三种方式。
其中，人工涂装的方式主要使用溶剂型涂料对大型钢管涂装，先将钢管表面经人工 喷砂或机械抛丸处理后， 然后采用人工辊涂或喷涂方式， 将涂料涂装在钢管表面。 采用 上述人工涂装方式， 虽然能实现钢管的防腐处理， 但存在着以下缺陷： （1 ) 由于涂料中 有机溶剂的含量较高， 涂层在干燥过程中有机溶剂会大量挥发， 这样不仅会污染环境， 而且工作环境差， 作业强度大， 对操作人员的健康存在隐患； （2) 同时由于大型钢管在 人工涂装时无法原地滚动， 再加上施工所需涂料的粘度不能太高， 通常涂料中有机溶剂 的含量有时高达 15%以上， 这会造成涂装后漆膜流挂， 产生上薄下厚的不均匀现象, 大 大降低了钢管涂层的整体防腐性能。 （3 )大型钢管的人工涂装一般在室内敞开的环境或 露天进行， 由于施工环境和天气等自然条件的限制， 可进行涂装作业的时间依赖于天气 情况， 无法保证大型钢管的涂装作业质量、 进度和效率； 同时在涂料涂装完成后， 涂层 的固化是在自然环境下完成， 所以还具有固化时间长， 占用的施工场地大的特点。
熔融环氧粉末自动涂装过程是在机械流水线上自动完成的。大型钢管在传动系统上 当螺旋滚动前进时， 钢管表面经抛丸机除锈处理后， 接着经中频感应将钢管加热到一定 的高温后， 然后迅速将环氧树脂粉末用静电喷涂方式涂装到钢管表面， 环氧粉末接触到 高温钢管后立即熔化成膜并附着在钢管表面， 最后再经快速水冷使涂层迅速冷却固化。 与人工涂装相比较， 其自动化程度明显提高， 并且涂层的施工、 固化均不受周围环境及 天气的影响， 工人劳动强度低， 作业效率高。 但作为单一的涂层体系， 在国外鲜见其应 用实例， 这主要是因为在涂层的施工过程中， 其温度变化太大， 而钢管和涂层的膨胀系
确 认 本 数又不同， 使得其涂层存在很高的内应力， 在外力作用下容易被破坏； 而破损后的涂层 则很难在施工现场采用相同的施工工艺进行修复。
而三层 PE涂层自动涂装生产线主要应用于埋地钢管的防腐涂装， 其加工的钢管长 度大多只能在十几米左右， 对于更长的钢管则不能加工。 因此三层 PE不能适用大型钢 管的防腐涂层的施工， 而且三层 PE涂层使用鲜见用于港口码头及海洋工程中。
目前已经公开的大型钢管自动涂装生产线， 例如中国专利公开号为 CN1673604A、 CN1672809A和中国专利授权公告号为 CNU22772C的专利文献中，披露的是采用底漆 加胶带缠绕或 PE作为涂覆料， 而对于采用高固体含量涂料的自动涂装生产线则鲜有报 道。 发明内容
本发明所要解决的技术问题是针对现有技术的现状，提供一种使用高固体含量涂料 且涂装生产效率高、环境污染小、涂层抗冲击强度好的大型钢管防腐涂层自动涂装工艺。
本发明所要解决的另一个技术问题是针对现有技术的现状，提供一种使用高固体含 量涂料且涂装生产效率高、 环境污染小、 涂层冲击强度好的大型钢管防腐涂层自动涂装 生产线。
本发明解决上述技术问题所采用的技术方案为： 该大型钢管防腐涂层自动涂装工 艺， 其特征在于包括下述步骤： ·
① 将钢管放置到钢管传送机构上，开启钢管传送机构，钢管首先经过去湿除污 ， 去除钢管表面的油污及水分；
② 去湿除污后的钢管进入自动抛丸机， 去除钢管表面的锈层及氧化层， 使钢管表 面满足喷漆前的清洁度和粗糙度的要求；
③ 接着钢管进入预热烘房内， 将待喷漆的钢管加热到第一温度值， 该第一温度值 的取值范围在所使用涂料的固化温度减去 40°C至所使用涂料的固化温度减去 20Ό之间；
④ 经加热后的钢管进入喷漆房，喷涂机将具有第二温度值的涂料喷涂到钢管表面， 该第二温度值的取值范围在所使用涂料的固化温度减去 40°C至所使用涂料的固化温度 减去 20°C之间；
⑤ 喷装了涂料的钢管进入漆膜固化房内， 设置在漆膜固化房内的热风循环系统送 出热风， 将钢管加热到所使用涂料的固化温度范围内；
⑥钢管进入冷却房内进行快速冷却；冷却房内可以使用风冷、水冷及其它冷却方式 冷却钢管； 其中风冷可以使用自然风冷却也可以使用冷空气冷却；
⑦若冷却后的钢管需要喷装多道漆层，则再依次进入下一个由喷漆房、漆膜固化房 和冷却房组成的喷漆固化单元进行第④、 第⑤、 第⑥步骤的操作； 直至完成全部的涂装 作业。 本方法根据所使用涂料的固化温度设置预热烘房内的第一温度值即钢管的预热温 度和涂料喷出的温度即第二温度值， 这样钢管和涂层同步加热， 大大加快漆膜的固化速 度， 减少涂层的固化时间。 、 为了进一步降低涂料中溶剂的挥发对环境造成的污染，并减少漆膜的针孔，所述的 涂料中溶剂含量可以小于 10%。
较好的， 所述的漆膜固化房内采用热空气循环加热工艺， 这样成本低， 安全且改善 涂层的固化环境。
所述的喷涂机可以采用高压无气喷涂机，涂料经自动加热机构涂料加热后进入所述 高压无气喷涂机的涂料入口，涂料加热后进入高压无气喷涂机到喷出所用的时间控制在
3分钟内。 采用高压无气喷涂机可以方便的控制涂料的喷出温度、 固化剂与涂料的混合 时机以及从涂料加热到喷出的时间。
大型钢管防腐涂层自动涂装生产线包括带动钢管旋转并沿钢管中心水平移动前行 的钢管传送机构、 用于去除钢管表面油污及水分的去湿除污机、 用来去除钢管表面锈层 及氧化层的自动抛丸机和将待喷漆钢管进行预加热的预热烘房，所述自动抛丸机放置在 所述去湿除污机和预热烘房之间， 其特征在于： 在所述的预热烘房之后还设置有喷漆固 化单元， 该喷漆固化单元由依次前后成直线分布的喷漆房、 漆膜固化房和冷却房组成， 其中喷漆房内设置有向钢管表面喷装防腐涂层的喷涂机， 而所述的漆膜固化房内设有热 风循环系统。
本发明中喷漆固化单元的设置，漆层的涂装、固化和冷却均采用机械自动化操作代 替了传统工艺中的手工涂刷、 自然环境中依靠自然条件固化和冷却， 涂装作业效率高， 尤其是漆膜的固化时间大大缩短， 由传统方法的 24小时缩短到本专利方法的 20分钟之 内， 涂装作业效率提高 10倍以上； 而且避免了自然环境因素对漆膜固化和冷却的不利 影响， 涂层的耐冲击强度大幅度提高； 同时还避免了溶剂的挥发对环境和操作人员造成 的污染。
所述的钢管传送机构可以包括有间隔、等高设置的多个滚轮组，每个滚轮组又由并 列分布且同向转动的两个滚轮组成， 并且相邻的两个滚轮组之间的距离满足钢管在输送 时至少同时位于两个滚轮组之上， 当然， 也可以采用现有技术中的其它传送机构。
所述的喷漆固化单元中仅设置两个滚轮组，且两个滚轮组分别位于喷漆房之前和冷 却房之后； 这样从涂层喷装到钢管上至漆膜固化、 冷却的过程中， 喷装的段落不会接触 到滚轮， 避免了漆层与钢管传送机构之间因为粘连而造成的漆膜破坏。
所述预热烘房内可以设有位于所述钢管的下方两侧且斜向钢管设置的喷嘴，所述喷 嘴与热空气源相连。 该加热方式加热速度快， 所需设备和加热源易得。
较好的，所述的喷涂机可以采用高压无气喷涂机，所述高压无气喷涂机连接涂料自 动加热装置； 所述的涂料自动加热装置可以连接在高压无气喷涂机的入口， 也可以连接 在高压无气喷涂机的中部即高压无气喷涂机的泵和涂料喷出通道之间；利用高压无气喷 涂机的特点， 可以将涂料加热后以雾状喷出， 从而可以大幅度降低涂料中溶剂的含量， 进而加快漆膜的固化。
上述方案中，较好的， 所述的喷漆固化单元可以按漆层设置多个， 当漆层需要三层 时， 该喷漆固单元可以有三个， 分别依次呈直线分布； 这是因为考虑到大型钢管的涂装 通常需要进行底漆、 中间漆和面漆三层涂装而特别设计的。
与现有技术相比较，由于本发明所提供的大型钢管防腐涂层自动涂装工艺及其生产 线是在一条生产线上实现钢管的去湿除污、表面处理、 预加热、 喷漆等工序的连续自动 化作业， 且结合钢管预热及高压无气自动加热喷涂技术， 实现了大型钢管的自动涂装连 续作业， 故本发明与传统的手工涂装作业方式相比较， 极大地降低了工人的劳动强度， 提高了生产效率（它的涂装作业效率可提高 10倍以上）； 涂料中的溶剂含量可以从传统 的 40~60%降低到 10%以下， 有机溶剂的挥发量减少了 4~6倍， 因而减少了有机溶剂的 挥发对环境所造成的污染， 节约了能源消耗， 最大限度地避免了涂装作业环境对涂装质 量的不利影响。 与熔融环氧粉末涂层相比较， 涂层的耐冲击强度大幅度提高， 将稳定达 到或超过国标要求（50kg*cm); 因此本发明大大缩短了作业时间， 降低了生产成本， 并 能确保大型钢管涂层的防腐施工质量及防腐性能， 这在实际试制中， 取得了意想不到的 技术效果， 所以值得在现有大型钢管中推广应用。
附图说明
图 1为本发明中生产线的流程框图；
图 2为图 1中 A-A向的剖面结构示意图；
图 3为图 1中 B-B向的剖面结构示意图；
图 4为图 1中 C-C向的剖面结构示意图。 具体实施方式
以下结合附图实施例对本发明作进一步详细描述。
如图 1所示， 该大型钢管防腐涂层自动涂装生产线包括： 钢管传送机构 1、 去湿除 污机 2、 自动抛丸机 3、预热烘房 4和由喷漆房 5、漆膜固化房 6和冷却房 7组成的喷漆 固化单元， 本实施例中需要涂装底漆、 中间漆和面漆三道漆， 因此前后依次呈直线分布 设置有三个固化单元， 即第一喷漆固化单元、 第二喷漆固化单元和第三喷漆固化单元。
其中所述的钢管传送机构 1包括有间隔、等高设置的多个滚轮组，每个滚轮组又由 并列分布且同向转动的两个滚轮组成， 每组滚轮组中的滚轮的轴心连线倾斜于水平面， 以使钢管在其上能够螺旋前进;并且钢管 8在输送时至少同时位于二组相邻的滚轮组上， 每个喷漆固化单元中仅设置两个滚轮组，且该两个滚轮组分别位于喷漆房 5之前和冷却 所述的去湿除污机 2采用燃气锅炉用柴油燃烧器，也可以采用现有的其它设备； 自 动抛丸机 3则采用常规的设备； 预热烘房 4内在钢管 8的下方两侧、 斜向钢管 8设置有 二个喷嘴， 请参见图 2， 各喷嘴与热空气源相连， 从钢管 8的下方两侧斜向钢管喷出热 空气以加热钢管 8。
各喷漆房 5内均设置有高压无气喷涂机 9， 高压无气喷涂机的喷嘴位于钢管 8的上 方并斜向钢管 8， 请参见图 3， 该高压无气喷涂机中涂料的入口与涂料自动加热装置的 出口相连， 其中涂料自动加热装置采用常规的涂料加热装置即可； 每个漆膜固化房 6内 均设置有热风循环系统， 该热风循环系统也采用常规技术； 本实施例中的冷却房 7均采 用自然风冷却 （若需要也可以采用空调冷风）。
本实施例中的钢管 8需要喷装三道漆层，即底漆为环氧树脂，其溶剂含量约为 8%、 固化温度为 90± 10°C， 中间漆采用环氧树脂， 其溶剂含量约为 6%、 固化温度为 90± 10 °C， 面漆采用环氧树脂， 其溶剂含量为 1%、 固化温度为 90± 10°C。
使用上述防腐涂层自动涂装生产线的大型钢管防腐涂层自动涂装工艺如下：
①将待喷装的直径为 1.8米、 长度为 60米的大型钢管 8用合适的起重机构吊放到 钢管传送机构 1上， 开启钢管传送机构， 每组滚轮组的两个滚轮同向转动， 使钢管 8在 滚轮组之间螺旋前进； 当钢管 8经过去湿除污机 2时， 柴油燃烧器产生的燃烧火焰喷向 钢管表面， 清除掉钢管 8表面的水分和油污；
② 去湿除污后的钢管 8进入自动抛丸机 3， 去除钢管表面的锈层及氧化层， 使钢 管表面满足喷漆前的清洁度和粗糙度的要求；
③接着钢管 8进入预热烘房 4内， 如图 2所示， 二个喷嘴将热空气流从钢管 8的 斜下方吹向钢管 8， 将钢管 8加热到第一温度值 50-70°C， 然后输送到喷漆房 5 ;
④ 自动加热机构将油漆加热到第二温度值 50-70°C后送入高压无气喷涂机， 与固 化剂混合均匀以雾状、 从钢管 8的斜上方喷涂到钢管 8表面； 如图 3所示； 控制油漆从 进入高压无气喷涂机到喷出的时间为 3分钟内；
⑤底漆喷装完成后， 钢管进入漆膜固化房 6内， 设置在漆膜固化房内的热风循环 系统送出热风， 如图 4所示， 热风从钢管 8的两侧对向吹向喷装了底漆的钢管， 将钢管 8加热到 90± 10°C，以使底漆的漆膜快速固化，并且热风循环带走底漆中挥发出的溶剂；
⑥然后， 钢管 8进入冷却房 7内， 自然风从钢管 8的两侧吹向钢管 8， 以使其快 速冷却；
由于喷漆固化单元中仅在喷漆房 5之前和冷却房 7之后设置两个滚轮组，因此底漆 喷装开始到漆膜固化、 冷却的整个过程中， 已喷涂的段落不会接触到滚轮， 因此没有冷 却的漆层不会与滚轮接触破坏漆膜。
⑦底漆冷却后的钢管 8依次进入第二喷漆固化单元和第三喷漆固化单元， 重复步 骤④、 ⑤、 ⑥； 其中第二喷漆固化单元中的喷漆房中自动加热机构将中间漆加热到
50-70Ό后进入高压无气喷涂机， 漆膜固化房内的温度为 90± 10°C ; 第三喷漆固化单元 中的喷漆房内的进入高压无气喷涂机的面漆的温度为 50-70°C， 漆膜固化房内的温度为 90± 10°C。
至此该大型钢管 8的喷装作业完成。
本实施例中未涉及部分均与现有技术相同。
采用上述自动化生产线在大型钢管上喷装三层防腐涂层，每道漆从喷装到固化后冷 却完成只要 20分钟的时间， 因此三道漆全部完成仅需 1个小时， 大大缩短了作业时间， 提高了生产效率， 并且因为全程自动化操作， 漆层的涂装质量也大大提高。

Claims

权 利 要 求
1、 一种大型钢管防腐涂层自动涂装工艺， 其特征在于包括下述步骤：
①将钢管放置到钢管传送机构上，开启钢管传送机构，钢管首先经过去湿除污机， 去除钢管表面的油污及水分；
② 去湿除污后的钢管进入自动抛丸机， 去除钢管表面的锈层及氧化层， 使钢管表 面满足喷漆前的清洁度和粗糙度的要求；
③ 接着钢管进入预热烘房内， 将待喷漆的钢管加热到第一温度值， 该第一温度值 的取值范围在所使用涂料的固化温度减去 40Ό至所使用涂料的固化温度减去 20°C之间；
④ 经加热后的钢管进入喷漆房，喷涂机将具有第二温度值的涂料喷涂到钢管表面， 该第二温度值的取值范围在所使用涂料的固化温度减去 40°C至所使用涂料的固化温度 减去 20°C之间；
⑤ 喷装了涂料的钢管进入漆膜固化房内， 设置在漆膜固化房内的热风循环系统送 出热风， 将钢管加热到所使用涂料的固化温度范围内；
⑥钢管进入冷却房内进行快速冷却；
⑦若冷却后的钢管需要喷装多道漆层，则再依次进入下一个由喷漆房、漆膜固化房 和冷却房组成的喷漆固化单元进行第④、 第⑤、 第⑥步骤的操作； 直至完成全部的涂装 作业。
2、 根据权利要求 1所述的大型钢管防腐涂层自动涂装工艺， 其特征在于： 所述的 涂料中溶剂含量小于 10%。
3、 .根据权利要求 1所述的大型钢管防腐涂层自动涂装工艺， 其特征在于： 所述的 漆膜固化房内采用热空气循环加热。
4、 根据权利要求 1所述的大型钢管防腐涂层自动涂装工艺， 其特征在于： 所述的 喷涂机为高压无气喷涂机，所述涂料从进入该高压无气喷涂机到喷出所用的时间控制在 3分钟内。
5、 一种大型钢管防腐涂层自动涂装生产线， 包括带动钢管旋转并沿钢管中心水平 移动前行的钢管传送机构、 用于去除钢管表面油污及水分的去湿除污机、 用来去除钢管 表面锈层及氧化层的自动抛丸机和将待喷漆钢管进行预加热的预热烘房，所述自动抛丸 机放置在所述去湿除污机和预热烘房之间， 其特征在于： 在所述的预热烘房之后还设置 有喷漆固化单元， 该喷漆固化单元由依次前后成直线分布的喷漆房、 漆膜固化房和冷却 房组成， 其中喷漆房内设置有向钢管表面喷装防腐涂层的喷涂机， 而所述的漆膜固化房 内设有热风循环系统。
6、 根据权利要求 5所述的大型钢管防腐涂层自动涂装生产线， 其特征在于： 所述 的钢管传送机构包括有间隔、等高设置的多个滚轮组， 每个滚轮组又由并列分布且同向 转动的两个滚轮组成，并且相邻的两个滚轮组之间的距离满足钢管在输送时至少同时位 于两个滚轮组之上。
7、 根据权利要求 6所述的大型钢管防腐涂层自动涂装生产线， 其特征在于： 所述 的喷漆固化单元中仅设置两个滚轮组， 且两个滚轮组分别位于喷漆房之前和冷却房之 后。
8、 根据权利要求 5所述的大型钢管防腐涂层自动涂装生产线， 其特征在于： 所述 预热烘房内设有位于所述钢管的下方两侧且斜向钢管设置的喷嘴，所述喷嘴与热空气源 相连。
9、 根据权利要求 5所述的大型钢管防腐涂层自动涂装生产线， 其特征在于： 所述 的喷涂机为高压无气喷涂机， 所述高压无气喷涂机连接涂料自动加热装置。
10、 根据权利要求 5至 9任一权利要求所述的大型钢管防腐涂层自动涂装生产线， 其特征在于： 所述的喷漆固化单元有三个， 分别依次呈直线分布。
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