Work facility

Abstract

A work facility that is capable of adjusting an air volume without a work defect and saving energy. The opening degree of an air volume adjusting damper corresponding to a filter booth for which the individual air volume measured by a corresponding individual flowmeter is the smallest among the respective individual air volumes for the filter booths is adjusted to a completely open state, whereas the opening degree of any other air volume adjusting damper is adjusted to such an opening degree that the individual air volume for the corresponding filter booth as measured by a corresponding individual flowmeter is equal to the smallest individual air volume, and a gas discharge fan is adjusted by a total air volume adjusting mechanism so that a total air volume measured by a total flowmeter is equal to a predetermined target total air volume.

Claims

1. A work facility, comprising: a work booth in which work is performed on a work target; a plurality of filter booths including respective filter units configured to allow emission gas emitted from the work booth to flow through the filter units for removal of a removal target contained in the emission gas; a gas discharge fan configured to cause exhaust gas to be discharged from the filter booths from which exhaust gas the removal target has been removed; a plurality of air volume adjusting dampers, each corresponding to one of the plurality of filter booths, the plurality of air volume adjusting dampers having respective opening degrees adjustable to change respective individual air volumes of the exhaust gas to be discharged from the respective filter booths; a plurality of individual air flow meters, each corresponding to one of the plurality of filter booths and one of the plurality of air volume adjusting dampers, the plurality of individual air flow meters adapted to measure the respective individual air volumes; a total air volume adjusting mechanism adapted to adjust an output of the gas discharge fan to change a total air volume, which is a total of the individual air volumes, the total air volume adjusting mechanism comprises an inverter configured to change the total air volume; and a total air flow meter adapted to measure the total air volume, wherein the opening degree of the air volume adjusting damper that corresponds to a smallest measured respective individual air volume is configured to be adjusted to a completely open state, whereas the opening degree of any of the other air volume adjusting dampers is configured to be adjusted so that the corresponding measured respective individual air volume is equal to a new smallest measured individual air volume, the gas discharge fan is adjusted by the total air volume adjusting mechanism so that the total air volume measured by the total air flow meter is equal to a predetermined target total air volume, and before the opening degrees of the air volume adjusting dampers and the gas discharge fan are adjusted, the respective opening degrees of the air volume adjusting dampers are each adjusted to the completely open state, and the gas discharge fan is adjusted by the total air volume adjusting mechanism so that the total air volume measured by the total air flow meter is equal to the predetermined target total air volume.

2. The work facility according to claim 1, wherein when operation of the work facility is suspended and is resumed later, the respective opening degrees of all the air volume adjusting dampers are in respective states in which the respective opening degrees were immediately before the suspension.

3. The work facility according to claim 1, wherein the respective opening degrees of the air volume adjusting dampers are manually adjustable directly or indirectly.

4. The work facility according to claim 1, further comprising: a plurality of damper controllers configured to adjust the respective opening degrees of the air volume adjusting dampers on a basis of the respective individual air volumes, wherein the respective opening degrees of the air volume adjusting dampers are each automatically adjustable by the corresponding one of the damper controllers.

5. The work facility according to claim 1, wherein in a case where (i) the output of the gas discharge fan has become maximum as a result of the total air volume adjusting mechanism adjusting the gas discharge fan, and (ii) the individual air volume for one of the filter booths which corresponds to one of the air volume adjusting dampers whose opening degree is in the completely open state, the individual air volume being measured by a corresponding one of the individual air flow meters, is lower than a predetermined lower limit individual air volume, the work facility is configured to prompt replacement of said one of the filter units corresponding to said one of the filter booths.

6. The work facility according to claim 1, wherein when one of the filter units is to be replaced, the filter unit to be replaced is detachable in a state where the opening degree of the one of the air volume adjusting dampers which corresponds to the one of the filter booths which includes the filter unit to be replaced is adjusted to a completely closed state, whereas the opening degree of any other one of the air volume adjusting dampers is configured to be adjusted to be larger so as to keep the total air volume achieved immediately before the one of the air volume adjusting dampers which corresponds to the one of the filter booths which includes the filter unit to be replaced became completely closed, and after a replacement filter unit is attached, the opening degree of the one of the air volume adjusting dampers which corresponds to the one of the filter booths which includes the replacement filter unit is adjusted to an opening degree equal to the opening degree to which the one of the air volume adjusting dampers which corresponds to the one of the filter booths which includes the replacement filter unit was adjusted when the filter unit having been replaced was unused, whereas the opening degree of said any other one of the air volume adjusting dampers is configured to be adjusted back to an opening degree that said any other one of the air volume adjusting dampers had before the opening degree of said any other one of the air volume adjusting dampers was adjusted to be larger.

7. The work facility according to claim 6, wherein after said one of the filter units is replaced, (i) the gas discharge fan is configured to be adjusted by the total air volume adjusting mechanism so that the total air volume measured by the total air flow meter is equal to the predetermined target total air volume, and (ii) the opening degree of one of the air volume adjusting dampers which corresponds to one of the filter booths for which the individual air volume measured by the corresponding one of the individual air flow meters is smallest among the respective individual air volumes for the filter booths is configured to be kept in the completely open state, whereas the opening degree of any other one of the air volume adjusting dampers is configured to be adjusted to the opening degree such that that the individual air volume measured by the corresponding one of the individual air flow meters is equal to the smallest individual air volume.

8. The work facility according to claim 1, wherein the work is painting, the work target is a paint target, and the work booth is a paint booth.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a diagram schematically illustrating the arrangement of a first embodiment of a paint facility.

(2) FIG. 2 is a diagram schematically illustrating the arrangement of a second embodiment of a paint facility.

(3) FIG. 3 is a diagram schematically illustrating the arrangement of a third embodiment of a paint facility.

(4) FIG. 4 is a flowchart illustrating a method for adjusting the air volume.

DESCRIPTION OF EMBODIMENTS

(5) The description below deals with a paint facility as an example of the work facility according to the present invention. The example involves (i) painting as the work for the present invention, (ii) a paint target as the work target for the present invention, (iii) a paint booth as the work booth for the present invention, and (iv) overspray contained in emission gas emitted from a paint booth as the removal target for the present invention.

First Embodiment

(6) The description below deals with a first embodiment of the paint facility according to the present invention with reference to drawings.

(7) (Paint Facility)

(8) FIG. 1 illustrates a paint facility 1 including (i) a paint booth 2 configured to spray paint on the body of an automobile as an example of the paint target, (ii) a plurality of filter booths 4 each configured to allow emission gas emitted downward through a work floor 3 of the paint booth 2 to flow through the filter booth 4 for removal of overspray contained in the emission gas, (iii) an air supply fan 5 as an example of an air supply device configured to supply air to the paint booth 2, and (iv) a gas discharge fan 6 as an example of a gas discharge device configured to discharge exhaust gas from which overspray has been removed through the filter booths 4. The air supply fan 5 and the gas discharge fan 6 are adjusted appropriately by a total air volume adjusting mechanism 61, so that the paint booth 2 can maintain an appropriate internal pressure. The total air volume adjusting mechanism 61 is configured to, for example, allow an electric motor to be controlled manually or automatically with use of an inverter to change the volume of air through the air supply fan 5 and the gas discharge fan 6. FIG. 1 shows the total air volume adjusting mechanism 61 directly connected to both the air supply fan 5 and the gas discharge fan 6. Although FIGS. 2-4 do not show a single total air volume adjusting mechanism 61 connected to both the air supply fan 5 and the gas discharge fan 6, one of skill in the art would understand, based on the present disclosure, that the total air volume adjusting mechanism 61, is still connected to and adjusts both the air supply fan 5 and the gas discharge fan 6 whether it is arranged in the configuration shown in FIG. 1 or the configuration shown in FIGS. 2-4.

(9) The paint booth 2 includes a paint booth room 10 containing, for example, (i) a conveyor mechanism (not shown in the drawings) configured to carry automobile bodies into and out of the paint booth room 10 and (ii) a spray device (not shown in the drawings) configured to spray a predetermined painting material onto the automobile bodies, carried in by the conveyor mechanism, from around the automobile bodies.

(10) The paint booth 2 has a top face having an air supply opening 14. The paint facility 1 includes, for example, an air conditioner (not shown in the drawings) in addition to the air supply fan 5 upstream of the air supply opening 14. Fresh air supplied through the air supply opening 14 passes through a dust removing filter 16 for dust removal before flowing down inside the paint booth 2. The air supply fan 5 desirably includes an inverter.

(11) The work floor 3 of the paint booth 2 includes, for example, a grating, and allows air in the paint booth 2 to flow downward therethrough. Turning on the gas discharge fan 6 causes air present inside the paint booth 2 and containing overspray to be emitted from the paint booth 2 through the work floor 3 as emission gas into the filter booths 4.

(12) The plurality of filter booths 4 are all contained in a filter booth room 11 present under the paint booth room 10 and integrally adjacent thereto. The filter booth room 11, in other words, encloses a space under the work floor 3. The paint booth room 10 and the filter booth room 11 may alternatively be two separate rooms.

(13) The filter booth room 11 has a guide flow path 12 configured to (i) receive emission gas emitted through the work floor 3 of the paint booth 2 and then (ii) distribute and guide the emission gas to the plurality of filter booths 4.

(14) The work floor 3 and the filter booths 4 differ from each other in terms of the speed at which air passes therethrough. The plurality of filter booths 4 have a total horizontal projection area that is smaller than the projection area of the work floor 3 of the paint booth 2. The filter booth room 11 thus has a guide flow path 12 under the work floor 3 so that emission gas is emitted to the individual filter booths 4 through the guide flow path 12. The guide flow path 12 has a height that prevents contact between, for example, a rail included in the conveyor mechanism and the filter booths 4.

(15) The filter booth room 11 also has an exhaust gas flow path 13 configured to collect exhaust gas discharged from the plurality of filter booths 4. The gas discharge fan 6 is present downstream of the exhaust gas flow path 13. The paint facility 1 includes a total flowmeter 60 (orifice flowmeter) as an example of the total air volume measuring mechanism, the total flowmeter 60 being configured to measure the total volume of exhaust gas discharged by the gas discharge fan 6.

(16) The filter booths 4 each include a filter unit 41 configured to remove overspray contained in emission gas emitted from the paint booth 2. Emission gas emitted through the work floor 3 of the paint booth 2 downward into the guide flow path 12 is caused to flow through the filter units 41. The paint facility 1 may alternatively omit the guide flow path 12, so that emission gas emitted through the work floor 3 is caused to directly flow through the filter units 41.

(17) The filter units 41 each include an upstream element 42 present upstream in the airflow direction and a downstream element 43 optionally present downstream in the airflow direction to increase the performance of collecting overspray.

(18) A major portion of overspray contained in emission gas emitted from the paint booth 2 can be collected with use of even the upstream element 42, which has a relatively low collecting performance.

(19) The upstream element 42 has an overspray collecting performance lower than that of the downstream element 43, and includes, for example, a mist separator 42a made of paper and an auxiliary filter 42b made of nonwoven fabric.

(20) The mist separator 42a is in the form of a box that is made by appropriately bending a cardboard or kraft sheet and that has an airflow path inside. The mist separator 42a receives emission gas containing overspray at an entrance portion thereof. As the emission gas passes through the airflow path, the overspray collides with and adheres to a wall surface of the airflow path. The mist separator 42a thus discharges exhaust gas from an exit portion thereof from which exhaust gas the overspray has been removed.

(21) The upstream element 42, which is configured to remove a major portion of overspray and tends to need to be replaced frequently, includes a mist separator 42a made of paper and an auxiliary filter 42b made of nonwoven fabric as described above. This allows overspray to be collected inexpensively.

(22) The downstream element 43, in contrast, has an overspray collecting performance higher than that of the upstream element 42.

(23) The downstream element 43 includes a medium-performance filter made of nonwoven fabric. The medium-performance filter has a large pressure loss per unit area as compared to the upstream element 42, and is thus, for example, pleated or bag-shaped for an increased filtration area. This prevents the overall pressure loss from becoming excessively large.

(24) Overspray that the upstream element 42 could not collect can be collected with use of the downstream element 43, which has a relatively high performance.

(25) Overspray that the upstream element 42 could not collect can be collected sufficiently with use of the medium-performance filter as the downstream element 43.

(26) The upstream element 42 and downstream element 43 of each filter unit 41 are placed on respective placement frames to be capable of being replaced separately depending on the degree of degradation due to overspray collection.

(27) The filter booths 4 each have a discharge opening 15 configured to discharge, to the exhaust gas flow path 13, air from which overspray has been removed through the filter unit 41. The filter booths 4 each include, at the discharge opening 15, an air volume adjusting damper 7 capable of adjusting the individual air volume for the filter booth 4. The air volume adjusting damper 7 for the present embodiment is operated manually.

(28) Adjusting the opening degree of the air volume adjusting damper 7 can adjust the individual air volume for the filter unit 41 included in the corresponding filter booth 4, which individual air volume decreases depending on the degree of clogging of the filter unit 41.

(29) The degree of clogging of each filter unit 41 may be evaluated on the basis of (i) an actually measured individual air volume (measured individual air volume) or (ii) an air volume rate calculated by dividing the measured individual air volume by a target individual air volume. The degree of clogging of each filter unit 41 can be evaluated on the basis of the air volume rate as follows: If the measured individual air volume is small compared to the target individual air volume, the air volume rate is smaller than 1. If the measured individual air volume is large as compared to the target individual air volume, the air volume rate is larger than 1. A filter booth 4 with an air volume rate of smaller than 1 is evaluated as having a measured individual air volume that is small for the opening degree of the air volume adjusting damper 7. For such a filter booth 4, the air volume adjusting damper 7 is adjusted to have a larger opening degree. A filter booth 4 with an air volume rate of larger than 1 is evaluated as having a measured individual air volume that is large for the opening degree of the air volume adjusting damper 7. For such a filter booth 4, the air volume adjusting damper 7 is adjusted to have a smaller opening degree.

(30) The filter booths 4 each include (i) a differential pressure measuring mechanism (not shown in the drawings) configured to measure a differential pressure of the filter unit 41 and (ii) an individual flowmeter 8 (orifice flowmeter) as an example of the individual air volume measuring mechanism, the individual flowmeter 8 being configured to measure the individual air volume for the filter unit 41. The individual flowmeter 8 is present between the filter unit 41 and the air volume adjusting damper 7.

(31) (Method for Adjusting Air Volume)

(32) The description below deals with how the paint facility 1 as the present embodiment adjusts the air volume, with reference to FIG. 4.

(33) Before the start of a painting process by the paint facility 1, an operator adjusts the opening degree of the air volume adjusting damper 7 of each filter booth 4 to a completely open state (#1). In this state, the air supply fan 5 and the gas discharge fan 6 are turned on. The air supply fan 5 runs at a predetermined rotation speed, while the gas discharge fan 6 is adjusted by the total air volume adjusting mechanism so that the total air volume measured by the total flowmeter 60 is equal to a predetermined target total air volume (#2). This causes the paint booth 2 to have a predetermined target room pressure.

(34) After the internal airflow of the paint booth 2 becomes stable, the individual air volume for each filter booth 4 is measured with use of the individual flowmeter 8. The operator adjusts the opening degree of the air volume adjusting damper 7 of any filter booth 4 with an air volume rate of larger than 1 so that the measured individual air volume is equal to the target individual air volume (#3).

(35) Adjusting the opening degree of the air volume adjusting damper 7 as described above decreases the total air volume, which is the total of individual air volumes (No in #4). Thus, the gas discharge fan 6 is adjusted by the total air volume adjusting mechanism 61 so that the measured total air volume is equal to the predetermined target total air volume (#5).

(36) When the respective individual air volumes of all the filter booths 4 have been adjusted so as to be equal to one another (Yes in #4), the operator remembers the opening degree of each air volume adjusting damper 7 as an initial value. This is the end of the initialization.

(37) As described above, the opening degree of each air volume adjusting damper 7 is adjusted to the completely open state. The gas discharge fan 6 is adjusted by the total air volume adjusting mechanism 61 so that the measured total air volume is equal to a predetermined target total air volume. Subsequently, the opening degree of the air volume adjusting damper 7 of the filter booth 4 with the smallest measured individual air volume is adjusted to the completely open state. The opening degree of any other air volume adjusting damper 7 is adjusted so that its measured individual air volume is equal to the smallest measured individual air volume. The gas discharge fan 6 is adjusted by the total air volume adjusting mechanism 61 so that the measured total air volume is equal to the predetermined target total air volume.

(38) After the internal airflow of the paint booth 2 becomes stable, automobile bodies start to be carried into the paint booth 2 for the start of the painting process (#6).

(39) During the painting process, if a filter unit 41 is clogged by overspray, the individual air volume for the filter booth 4 is decreased, thereby causing a decrease in the total air volume.

(40) The operator checks whether the measured total air volume is smaller than the target total air volume to determine whether the total air volume has been decreased (#7).

(41) If the total air volume has been decreased (Yes in #7), the painting process is suspended, and the operator checks the air volume rate of each filter booth 4. The operator adjusts the opening degree of the air volume adjusting damper 7 of any filter booth 4 with an air volume rate of smaller than 1 (#8).

(42) Adjusting the opening degree of the air volume adjusting damper 7 as described above changes the total air volume, which is the total of individual air volumes. The gas discharge fan 6 is thus adjusted by the total air volume adjusting mechanism 61 so that the measured total air volume is equal to the target total air volume (#9).

(43) After the internal airflow of the paint booth 2 becomes stable, the operator checks the air volume rate of each filter booth 4. The operator adjusts the opening degree of the air volume adjusting damper 7 of any filter booth 4 with an air volume rate of larger than 1 (#10).

(44) Adjusting the opening degree of the air volume adjusting damper 7 as described above changes the total air volume, which is the total of individual air volumes. The gas discharge fan 6 is thus adjusted by the total air volume adjusting mechanism 61 so that the measured total air volume is equal to the target total air volume (#11).

(45) After the internal airflow of the paint booth 2 becomes stable, the operator checks whether the measured individual air volume for each filter booth 4 is equal to the target individual air volume (#12).

(46) Steps #8 to #12 are repeated until the measured individual air volume for each filter booth 4 is equal to the target individual air volume (No in #12).

(47) The above procedure is as follows: The opening degree of the air volume adjusting damper 7 of the filter booth 4 with the smallest measured individual air volume is adjusted to the completely open state. The opening degree of any other air volume adjusting damper 7 is adjusted so that its measured individual air volume is equal to the smallest measured individual air volume. The gas discharge fan 6 is adjusted by the total air volume adjusting mechanism 61 so that the measured total air volume is equal to the predetermined target total air volume.

(48) If the measured individual air volume for each filter booth 4 is equal to the target individual air volume (Yes in #12), the painting process is resumed (#6).

(49) While steps #6 to #12 are repeated, if the measured total air volume shows a decrease (Yes in #7), if the opening degree of an air volume adjusting damper 7 has been adjusted (#8, #10), or if the gas discharge fan 6 has been adjusted (#9, #11), whether the filter units 41 each need replacing is determined. If, after each of steps #7 to #11, any filter unit 41 has a differential pressure as measured with use of the differential pressure measuring mechanism which differential pressure exceeds a predetermined upper limit differential pressure, it is determined that that filter unit 41 needs replacing. If it has been determined that a filter unit 41 needs replacing, an alarm is triggered to that effect.

(50) While steps #6 to #12 are repeated, if the gas discharge fan 6 has been adjusted (#9, #11), whether the filter units 41 each need replacing is determined. If the gas discharge fan 6 has been adjusted to produce its maximum output, and any air volume adjusting damper 7 with an opening degree in the completely open state has an air volume rate of smaller than 1, it is determined that the filter unit 41 of the filter booth 4 including that air volume adjusting damper 7 needs replacing. If it has been determined that a filter unit 41 needs replacing, an alarm is triggered to that effect.

(51) A filter unit 41 is replaced through the following procedure: The opening degree of the air volume adjusting damper 7 included in the filter booth 4 including a filter unit 41 to be replaced is adjusted to a completely closed state. The opening degree of any other air volume adjusting damper 7 is adjusted to be larger so as to keep the total air volume achieved immediately before the air volume adjusting damper 7 included in the filter booth 4 including the filter unit 41 to be replaced became completely closed. In this state, the filter unit 41 to be replaced is detached.

(52) After a new filter unit 41 is attached, the opening degree of the air volume adjusting damper 7 included in the filter booth 4 including the new filter unit 41 is adjusted to the initial value. The opening degree of any other air volume adjusting damper 7 is adjusted to the opening degree kept before it was adjusted to be larger.

(53) Subsequently, the gas discharge fan 6 is adjusted by the total air volume adjusting mechanism 61 so that the measured total air volume is equal to the predetermined target total air volume (#5), and all the filter booths 4 have respective individual air volumes equal to one another (Yes in #4). After the internal airflow of the paint booth 2 becomes stable, the painting process is resumed (#6).

(54) The above procedure is as follows: After a filter unit 41 is replaced, the gas discharge fan 6 is adjusted by the total air volume adjusting mechanism 61 so that the measured total air volume is equal to a predetermined target total air volume. The opening degree of the air volume adjusting damper 7 of the filter booth 4 with the smallest measured individual air volume is kept in the completely open state. In this state, the opening degree of any other air volume adjusting damper 7 is adjusted so that its measured individual air volume is equal to the smallest measured individual air volume.

Second Embodiment

(55) The description below deals with a second embodiment of the paint facility 1 according to the present invention with reference to FIG. 2. Any member of the present embodiment that is similar to a member of the first embodiment above is assigned the same reference sign, and is not described here. The description below thus mainly deals with differences as compared to the first embodiment.

(56) (Paint Facility)

(57) The paint facility 1 as the present embodiment includes (i) a plurality of actuators 70 each configured to adjust the opening degree of the corresponding air volume adjusting damper 7 and (ii) a plurality of damper operators 71 each configured to operate the corresponding actuator 70. An operator can operate the damper operators 71 to remotely operate the air volume adjusting dampers 7 via the actuators 70.

(58) The gas discharge fan 6 included in the paint facility 1 as the present embodiment includes a total air volume controller 61 (which is an example of the “total air volume adjusting mechanism”) configured to automatically adjust the output of the gas discharge fan 6 on the basis of the result of measurement by the total flowmeter 60. If, for instance, clogging due to overspray has changed the total air volume, the total air volume controller 61 automatically adjusts the gas discharge fan 6 to change the total air volume accordingly.

(59) (Method for Adjusting Air Volume)

(60) The description below deals with how the paint facility 1 as the present embodiment adjusts the air volume while the paint facility 1 is in operation. The overall flow is similar to the air volume adjusting method for the first embodiment above. The description below covers the overlap as well with reference to FIG. 4.

(61) Before the start of a painting process by the paint facility 1, an operator operates the damper operator of each filter booth 4 to adjust the opening degree of the corresponding air volume adjusting damper 7 via the corresponding actuator 70 to a completely open state (#1). In this state, the air supply fan 5 and the gas discharge fan 6 are turned on. The air supply fan 5 runs at a predetermined rotation speed, while the gas discharge fan 6 is adjusted by the total air volume controller 61 so that the total air volume measured by the total flowmeter 60 is equal to a predetermined target total air volume (#2). This causes the paint booth 2 to have a predetermined target room pressure. The total air volume controller 61 stores information on the target total air volume.

(62) After the internal airflow of the paint booth 2 becomes stable, the individual air volume for each filter booth 4 is measured with use of the individual flowmeter 8. The operator adjusts the opening degree of the air volume adjusting damper 7 of any filter booth 4 with an air volume rate of larger than 1 through operation of the corresponding damper operator so that the measured individual air volume is equal to the target individual air volume (#3).

(63) Adjusting the opening degree of the air volume adjusting damper 7 as described above decreases the total air volume, which is the total of individual air volumes (No in #4). Thus, the gas discharge fan 6 is adjusted by the total air volume controller 61 so that the measured total air volume is equal to the predetermined target total air volume (#5).

(64) When the respective individual air volumes of all the filter booths 4 have been adjusted so as to be equal to one another (Yes in #4), the operator records the opening degree of each air volume adjusting damper 7 as an initial value. This is the end of the initialization.

(65) As described above, the opening degree of each air volume adjusting damper 7 is adjusted to the completely open state. The gas discharge fan 6 is adjusted by the total air volume controller 61 so that the measured total air volume is equal to a predetermined target total air volume. Subsequently, the opening degree of the air volume adjusting damper 7 of the filter booth 4 with the smallest measured individual air volume is adjusted to the completely open state. The opening degree of any other air volume adjusting damper 7 is adjusted so that its measured individual air volume is equal to the smallest measured individual air volume. The gas discharge fan 6 is adjusted by the total air volume controller 61 so that the measured total air volume is equal to the predetermined target total air volume.

(66) After the internal airflow of the paint booth 2 becomes stable, automobile bodies start to be carried into the paint booth 2 for the start of the painting process (#6).

(67) During the painting process, if a filter unit 41 is clogged by overspray, the individual air volume for the filter booth 4 is decreased, thereby causing a decrease in the total air volume.

(68) The total air volume controller 61 checks whether the measured total air volume is smaller than the target total air volume to determine whether the total air volume has been decreased (#7).

(69) If the total air volume has been decreased (Yes in #7), the painting process is suspended, and the operator checks the air volume rate of each filter booth 4. The operator adjusts the opening degree of the air volume adjusting damper 7 of any filter booth 4 with an air volume rate of smaller than 1 through operation of the corresponding damper operator (#8).

(70) Adjusting the opening degree of the air volume adjusting damper 7 as described above changes the total air volume, which is the total of individual air volumes. The gas discharge fan 6 is thus adjusted by the total air volume controller 61 so that the measured total air volume is equal to the target total air volume (#9).

(71) After the internal airflow of the paint booth 2 becomes stable, the operator checks the air volume rate of each filter booth 4. The operator adjusts the opening degree of the air volume adjusting damper 7 of any filter booth 4 with an air volume rate of larger than 1 through operation of the corresponding damper operator (#10).

(72) Adjusting the opening degree of the air volume adjusting damper 7 as described above changes the total air volume, which is the total of individual air volumes. The gas discharge fan 6 is thus adjusted by the total air volume controller 61 so that the measured total air volume is equal to the target total air volume (#11).

(73) After the internal airflow of the paint booth 2 becomes stable, the operator checks whether the measured individual air volume for each filter booth 4 is equal to the target individual air volume (#12).

(74) Steps #8 to #12 are repeated until the measured individual air volume for each filter booth 4 is equal to the target individual air volume (No in #12).

(75) The above procedure is as follows: The opening degree of the air volume adjusting damper 7 of the filter booth 4 with the smallest measured individual air volume is adjusted to the completely open state. The opening degree of any other air volume adjusting damper 7 is adjusted so that its measured individual air volume is equal to the smallest measured individual air volume. The gas discharge fan 6 is adjusted by the total air volume controller 61 so that the measured total air volume is equal to the predetermined target total air volume.

(76) If the measured individual air volume for each filter booth 4 is equal to the target individual air volume (Yes in #12), the painting process is resumed (#6).

(77) While steps #6 to #12 are repeated, if the measured total air volume shows a decrease (Yes in #7), if the opening degree of an air volume adjusting damper 7 has been adjusted (#8, #10), or if the gas discharge fan 6 has been adjusted (#9, #11), whether the filter units 41 each need replacing is determined. If, after each of steps #7 to #11, any filter unit 41 has a differential pressure as measured with use of the differential pressure measuring mechanism which differential pressure exceeds a predetermined upper limit differential pressure, it is determined that that filter unit 41 needs replacing. If it has been determined that a filter unit 41 needs replacing, an alarm is triggered to that effect.

(78) While steps #6 to #12 are repeated, if the gas discharge fan 6 has been adjusted (#9, #11), whether the filter units 41 each need replacing is determined. If the gas discharge fan 6 has been adjusted to produce its maximum output, and any air volume adjusting damper 7 with an opening degree in the completely open state has an air volume rate of smaller than 1 (for example, an individual air volume smaller than a predetermined lower limit individual air volume), it is determined that the filter unit 41 of the filter booth 4 including that air volume adjusting damper 7 needs replacing. If it has been determined that a filter unit 41 needs replacing, an alarm is triggered to that effect.

(79) A filter unit 41 is replaced through the following procedure: The opening degree of the air volume adjusting damper 7 included in the filter booth 4 including a filter unit 41 to be replaced is adjusted to a completely closed state. The opening degree of any other air volume adjusting damper 7 is adjusted to be larger so as to keep the total air volume achieved immediately before the air volume adjusting damper 7 included in the filter booth 4 including the filter unit 41 to be replaced became completely closed. In this state, the filter unit 41 to be replaced is detached.

(80) After a new filter unit 41 is attached, the opening degree of the air volume adjusting damper 7 included in the filter booth 4 including the new filter unit 41 is adjusted to the initial value. The opening degree of any other air volume adjusting damper 7 is adjusted to the opening degree kept before it was adjusted to be larger.

(81) Subsequently, the gas discharge fan 6 is adjusted by the total air volume controller 61 so that the measured total air volume is equal to the predetermined target total air volume (#5), and all the filter booths 4 have respective individual air volumes equal to one another (Yes in #4). After the internal airflow of the paint booth 2 becomes stable, the painting process is resumed (#6).

(82) The above procedure is as follows: After a filter unit 41 is replaced, the gas discharge fan 6 is adjusted by the total air volume controller 61 so that the measured total air volume is equal to a predetermined target total air volume. The opening degree of the air volume adjusting damper 7 of the filter booth 4 with the smallest measured individual air volume is kept in the completely open state. In this state, the opening degree of any other air volume adjusting damper 7 is adjusted so that its measured individual air volume is equal to the smallest measured individual air volume.

Third Embodiment

(83) The description below deals with a third embodiment of the paint facility 1 according to the present invention with reference to FIG. 3. Any member of the present embodiment that is similar to a member of the first embodiment above is assigned the same reference sign, and is not described here. The description below thus mainly deals with differences as compared to the first embodiment.

(84) (Paint Facility)

(85) The paint facility 1 as the present embodiment includes (i) a plurality of actuators 70 each configured to adjust the opening degree of the corresponding air volume adjusting damper 7 and (ii) a plurality of damper controllers 72 (which is an example of the “damper controlling mechanism”) each configured to automatically adjust the corresponding actuator 70 on the basis of the result of measurement by the corresponding individual flowmeter 8. If, for instance, clogging due to overspray has changed the individual air volume for a filter booth 4, the damper controller 72 included in that filter booth 4 automatically adjusts the opening degree of the corresponding air volume adjusting damper 7 via the corresponding actuator 70 to change the individual air volume accordingly.

(86) The gas discharge fan 6 included in the paint facility 1 as the present embodiment includes a total air volume controller 61 (which is an example of the “total air volume adjusting mechanism”) configured to automatically adjust the output of the gas discharge fan 6 on the basis of the result of measurement by the total flowmeter 60. If, for instance, clogging due to overspray has changed the total air volume, the total air volume controller 61 automatically adjusts the gas discharge fan 6 to change the total air volume accordingly.

(87) (Method for Adjusting Air Volume)

(88) The description below deals with how the paint facility 1 as the present embodiment adjusts the air volume while the paint facility 1 is in operation. The overall flow is similar to the air volume adjusting method for the first embodiment above. The description below covers the overlap as well with reference to FIG. 4.

(89) Before the start of a painting process by the paint facility 1, the opening degree of the air volume adjusting damper 7 of each filter booth 4 is adjusted by the corresponding damper controller 72 via the corresponding actuator 70 to a completely open state (#1). In this state, the air supply fan 5 and the gas discharge fan 6 are turned on. The air supply fan 5 runs at a predetermined rotation speed, while the gas discharge fan 6 is adjusted by the total air volume controller 61 so that the total air volume measured by the total flowmeter 60 is equal to a predetermined target total air volume (#2). This causes the paint booth 2 to have a predetermined target room pressure. The total air volume controller 61 stores information on the target total air volume.

(90) After the internal airflow of the paint booth 2 becomes stable, the individual air volume for each filter booth 4 is measured with use of the individual flowmeter 8. The opening degree of the air volume adjusting damper 7 of any filter booth 4 with an air volume rate of larger than 1 is adjusted by the corresponding damper controller 72 through operation of the corresponding damper operator so that the measured individual air volume is equal to the target individual air volume (#3).

(91) Adjusting the opening degree of the air volume adjusting damper 7 as described above decreases the total air volume, which is the total of individual air volumes (No in #4). Thus, the gas discharge fan 6 is adjusted by the total air volume controller 61 so that the measured total air volume is equal to the predetermined target total air volume (#5).

(92) When the respective individual air volumes of all the filter booths 4 have been adjusted so as to be equal to one another (Yes in #4), information on the opening degree of each air volume adjusting damper 7 is stored in the corresponding damper controller 72 as an initial value. This is the end of the initialization.

(93) As described above, the opening degree of each air volume adjusting damper 7 is adjusted to the completely open state. The gas discharge fan 6 is adjusted by the total air volume controller 61 so that the measured total air volume is equal to a predetermined target total air volume. Subsequently, the opening degree of the air volume adjusting damper 7 of the filter booth 4 with the smallest measured individual air volume is adjusted to the completely open state. The opening degree of any other air volume adjusting damper 7 is adjusted so that its measured individual air volume is equal to the smallest measured individual air volume. The gas discharge fan 6 is adjusted by the total air volume controller 61 so that the measured total air volume is equal to the predetermined target total air volume.

(94) After the internal airflow of the paint booth 2 becomes stable, automobile bodies start to be carried into the paint booth 2 for the start of the painting process (#6).

(95) During the painting process, if a filter unit 41 is clogged by overspray, the individual air volume for the filter booth 4 is decreased, thereby causing a decrease in the total air volume.

(96) The total air volume controller 61 checks whether the measured total air volume is smaller than the target total air volume to determine whether the total air volume has been decreased (#7).

(97) If the total air volume has been decreased (Yes in #7), the painting process is suspended, and the air volume rate of each filter booth 4 is checked by the corresponding damper controller 72. The opening degree of the air volume adjusting damper 7 of any filter booth 4 with an air volume rate of smaller than 1 is adjusted by the corresponding damper controller 72 through operation of the corresponding damper operator (#8).

(98) Adjusting the opening degree of the air volume adjusting damper 7 as described above changes the total air volume, which is the total of individual air volumes. The gas discharge fan 6 is thus adjusted by the total air volume controller 61 so that the measured total air volume is equal to the target total air volume (#9).

(99) After the internal airflow of the paint booth 2 becomes stable, the air volume rate of each filter booth 4 is checked by the corresponding damper controller 72. The opening degree of the air volume adjusting damper 7 of any filter booth 4 with an air volume rate of larger than 1 is adjusted by the corresponding damper controller 72 through operation of the corresponding damper operator (#10).

(100) Adjusting the opening degree of the air volume adjusting damper 7 as described above changes the total air volume, which is the total of individual air volumes. The gas discharge fan 6 is thus adjusted by the total air volume controller 61 so that the measured total air volume is equal to the target total air volume (#11).

(101) After the internal airflow of the paint booth 2 becomes stable, whether the measured individual air volume for each filter booth 4 is equal to the target individual air volume is checked by the corresponding damper controller 72 (#12).

(102) Steps #8 to #12 are repeated until the measured individual air volume for each filter booth 4 is equal to the target individual air volume (No in #12).

(103) The above procedure is as follows: The opening degree of the air volume adjusting damper 7 of the filter booth 4 with the smallest measured individual air volume is adjusted to the completely open state. The opening degree of any other air volume adjusting damper 7 is adjusted so that its measured individual air volume is equal to the smallest measured individual air volume. The gas discharge fan 6 is adjusted by the total air volume controller 61 so that the measured total air volume is equal to the predetermined target total air volume.

(104) If the measured individual air volume for each filter booth 4 is equal to the target individual air volume (Yes in #12), the painting process is resumed (#6).

(105) While steps #6 to #12 are repeated, if the measured total air volume shows a decrease (Yes in #7), if the opening degree of an air volume adjusting damper 7 has been adjusted (#8, #10), or if the gas discharge fan 6 has been adjusted (#9, #11), whether the filter units 41 each need replacing is determined. If, after each of steps #7 to #11, any filter unit 41 has a differential pressure as measured with use of the differential pressure measuring mechanism which differential pressure exceeds a predetermined upper limit differential pressure, it is determined that that filter unit 41 needs replacing. If it has been determined that a filter unit 41 needs replacing, an alarm is triggered to that effect.

(106) While steps #6 to #12 are repeated, if the gas discharge fan 6 has been adjusted (#9, #11), whether the filter units 41 each need replacing is determined. If the gas discharge fan 6 has been adjusted to produce its maximum output, and any air volume adjusting damper 7 with an opening degree in the completely open state has an air volume rate of smaller than 1 (for example, an individual air volume smaller than a predetermined lower limit individual air volume), it is determined that the filter unit 41 of the filter booth 4 including that air volume adjusting damper 7 needs replacing. If it has been determined that a filter unit 41 needs replacing, an alarm is triggered to that effect.

(107) A filter unit 41 is replaced through the following procedure: The opening degree of the air volume adjusting damper 7 included in the filter booth 4 including a filter unit 41 to be replaced is adjusted to a completely closed state. The opening degree of any other air volume adjusting damper 7 is adjusted to be larger so as to keep the total air volume achieved immediately before the air volume adjusting damper 7 included in the filter booth 4 including the filter unit 41 to be replaced became completely closed. In this state, the filter unit 41 to be replaced is detached.

(108) After a new filter unit 41 is attached, the opening degree of the air volume adjusting damper 7 included in the filter booth 4 including the new filter unit 41 is adjusted to the initial value. The opening degree of any other air volume adjusting damper 7 is adjusted to the opening degree kept before it was adjusted to be larger.

(109) Subsequently, the gas discharge fan 6 is adjusted by the total air volume controller 61 so that the measured total air volume is equal to the predetermined target total air volume (#5), and all the filter booths 4 have respective individual air volumes equal to one another (Yes in #4). After the internal airflow of the paint booth 2 becomes stable, the painting process is resumed (#6).

(110) The above procedure is as follows: After a filter unit 41 is replaced, the gas discharge fan 6 is adjusted by the total air volume controller 61 so that the measured total air volume is equal to a predetermined target total air volume. The opening degree of the air volume adjusting damper 7 of the filter booth 4 with the smallest measured individual air volume is kept in the completely open state. In this state, the opening degree of any other air volume adjusting damper 7 is adjusted so that its measured individual air volume is equal to the smallest measured individual air volume.

Other Embodiments

(111) 1. The automatic adjustment by the total air volume controller or damper controllers for the above-described embodiments is not limited to any particular type, and may be based on PID control or AI control.

(112) 2. The paint facility of the present invention may, as necessary, further include a device configured to detect a lateral airflow in the paint booth and be configured to, if the device has detected a lateral airflow, adjust the air volume adjusting dampers to prevent the lateral airflow.

(113) Although the present invention is described as above with reference to drawings, the present invention is not limited to the arrangements illustrated in the drawings, and may be embodied variously without departing from the scope of the present invention.

INDUSTRIAL APPLICABILITY

(114) The work facility of the present invention is usable in a suitable manner particularly in such technical fields as those which involve painting the entire body of, for example, an automobile, a railway vehicle, an airplane, or a ship as well as various parts thereof and those which involve a clean room for producing, for example, a semiconductor device or a food item.

REFERENCE SIGNS LIST

(115) 1 Paint facility (which is an example of the “work facility”) 10 Paint booth room 11 Filter booth room 12 Guide flow path 13 Exhaust gas flow path 14 Air supply opening 15 Discharge opening 16 Dust removing filter 2 Paint booth (which is an example of the “work booth”) 3 Work floor 4 Filter booth 41 Filter unit 42 Upstream element 42a Mist separator 42b Auxiliary filter 43 Downstream element 5 Air supply fan (which is an example of the “air supply device”) 6 Gas discharge fan (which is an example of the “gas discharge device”) 60 Total flowmeter (which is an example of the “total air volume measuring mechanism”) 61 Total air volume controller (which is an example of the “total air volume adjusting mechanism”) 7 Air volume adjusting damper 70 Actuator 71 Damper operator 72 Damper controller (which is an example of the “damper controlling mechanism”) 8 Individual flowmeter (which is an example of the “individual air volume measuring mechanism”)