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Hayden’s Technical Comparison with Other Design Companies—Drying Oven

Release time:

2013-07-23

Hayden air-flow mixing type—other suppliers’ conventional circulating types: circulation frequency 16 cycles/min vs. 2 cycles/min; body temperature difference no greater than 50°C vs. no greater than 110°C—especially effective in addressing insufficient heating at the bottom of the car body, where corrosion is most likely to occur. Operating costs are lower when large circulating fans are not used, resulting in lower energy consumption; using large circulating fans significantly increases energy consumption. The heating zone employs fully contoured radiant panels, ensuring uniform heating throughout the vehicle—same as the left side. Maintenance involves only a few high-temperature dampers; the piping system is complex and makes rapid heating difficult. Generally, duct lengths are very short, matching the length of the drying tunnel. Design is complex, with a short commissioning period. Separate-type exhaust gas treatment systems are available; integrated exhaust gas treatment systems are also available. Serial number Content General factory configuration Hayden configuration 1 Wall panel: foam plastic, steel plate thickness only 0.5–0.6 mm; rock wool density 140 kg/m³, steel plate thickness 1.0–1.2 mm. Insulation performance and service life differ; does not meet fire safety requirements. High-temperature sealant: during wall panel installation, either no sealant is used or domestically produced sealants containing “silicon” are used. It is crucial to use imported high-temperature sealants free of “silicon” when installing the drying oven. Sealants containing “silicon” can lead to long-term problems with coating quality. 2 Internal circulating ducts: typically made of galvanized steel sheets from general steel mills, with sheet thickness of 0.8–1.0 mm and zinc layer thickness of 50–60 mg/m². High-quality galvanized steel sheets from Baosteel have a sheet thickness of 1.2–1.5 mm and a zinc layer thickness of 80 mg/m². Differences in the thickness of galvanized steel sheets and zinc layers directly affect product appearance, service life, and oxidation resistance. Oxidation of the zinc layer will also severely impact product quality. 3 External circulating ducts: typically made of galvanized steel sheets from general steel mills, with sheet thickness of 1.0–1.2 mm and zinc layer thickness of 50–60 mg/m². High-quality galvanized steel sheets from Baosteel have a sheet thickness of 1.5–2.0 mm and a zinc layer thickness of 80 mg/m². Differences in the thickness of galvanized steel sheets and zinc layers directly affect product appearance, service life, and oxidation resistance. 4 Heating system: Italian or Taiwanese burners, self-made heat exchangers (or direct-fired type without heat exchanger), self-made hot-air filtration chambers, domestic filters. German or American burners, high-efficiency heat exchangers manufactured by professional vendors, equipped with fully imported control valve groups, professional-manufactured hot-air filtration chambers, and imported filters. The quality of burners and heat exchangers directly affects heat exchange efficiency, energy utilization rate, flue gas temperature, equipment safety during operation, equipment lifespan, maintenance rate, and overall production line efficiency, among other factors. 5 Hot-air circulating fans: generally high-temperature resistant, high-efficiency, low-noise premium fans (imported bearings); domestic and imported filters differ dramatically in filtration efficiency and precision. 6 Supply air filters: domestic filters vs. imported filters. 7 Exhaust air filters: none vs. imported filters. 8 Duct insulation: insulation thickness 50 mm, outer panel made of 0.5–0.6 mm color-coated steel; insulation thickness 100 mm, outer panel made of 1.0 mm galvanized steel. 9 Exhaust gas outlet: one set vs. two sets. Setting up two separate exhaust systems ensures that, in case of an emergency requiring furnace shutdown, hot air inside the furnace can be quickly expelled, thus avoiding unnecessary damage caused by over-drying of workpieces. 10 Control system: domestic components, domestically produced control cabinet; fully imported components, control cabinets produced by joint ventures. Control accuracy and reliability differ dramatically. 11 Material selection: general steel mills vs. high-quality steel from Baosteel. 12 Component selection: general manufacturers vs. joint ventures or well-known domestic enterprises. 13 Equipment machining accuracy: general vs. very good. 14 Overall reliability: general vs. very good.

	Hayden air-flow mixing type	Other suppliers' conventional cyclic type
Number of cycles	16 times/minute	2 times/minute
Body temperature difference	No more than 50°C	No higher than 110°C—especially to address insufficient heating at the vehicle’s underbody, where corrosion is most likely to occur.
Operating costs	Does not use large circulating fans, resulting in low energy consumption.	Using large-scale circulating fans results in high energy consumption.
Heating zone	Using fully contoured radiant panels, the entire vehicle heats up evenly.	Same as left
Maintenance	Only a few high-temperature dampers.	The pipeline is complex and difficult.
Warming up	Quick	General
Duct length	Very short	Complex design with the same length as the drying tunnel.
Debugging cycle	Short	Complex
Split-type exhaust gas treatment	Possible	Possible
Integrated exhaust gas treatment	Possible	Possible

Serial number	Content	General factory configuration	Hayden configuration
1	Wall panel	Foam plastic, steel plate thickness only 0.5–0.6 mm	Rockwool with a density of 140 kg/m³, steel plate thickness: 1.0–1.2 mm	The thermal insulation performance and service life are different, and they do not meet fire safety requirements.
	High-temperature sealant	Do not use or use domestically produced silicone-containing sealants when installing siding.	Use imported high-temperature sealant that is free of “silicon.”	When installing a drying oven, it is crucial to use high-temperature sealants that do not contain “silicon.” Sealants containing “silicon” can lead to future problems with coating quality.
2	Internal circulating duct	Galvanized steel sheets produced by typical steel mills have a sheet thickness of 0.8 to 1.0 mm and a zinc coating thickness of 50 to 60 mg/m².	Baosteel produces high-quality galvanized steel sheets with a sheet thickness of 1.2 to 1.5 mm and a zinc coating thickness of 80 mg/m².	The thickness of the galvanized steel sheet and the thickness of the zinc coating directly affect the product’s aesthetic appearance, service life, and oxidation resistance. Moreover, the oxidation of the zinc coating can significantly compromise product quality.
3	External circulation duct	Galvanized steel sheets produced by typical steel mills have a sheet thickness of 1.0 to 1.2 mm and a zinc coating thickness of 50 to 60 mg/m².	Baosteel produces high-quality galvanized steel sheets with a thickness of 1.5 to 2.0 mm and a zinc coating weight of 80 mg/m².	The thickness of the galvanized steel sheet and the thickness of the zinc coating directly affect the product’s aesthetic appearance, service life, and oxidation resistance.
4	Heating system	Burners made in Italy or Taiwan, self-made heat exchangers (or direct-fired models without heat exchangers), self-made hot-air filtration chambers, domestically produced filters.	Burners made in Germany or the U.S., high-efficiency heat exchangers manufactured by professional suppliers equipped with fully imported control valve assemblies, hot-air filtration chambers produced by professional manufacturers, and imported filters.	The quality of burners and heat exchangers directly affects the efficiency of heat exchange, energy utilization rate, flue gas temperature, safety during equipment operation, equipment service life, maintenance frequency, and the overall efficiency of the production line, among other factors...
5	Hot air circulation fan	General fan	High-temperature resistant, high-efficiency, low-noise premium fan (imported bearings)	The filtration efficiency and filtration accuracy of domestically produced filters and imported filters are completely different.
6	Air supply filter	Domestic filter	Imported filter
7	Air intake filter	None	Imported filter
8	Duct insulation	Insulation thickness: 50 mm; outer panel: colored steel sheet, 0.5–0.6 mm thick.	Insulation thickness: 100mm; outer panel: 1.0mm galvanized steel sheet.
9	Exhaust outlet	A set	Two sets	Setting up two separate exhaust systems is intended to ensure that, in the event of an abnormal situation requiring furnace shutdown, the hot air inside the furnace can be quickly expelled, thereby preventing overheating of the workpieces and avoiding unnecessary losses.
10	Control system	Domestic components, domestically manufactured control cabinet body	All imported components, control cabinet body manufactured by the joint venture.	Control precision and reliability are completely different.
11	Material Selection	General steel plant	High-quality steel products from Baosteel
12	Selection of the kit	General manufacturer	Joint venture or well-known domestic enterprise
13	Processing accuracy of the equipment	General	Very good
14	Overall Reliability	General	Very good

Relevant plan

Design and Solutions

2017-09-27

Production line informatization

The industrialization and informatization of equipment manufacturing are undergoing a high degree of integration. Intelligent devices—represented by industrial robots—are emerging in large numbers. Moreover, leveraging mobile internet technologies, intelligence is penetrating from industrial settings all the way to end-user devices. For instance, real-time collection and analysis of production data are being used to enhance the intelligence of machine tools themselves; smart human-machine interfaces are being developed to improve the operability of production platforms, and so forth. The rise of vehicle-to-everything (V2X) technology is also integrating the entire lifecycle of vehicles—from manufacturing and usage to traffic management, maintenance, and information services into a cohesive whole. Without the software and hardware coordination of its electrical components, a painting-line process equipment would be like a person without a brain and nervous system—a cold, lifeless piece of machinery, just as a person without a brain and nervous system would be. It is precisely because of industrial informatization technologies and the ceaseless flow of information they generate that these seemingly inert machines can come alive, transforming into a unified, organically functioning entity. Currently, the information-based equipment on production lines includes process cabinets that manage power and control circuits, touchscreen workstations for on-site monitoring of production status, and central control systems for monitoring conveyor operations and process equipment. In addition, body-tracking systems have enabled flexible production, allowing production and sales personnel to promptly check on ordered vehicles. Such systems also help managers schedule production plans efficiently and coordinate overall production activities in real time. In a sense, production scheduling based on body-tracking systems not only seamlessly integrates with production plans but also significantly reduces energy consumption in workshops. All kinds of equipment in the painting workshop’s conveyor systems can be monitored from the central control room—including equipment status, alarm information, alarm archives, and alarm queries. Industrialization and informatization are now deeply converging, leading to the widespread emergence of intelligent devices, exemplified by industrial robots. Furthermore, thanks to mobile internet technologies, industrial intelligence—characterized by process control—is increasingly permeating toward general-purpose smart terminals. For example, by harnessing production data collection and analysis, we can enhance the intelligent feedback capabilities of machine tools; by adopting app-based technologies, we can create smart human-machine interfaces that improve the operability of production platforms; and the rise of V2X technology is integrating the entire lifecycle of vehicles—from manufacturing and usage to traffic management, maintenance, and information services into a seamless whole. We possess the capability to design the electrical control components for complete painting-shop equipment sets, and we can independently design and implement programming for central controllers and process-monitoring systems. Even for critical painting-intelligent equipment—such as painting robots—we have the expertise to program and control them. We believe that, as China’s mechanical precision-machining technologies continue to develop and improve, the localization of painting robots will no longer remain just a dream.

2017-04-26

Coating Engineering Design and Project Management

Modern automobile manufacturing typically consists of four major stages: stamping, welding, painting, and final assembly. Among these, the painting workshop is one of the most complex in terms of equipment and processes; investment in a painting workshop often accounts for more than 30% of the total investment in both processes and equipment. To build a successful painting production line, it is essential to have outstanding painting engineering design and project management capabilities. Hayden boasts an engineering team with 20 years of industry experience and, through strategic collaborations with international peers, continuously tracks and adopts new technologies and proven engineering practices. For example, our successful partnerships with overseas collaborators on two large-scale projects—Jiangling and Venucia—as well as the Russian AUTOVAZ project and the Brazilian Mercedes-Benz project—all demonstrate our ability to deliver superior technology to customers, creating high-level painting production conditions and environments at competitive costs and with exceptional efficiency. Our strategies for addressing challenges in painting engineering design and project management include: Engineering management solutions that balance efficiency and cost to ensure customers achieve a satisfactory return on investment; detailed health and safety plans; an excellent project management team; and comprehensive quality monitoring throughout the entire project lifecycle, ensuring compliance with policies and regulations both in China and globally. We also place great emphasis on fully understanding the value of operational services and taking full responsibility for the entire project lifecycle. As for technical solutions, during the design phase, our unique expertise ensures that we provide users with efficient, dynamic, and integrated systems. By combining excellent design principles with considerations for high efficiency, high reliability, high maintainability, and uncompromising quality, we comprehensively meet the specific requirements of each project. Our key advantages are as follows: Layout design philosophy—in the layout planning stage, we take into account all customer technical specifications, detailed design data and layout parameters specified in the requirements, as well as compliance with international technical standards, work practices, and methodologies. In developing the layout design, we consider the overall concept, providing numerous long-term benefits, including extended equipment maintenance and reliability, rational allocation of auxiliary production areas, centralized placement of exhaust stacks for atmospheric emissions, optimal utilization of equipment, comprehensive installation support, and consistent process alignment. Process equipment design fully considers the customer’s specific requirements regarding process timing, dimensions, and functionality, while leveraging our global capabilities and cutting-edge technologies to meet users’ needs for uniquely customized solutions.

2017-04-26

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