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15
2025
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08
Agricultural Machinery Electrostatic Spraying Overall Line Solution
Author：
Chuangzhi Coating
As outdoor operation equipment, agricultural machinery is exposed to complex environments such as wind, sun, rain and soil corrosion for a long time, which has high requirements on the weather resistance, wear resistance and corrosion resistance of the coating. The traditional spraying process not only has unstable coating quality, but also has problems such as low paint utilization rate and environmental pollution. As a professional manufacturer of coating line equipment, we have developed an overall electrostatic spraying line solution according to the characteristics of agricultural machinery. Through intelligent and automated production processes, we provide enterprises with efficient, environmentally friendly and high-quality coating services.
Pretreatment System: Laying a Solid Foundation for Coating Adhesion
Agricultural machinery workpieces (such as tractor chassis, harvester shells, etc.) are mostly thick steel plates or cast iron parts. The surface is prone to have impurities such as scale, rust and oil stains. The quality of pretreatment directly affects the coating adhesion.
Our pretreatment system adopts a multi-station spray process, including pre-degreasing, main degreasing, water washing, surface adjustment, phosphating, passivation and other links. For heavy workpieces, high-temperature and high-pressure spraying (temperature 60-70℃, pressure 0.8-1.0MPa) is used in the degreasing stage, together with a special alkaline degreaser, which can quickly remove stubborn oil stains such as engine oil and butter on the surface. Zinc-based phosphating solution is selected for phosphating treatment, forming a uniform phosphating film (film weight 3-5g/m²) on the workpiece surface. This film has strong adhesion with the subsequent coating, which can significantly improve the corrosion resistance of the coating.
To meet the processing needs of large agricultural machinery workpieces, the pretreatment tank is designed with a large size and equipped with a workpiece turning mechanism to ensure that the inner and outer surfaces, corners and gaps of the workpiece can be fully processed. The treated workpiece is passed through a fully automatic drying channel (temperature 80-100℃) to remove surface moisture, avoiding water entering the spraying link and affecting the coating quality.
Electrostatic Spraying System: Precise and Efficient Coating Formation
The electrostatic spraying system is the core of the whole line, which can realize efficient utilization and uniform adhesion of coatings.
According to the coating requirements of different parts of agricultural machinery, we have configured multiple sets of electrostatic spraying equipment. For large-area flat workpieces (such as fuselage shells), a reciprocating electrostatic spraying machine is used, which can automatically adjust the spraying stroke according to the workpiece size. With a high-voltage electrostatic generator (voltage 80-100kV), the paint particles are negatively charged and evenly adsorbed on the workpiece surface under the action of electrostatic attraction. The coating thickness deviation can be controlled within ±5μm. For complex structural parts (such as gearboxes, hydraulic pipeline interfaces), a multi-axis linkage robot electrostatic spray gun is equipped. The robot can accurately extend into the grooves, holes and other parts of the workpiece for spraying through 3D visual positioning, ensuring no spraying dead angle.
The coating supply system adopts closed-loop control, which monitors the coating output in real time through a flow sensor and adjusts it in conjunction with the spraying speed and workpiece area to ensure stable coating thickness. At the same time, the system is equipped with an efficient powder recovery device (for powder coatings) or solvent recovery system (for liquid coatings). The utilization rate of powder coatings can reach more than 95%, and that of liquid coatings can reach more than 70%, which greatly reduces material consumption.
Curing System: Ensuring Stable Coating Performance
The curing system provides appropriate temperature and time conditions for the coating to form a hard film with excellent performance.
Considering that agricultural machinery coatings need to have good weather resistance and wear resistance, the curing oven adopts a segmented temperature control design, with independent control of the heating zone, constant temperature zone and cooling zone. For powder coatings, the curing temperature is usually set at 180-200℃, and the constant temperature time is 20-30 minutes to ensure complete melting and curing of the powder; for liquid coatings, the curing temperature can be adjusted between 120-180℃ according to different coating types.
The interior of the curing oven adopts a hot air circulation system with uniform and stable wind speed, ensuring that the temperature of each part of the workpiece is consistent, and avoiding uneven coating performance caused by local temperature deviation. The furnace body is made of high-efficiency thermal insulation materials with small heat loss, and is equipped with a waste heat recovery device, which can recover the heat of the discharged hot air for preheating fresh air, reducing energy consumption.
Auxiliary and Control Systems: Ensuring Efficient Operation of the Whole Line
The whole line is equipped with perfect auxiliary systems and intelligent control systems to ensure smooth and stable production.
The conveying system adopts a heavy-duty overhead conveyor, which has a large load capacity (single hook can bear more than 500kg), runs stably, and can realize continuous conveying of workpieces between various processes. The control system adopts PLC programming control, which can realize the automatic operation of the whole line. Operators can monitor the operation status and process parameters (such as temperature, pressure, coating thickness, etc.) of each equipment through the touch screen in the central control room. When the system is abnormal (such as insufficient spraying pressure, excessive curing temperature), it will automatically send an alarm signal and display the fault location and cause, facilitating quick troubleshooting and maintenance.
In addition, the whole line is also equipped with a workpiece identification system, which can automatically identify different types of agricultural machinery workpieces and call the corresponding spraying programs and process parameters to realize flexible production of multi-variety workpieces.
Application Effect: Improving Quality and Efficiency
After a large agricultural machinery manufacturer introduced our electrostatic spraying whole line, the production efficiency was greatly improved, and the coating volume of agricultural machinery workpieces per shift increased by 50% compared with the traditional process. The coating quality has been significantly improved. There is no rust in the salt spray test (500 hours), and the coating adhesion reaches level 0, meeting the use requirements of agricultural machinery in harsh environments. At the same time, the improvement of coating utilization rate enables enterprises to save about 300,000 yuan in material costs every year, and energy consumption is reduced by 20%, achieving good economic and environmental benefits.
Conclusion
The overall line solution for electrostatic spraying of agricultural machinery provides high-quality coating protection for agricultural machinery through scientific pretreatment, precise electrostatic spraying and stable curing processes. Its automatic and intelligent characteristics not only improve production efficiency and reduce costs, but also meet environmental protection requirements. Choosing a professional overall line solution can help agricultural machinery enterprises improve their product competitiveness and gain an advantageous position in the market.
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