Laser Cutting/Welding Fume Extractor

TODC-6L Design Solution

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I.BACKGROUND

The pollutant produced in the process of cutting and welding is

metal dust. As the cutting (plasma or laser) and welding dust is very fine,
its particle size is only less than 0.38 microns, the metal dust is easy to float
and settle on the surrounding equipment, so that the service life of the
electronic components of these devices will be affected, such as CNC
cutting machine controllers and electronic components of welding
equipment and other electrical equipment. In addition, the fume dust will
pollute the whole operating environment and affect the cutting quality of
the cutting parts. Moreover, these metal elements and material surface
elements will produce a variety of harmful gases and fume under the
action of high temperature, which will also endanger the health of workers.
It makes workers vulnerable to diseases such lung disease and alcoholic
liver.
In order to prolong the service life of the equipment-prevent the dust
produced during cutting from affecting the reliability of the control system
and other electronic components of the CNC cutting machine, improve
the product quality, protect the environment and improve the working
conditions; prevent all kinds of fume dust and exhaust gas from harming
humor body during cutting. A fume and dust purification system is
installed at the pollution source. The fume and dust purification system is
usually composed of suction hood (fume worktable), pipe, air valve, dust
collector with spark trap, fan and electric control device.
The filter cartridge we use is a patent protection which provided by
Ahlstrom, Finland.
High filtration efficiency: 99.999% emission under 0.1-0.5 micron dust
particle size (cutting&welding dust particle size is 0.38 micron); filter
element-long service life of filter cartridge; filter material has flame
retardant function.
Topsinn equipment is advanced and low in energy consumption,
reasonable in structure and low in maintenance.

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 II.DESIGN SCHEME:
2.1 Design Basis
《Comprehensive Emission Standard of Air Pollutants》 (GB16297-2012)
《Hygienic Standard for Design of Industrial Enterprises》 (GBZ1-2002)
《Occupational Exposure Limits for Harmful Factors in the Workplace》 (GBZ2-2002)
《Code for Design of Heating, Ventilation and Air Conditioning》 (GB50019-2003)
《Design Code for Power Distribution of General Electrical Equipment》 (GB50055-93)
《Code for Design of Low Voltage Distribution》 (GB50054-95)

2.2 Manufacture,Testing standard

《Dust Collector》 (JB/T 10341-2002).
《Technical Performance and Test Method of Dust Collector》(GB/T 11653-2000)
《Guidelines for Pressure Relief of Dust explosion》(GB/T 15605-2008)
《Specification for centrifugal fans for General Use》(JB/T 10563-2006)
《Industrial Fan Noise Limits》(JB/T 8690-1998)
《Fan Vibration Detection and its Limit》(JB/T 8689-1998)
《Technical Specification for Ventilation Ducts》(JGJ141-2004)
《Code for Acceptance of Construction Quality of Ventilation and Air-conditioning Engineering》
(GB 50243Mel 2002).
《Corrosion Grade and Derusting Grade of Steel Surface before Painting》(GB8923-88)
《Environmental Noise Emission Standard for Industrial Enterprises》 (GB12348-2008)

2.3 Design Principles

According to the specific process conditions of the cutting machine, in order

to achieve remarkable dust control effect, reduce equipment investment,
reduce operating costs, and ensure long-term and stable operation of the
equipment, the design of this project follows the following principles:
A. the design and selection of the equipment for the dust removal system
follow the principle of "technologically advanced, economical and practical".
B. The dust collector is reasonable, practical, reliable, advanced, stable in
operation, low in energy consumption, good in dust removal effect and small
in footprint.
C. the design should have reasonable investment and low operating cost. The
investment and operation cost of dust collector can be reduced by
strengthening the sealing and plugging of process equipment, reducing dust
and air volume.
D. convenient maintenance and management: the transformation uses
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 reliable and vulnerable parts as far as possible, the technological process is
simple, and the failure rate of the system and the maintenance rate of
equipment are reduced. At the same time, it takes into account the
convenience of mainframe equipment maintenance.
E. The emission concentration of fume dust meets the emission standard of
environmental protection air pollutants.

2.4 Design Scope

2.4.1 Dust treatment process design
2.4.2 plane layout Design of Dust treatment system
2.4.3 Dust treatment system equipment (including dust removal pipe
dust removal system and auxiliary facilities)

III.Engineer Scope
1.air duct fortifications 2.Dust Collector
3.power system 4.control device

IV.Dust Collector Selection

TODC-L series settling box type sunk flow integrated dust collector
a.A settling box structure, which is beneficial to dust filtration and
sedimentation.
b.The overall area is small
c.The filter material which is basically made of cloth bag is equipped with
nano-film to intercept all the size particles and block the large particle
debris dust with the fine dust on the surface to reduce wear and prolong
life.

TODC-L series dust collector is the first in the world to use gravity and
downward air flow pattern to promote the self-purification process, dusty
air enters from the bottom, and then out from the top of the other side,
the design realizes the dust flow pattern downward "inertia settlement"
dust removal principle, but also makes the dust-carrying air flow direction
consistent with the gravity direction, so that the dust is easier to settle
and remove, and will not be brought back to the filter cartridge.
During the dust collector running, the dusty air enters the TODC-L from
the top inlet, through the filter cartridge, the dust is captured on the outer
surface of the filter cartridge, and the clean air is released into the clean
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air chamber through the center of the filter cartridge and then discharged
through the outlet. When the filter cartridge is cleaned, the solid-state
control timer will automatically select a pair of filter cartridges for dust
removal, so the high-pressure compressed air will rush directly into the
center of the filter cartridge and blow off the dust on the surface of the
filter material. The dust follows the main air flow and falls down into the
ash bucket under the action of gravity.
Topsinn Dust Collector can eradicate the problem of secondary cleaning
and improve the filtration efficiency.

4.1Topsinn Dust Collector Advantages:

4.1.1 Dust Collector Housing

The standard structure is made of No. 7 (5mm thick) and No. 10 steel
(4mm thick). Through reinforcement, the design can withstand up to-20
inch water column (5000pa).

4.1.2 Filter cartridge Bracket

Galvanized steel, unique triangular design structure, in line with the
principle of mechanics; take and put the filter cartridge is convenient and
simple, automatically adjust the reasonable position of the filter cartridge,
so that the filter cartridge is more safely and accurately fixed on the top of
the dust screw rotation design, so that the filter cartridge, filter cover, dust
collector housing are powerful combination, excellent sealing
performance to ensure that dusty air will not be leaked to the clean air
side.

4.1.3 Filter Cartridge Cover

The cover is a stamping molding, through the electrophoretic
painting technology, the protective paint is evenly arranged on the
surface of the barrel cover, ensuring that the thickness is the same, strong
and beautiful, and the phenomenon of paint or bubbles will not occur
within 10 years, the triangular plastic installation handle of the cover,
humanized design, can quickly rotate and install the filter cover.

4.1.4 Filter Element

The dust collector uses a high-efficiency filter element. it is different
from the general traditional filter material, and its surface is covered with
a layer of polytetrafluoroethylene film. The fiber gap of the traditional
filter material (such as cotton cloth, cotton satin, paper and other
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traditional cellulose, etc.) is 5~60um, when the fume dust passes through,
a part of the dust particles will enter the filter and block the filter element;
when the blocking situation gradually deteriorates and the dust can not
be cleaned effectively, the air resistance of the filter element will increase,
and the air flow that can pass through will decrease accordingly. If there is
no automatic dust removal, the filtration effect will decline rapidly, and
the filter material used in this series of dust collector is covered with a
layer of polytetrafluoroethylene film, and its tiny sieve hole can block
most of the submicron dust particles; submicron dust particles gather on
the surface of the filter material and form a permeable dust cake, most of
the dust particles are blocked on the outer surface of the filter material
and can not enter the inside of the filter material, and can be removed in
time and effectively under the purging of compressed air. The filter
material has quite high filtration efficiency, which is at least 3-5 times
higher than that of the traditional filter material, and the filtration
efficiency of ≥ 0.1 μ m dust is more than 99.99%, and the service life is
more than 2 times higher than that of the traditional one.

The filter element adopts PTFE film-coated filter material, which is a

new type of fume and dust capture filter element, and its filtration effect
can leave a deep impression even in a particularly harsh environment. For
non-cohesive dust, PTFE coated filter element can achieve high filtration
efficiency. The filter element maintains a constant filtration capacity even if
the ambient temperature is lower than the dew point temperature. The
high mechanical stability of the material ensures the long service life of the
filter element. The structural design of the filters ensures that they are
compatible with the existing filtration systems. PTFE membrane filter
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material has the advantages of membrane filtration and rigid body
filtration. A strong rigid filter with small size and large filter area allows
high working pressure and has a very long service life.

4.1.5 Self-cleaning Principle of Filter Cartridge

It is realized through the pulse injection mechanism controlled by the
pressure difference sensor: after the dust collector has been running for a
period of time, the fine dust is adsorbed on the surface of the filter
material, which reduces the air permeability of the filter material. One of
the two detection heads of the pressure difference sensor is installed on
the original air side and the other on the inlet air side. When the pressure
difference detected by the pressure difference sensor exceeds a certain set
value, the pressure difference signal is output, the pulse generator starts
the pulse injection valve sequentially after receiving the signal, and clean
compressed air is ejected from the valve port. The ejected air purges the
filter cartridge until the pressure difference is lower than another set value;
the fine dust adsorbed on the surface of the filter material is removed
under the action of air flow and falls in the dust collection bucket in the
lower part of the chamber.
Pulse injection requires 0.6 MPa of clean compressed air, and a
continuous and constant air supply must be maintained in operation.

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 According to the matching experience of Messer, we
recommend 6 pcs of filter cartridges, 7.5KW fan and with
spark trap on the side.

4.2.1TODC-6L Outline Size：

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4.2.2 TODC-6L Technical Parameter

Model TODC-6L
Ahlstrom-Filand,F9
Filter cartridge material
(Optional:HV-USA)
Number of Filter cartridge 6
Air volume 6000m3/h

Air pressure 3600pa

Filtration efficiency 99.99%

Filtering area 120M2
Fan 7.5KW SIEMENS/WEG Motor
Dust capacity 50L

Power requirements THREE-PHASE FOUR-WIRE，380V

0.6MP,
Air pressure request
Compressed air without oil and water

Unit weight 900KG

Outline Dimension(mm)

Emission concentration（mg/M3） <10

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Company Profile:

Dongguan TOPSINN Intelligent equipment Co.,Ltd is a

high-tech enterprise integrating R&D,production ,sales and
service.the headquarter in dongguan city,the pearl river delta
economic zone ,the world's manufacturing center .the branch is
located in wuxi city,and set up offices in Jinan and Wuhan city.
The workshop covers an area of more than 8000 square meters,
with offices and R & D laboratory more than 1000 square
meters,with more than 80 employees.TOPSINN has laser cutting
machines, CNC cutting, folding, cutting and other sheet metal
processing production lines.
With an open and integrated attitude,TOPSINN has gathered a
team of professional technical personnel in the industry, relying
on strong R & D strength, superb technical engineering and
perfect quality control system.

TOPSINN is a professional solution provider in the filed of

Industrial Dust Collection;Enviromental Laser Cleaner ;Metal
Grinding and Polishing Table ;Welding Fume Purification;Oil Mist
Separation,Treatment of VOCs Wast Gas;Effluent Treatment etc.

Advanced technology,excellent quality and professional

service make TOPSINN greatly enhance the market
competitiveness and gain wide favour and praise from domestic
and aboard customers.

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CE certificate ISO9001 certificate

Other patent certificates

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High-Tech Enterprise Certificate

TOPSINN Patented Control System

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