汽车涂装生产线能耗的研究分析及节能优化

Research and Analysis of Energy Consumption in Automotive Painting Production Line and Energy-Saving Optimization

通过对某汽车涂装生产线的电、天然气能源使用情况进行研究分析,结果表明,制冷系统、送排风系统、烤箱系统、前处理电泳系统、挥发性有机化合物(VOC)废气处理系统、锅炉、照明系统等为车间内主要能耗设备。通过采取一系列新的技术和精益管理两个方面的节能优化措施,例如:优化制冷机组的控制系统;送风空调的温湿度从“点”控制优化为“窗口”控制;烤箱应用“智能控制系统”以及排气热回收;高能耗照明灯优化成低能耗的LED灯及应用“智能照明节能控制系统”;生产间隙及节假日的节能管理;制定合理的设备维护保养周期等,都能有效降低生产线运行的能耗,实现节能减排和降低单车制造成本的目标。

The research and analysis of the electricity and natural gas consumption in an automotive painting line reveals that cooling system,air supply unit(ASU)and exhaust air system,ovens system,pre-treatment(PT)and electrodeposition(ED)system,VOC treatment,boiler,lighting system are the main energy consumption equipment.Through taking a series of new technology and lean management energy-saving optimization countermeasures,the energy consumption in the painting shop can be significantly reduced.For example,the control system of the cooling system is optimized.The temperature and humidity of the ASU are optimized from the"point"control to the"window"control.The ovens use"intelligent control system"and exhaust heat recovery.The high energy consumption lights are replaced with low energy consumption LED lights and the intelligent lighting energy-saving control system is used.The electricity saving management are optimized during production gaps and holidays.The reasonable equipment maintenance plan is proposed.