Camfil Air Pollution Control partnered with a major auto parts manufacturer that used dust collectors to ensure clean air in robotic welding cells. Their goal was to reduce the downtime associated with dust collector maintenance, but the results were far from ideal.
The facility operators believed they had the best system available, as their previous vendor provided complex computational fluid dynamics (CFD) data showing airflow performance. The vendor claimed the system would prevent fires. However, reality proved otherwise. The dust collection systems caused frequent downtime, expensive repairs, and even internal fires within the collectors themselves.
**Fire, Filter, and Fan Frustrations**
The company struggled with recurring issues in its dust collection systems, which led to significant production delays. Fires in the collectors often forced entire production lines to shut down for days. When pressure built up in the system, the fans would kick in, making it impossible to pulse-clean the filters. As a result, staff had to manually clean the filters during lunch breaks and other off-hours, causing at least two hours of daily downtime. Additionally, the filters needed replacing every six months, increasing both time and operational costs.
The noise from the fans also became a problem, leading to complaints from nearby residents. The fans were prone to overheating, requiring the annual replacement of multiple 50-horsepower motors. Accessing the fans for maintenance was especially challenging in winter, as the collectors were located outdoors.
**Welding Dust and Fume Experts**
Recognizing the need for a more reliable dust collection partner, the facility managers reached out to Camfil APC. Wayne Zimmer from Camfil APC brought a Gold Series dust collector demo trailer to the site, showcasing how easy it was to maintain and remove filters. This hands-on demonstration helped the team understand the benefits of a more efficient system.
Camfil APC then installed a new Gold Series dust collector with an entirely redesigned ductwork system for the welding cells. This system allowed safe recirculation of filtered air back into the plant, thanks to integrated safety monitoring filters.
Thanks to the improved efficiency, the manufacturer hasn’t needed to purchase new filters in over three years. There have been no fires in the collectors, and no additional maintenance has been required for the fans or electrical systems. Impressed by these results, the company decided to install two more dust collection systems from Camfil APC.
**Watch the Full Switching Story**
To learn more about the full transition, watch Zimmer in this video titled “Preventing Downtime for Filter Cleaning.â€
**Dangerous Airborne Particles in Welding Operations**
Welding and cutting activities—whether manual or automated—release harmful fumes made up of fine airborne particles. These contaminants can pose serious health and safety risks to workers. Processes like arc gouging, plasma cutting, and laser cutting generate these fumes, and the amount increases with higher production levels.
The most effective way to reduce exposure is through well-designed dust collection systems equipped with high-efficiency primary cartridge-style filters. In some cases, secondary safety filters may be necessary to capture specific particulates.
**Important Safety and Health Regulations**
After installing customized Camfil APC systems, the auto parts manufacturer was able to recirculate cleaned air back into the workspace. However, the reintroduced air must stay below OSHA permissible exposure limits (PELs) for metal contaminants from welding processes. Facilities that exhaust air outdoors must also meet EPA emission standards.
OSHA PELs are based on an eight-hour time-weighted average (TWA) for metals found in welding fumes. These limits determine the minimum filtration efficiency required for dust collectors. Even if the air meets PELs, some workers may still face health risks, so further reductions in exposure may be necessary.
The EPA’s National Emission Standards for Hazardous Air Pollutants (NESHAP) Rule 6X regulates facilities that vent contaminated air directly outdoors. It covers hazardous pollutants like cadmium, chromium, lead, nickel, and manganese from metal finishing processes.
Cartridge filtration is recognized in Rule 6X as an acceptable control method to eliminate visible emissions. Installing dust and fume collectors with high-efficiency cartridge filtration systems like Camfil APC’s Gold Series helps welding facilities stay compliant with EPA regulations.
Click here to explore more solutions for managing airborne particles in welding environments.
Warp Knitting Electric Parts
Warp knitting electrical components refer to the different electrical parts and accessories used in the production of warp knitted fabrics. These components are essential in ensuring the efficient and effective operation of the warp knitting machines. Some of the common electrical components used in warp knitting include:
1. Motors: These are the power source for the warp knitting machines. They convert electrical energy into mechanical energy to drive the machine's moving parts.
2. Control panels: These are the interface between the operator and the machine. They allow the operator to control and monitor the machine's speed, tension, and other parameters.
3. Sensors: These are used to detect various parameters such as yarn tension, fabric width, and machine speed. They are essential in ensuring the quality of the fabric produced.
4. Electronic cards: These are the brain of the machine. They control the various functions of the machine and ensure that it operates smoothly.
5. Power supplies: These provide the necessary electrical power to the machine and its components.
6. Cables and connectors: These are used to connect the various electrical components of the machine.
Overall, the proper selection and use of warp knitting electrical components are crucial in ensuring the production of high-quality warp knitted fabrics.
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