Explosion proof light fixture in the spray paint room lighting application analysis

1. Paint spray booth lighting special challenges and Explosion proof light fixture core value

Paint spray booth as volatile organic compounds [VOCs] and combustible aerosols highly aggregated typical hazardous places, its lighting system needs to meet the explosion-proof, anti-corrosion, high illuminance and other composite needs.

According to GB50058-2014 “Explosion Hazardous Environment Electrical Installation Design Code”, the spraying operation area is defined as IIA / IIB class explosive gas environment 1, must be used in accordance with the Ex d IIB T4 and above explosion-proof lighting equipment.

Traditional lighting equipment in such environments there is a risk of ignition of electric sparks, while the professional design of Explosion proof light fixtures approved structural protection and light source control technology, the surface temperature can be controlled in the T6 group [≤ 80 °C] within the safety range, into the cornerstone of the spray paint room safety operations.

Paint booth lighting three core requirements

Explosion-proof performance: the need to block the lamps and lanterns internal circuit sparks and external xylene, acetone and other combustible gases contact

Chemical resistance: acid and alkali components in the paint mist requires the lamps and lanterns to reach WF2 anticorrosive grade, the shell needs to use aluminum alloy die-casting + nano-spray process.

Optical quality: color rendering index Ra>80, color temperature 5000K natural light, to ensure the accuracy of the paint color detection

2. Explosion proof light fixture technical characteristics and spray paint room scenarios to adapt to the program

2.1 Explosion-proof structure innovation design

Paint booth special Explosion proof light fixture using explosion-proof [Ex d] and increased safety [Ex e] composite explosion-proof structure:

Die-casting aluminum shell and tempered glass shield constitute multiple explosion-proof barrier cavity filled with heat-conducting silica gel, the implementation of high-speed heat diffusion [surface temperature <65 °C] into the mouth of the configuration of the double sealing ring, to prevent the infiltration of paint mist a 500W module Explosion proof light fixturecase shows that its approval of the GB3836.1-2010 certification, explosion-proof marking up to the Ex d e mb IIC T6 Gb, which can cover the 21 area of dust explosion-proof requirements. Requirements.

2.2 Scientific matching of power and light efficiency

Select the appropriate power according to the spray booth area and working precision:

Room size <50 square meters, recommended power 140W, installation density of 4 lamps/10 square meters, illuminance guidelines ≥ 300Lux

Room size 50-200 square meters, the recommended power 300-500W, installation density of 3 / 10 square meters, illuminance guidelines ≥ 500Lux

Room size > 200 square meters, the recommended power 600W, the installation density of 2 / 10 square meters, illuminance guidelines ≥ 800Lux

Such as an automobile spraying workshop using 16 140W Explosion proof light fixtures, the implementation of 500Lux uniform illumination, light source efficiency of 130lm / W

2.3 Intelligent control system integration

A new generation of explosion-proof lights to help the following intelligent features:

Motion sensor dimming: unmanned operation automatically switch to 30% energy-saving mode

Paint mist concentration linkage: synergize with VOCs monitoring system, emergency lighting is triggered when the gas exceeds the standard.

Failure self-diagnosis: Approve IoT module to upload real-time operation data such as light failure and temperature.

3. five dimensions of spray booth Explosion proof light fixture selection

Explosion-proof certification compliance: CNEx/PCEC and other organizations must obtain Ex d IIB T4 certification.

Optical system customization: wide beam [120 °] lamps and lanterns suitable for vehicle spraying, narrow beam [60 °] for precision parts inspection

Convenient maintenance: Quick-open structure design makes the operation of changing lamps <3 minutes, reducing the loss of production downtime.

Environmental adaptability: Choose IP66 protection grade + WF2 corrosion protection grade to cope with high-pressure water jet cleaning scenarios.

Evaluation of energy-efficiency ratio: Prioritize the selection of products with luminous efficacy of more than 100lm/W. The annual power consumption of 500W lamps can be reduced by 62% compared with that of traditional equipment.

4. Industry application cases and benefit analysis

A high-end furniture spray booth renovation project

Original system problems:

The surface temperature of 400W metal halide lamp reaches 120℃, which has triggered the paint mist flash fire accident with an annual maintenance cost of more than 80,000 RMB [including explosion-proof glass replacement].

Remodeling program:

Installation of 24 sets of 300W module Explosion proof light fixtures [Ex d IIB T6/IP66] integrated microwave induction and 0-10V dimming system

Comparison of effectiveness:

Annual electricity cost: 156,000 before remodeling, 58,000 after remodeling, an increase of 62.8%.

Failure rate: 37 times/year before remodeling, 2 times/year after remodeling, up 94.6%.

Paint rework rate: 8.2% before remodeling, 1.5% after remodeling, up 81.7%.

The payback period is only 1.8 years, and it has been awarded the provincial safe production demonstration project.

5. Prospect of technological development momentum

Material innovation: graphene coating technology can reduce the weight of the lamps and lanterns by 40%, heat dissipation efficiency increased by 3 times

Energy autonomy: photovoltaic + energy storage Explosion proof light fixture system has been piloted in the outdoor paint shed, the implementation of off-grid lighting

Digital Twin: approval of the 3D modeling preview of the distribution of the light spot, customized to deal with the problem of the shadows of large-scale workpieces.