Applications
PROBLEMS OF WELDING FUME EXTRACTION PROCESS
Vacuum extraction of the welding process is key to maintaining a clean working environment within the production hall. The filter units we manufacture are ideal for extracting fumes, dust, smoke and aerosols generated during metal welding. Welding fumes contain substances hazardous to human health, such as metal oxides and their alloys, which are PM 2.5 in size and can be harmful to the human body. These welding fume particles can be carcinogenic and cause permanent health problems.
There is no one-size-fits-all solution for the extraction of welding workplaces. The client's production programme, the size of the weldments and the welding procedures must be taken into account. At the same time, sufficient extraction of welding fumes must be ensured so that workers have as little contact with them as possible. For effective extraction in welding shops, neither the type of filter used nor its manufacturer is a decisive factor. The most important thing is to correctly determine the amount of air to be extracted and to design adequate extraction equipment. The closer the extraction is to the source, the better and more efficiently the smoke is captured.
Large welding workplaces, where large weldments are produced, pose a significant challenge to ensure ideal extraction. One possible solution is suction arms with extension arms that cover the entire work area. However, since welders often refuse to use the arms, we suggest central, under-ceiling extraction systems. The collection duct is located under the ceiling and the filtered air is returned to floor level.
For local welding workplaces where smaller weldments are welded, it is possible to install exhaust screens that capture almost all welding fumes. These solutions are suitable for repair workplaces after robotic welding or small local welding workplaces up to a weldment size of max. 2 meters. A fume extraction hood is installed at the extraction table with a lower and upper welding smoke trap. The extraction effect ensures that the rising smoke is diverted away from the worker. The welder is completely protected thanks to the sufficient draft of the exhaust system and does not have to have his own filtered air supply to the welding mask.
Robotic workstations are nowadays very common especially in the automotive industry. Exhausting of welding robots, which are located in closed cells, is solved by exhaust hood located under the cell ceiling in the space above the welded part. In the case of welding robot extraction, we place great emphasis on the protection against sparks entering the filter equipment and reducing the risk of ignition in the filter by installing a sorbent dosing station.
Grouping of spot welding robots forming large workplaces with individual spot welding points. Smoking is practically everywhere and at very low intensities. Our opinion after many realizations is that it is NOT POSSIBLE to quality suck out spot welds with a local suction system. The smoke generated by spot welding is constantly blown into the area by the movement of the products by the manipulator. In the case of spot welding clamps equipped with local extraction, it can be clearly seen that the extraction efficiency is at most 10%. Another major problem is the position of the robots waiting for the product tray to be released. In this case, the robot with the smoking product stops in the top position and waits for the tray to be released. In this position, the product finishes smoking and the smoke spreads into the space. Our solution is to enclose the whole group of scoring robots in one process area with a clear sheet. The tarpaulins form the walls of the extracted space, the ceiling of the hall is the ceiling of the enclosed space. The sail forms an enclosed space above the robot workstations from which we extract the polluted air. The extraction system works by extracting the air from the scoring robot area and returning the air back to the hall area after filtering. This eliminates the spread of smoke from the scoring robots towards the area where operators are already present.
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