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As a core supporting equipment of the air shower system in clean workshops, the air shower exhaust fan is mainly responsible for discharging dust, odors and excess air flow generated during the air shower process, ensuring the balance of air circulation and the compliance of cleanliness inside the air shower. If the exhaust fan has insufficient air volume, it will not only affect the air shower purification effect, but also trigger a series of chain problems, bringing hidden dangers to the production environment and product quality.
I. Core Problems Caused by Insufficient Air Volume
1. Failure of Air Shower Purification Effect: The core function of an air shower is to blow off floating dust on the surface of the human body or goods through high-speed air flow. Insufficient air volume of the exhaust fan will lead to poor air circulation. The blown-off dust cannot be discharged in a timely manner, and part of the dust will reattach to the surface of the objects, resulting in substandard cleanliness after air shower. This will further pollute the internal environment of the clean workshop and affect the production safety of industries with high cleanliness requirements such as precision manufacturing, pharmaceutical production and food processing.
2. Indoor Air Pressure Imbalance: Clean workshops usually adopt positive pressure or negative pressure design. As a buffer area between the workshop and the outside world, insufficient air volume of the exhaust fan will destroy the air pressure difference between the air shower, the workshop and the outside world. If the workshop adopts positive pressure design, it may lead to the infiltration of external dusty air; if it adopts negative pressure design, the clean air in the workshop may leak. Both will damage the stability of the clean environment of the workshop.
3. Aggravated Hidden Dangers of Equipment Failures: Insufficient air volume will increase the air flow resistance inside the exhaust fan, causing the motor to run under overload for a long time and the temperature to rise. This will not only reduce the service life of the motor, but also may cause safety failures such as motor burnout and short circuit. At the same time, poor air flow will lead to the accumulation of dust on the impeller of the exhaust fan and the inner wall of the pipeline, accelerating equipment wear and further worsening the problem of insufficient air volume, forming a vicious cycle.
4. Deterioration of Operating Environment Comfort: The odors and warm air flow generated during the air shower cannot be discharged in time, which will lead to an increase in temperature and poor air quality inside the air shower, affecting the operating experience of operators. It may even cause discomfort to operators due to the stuffy environment and reduce work efficiency.
II. Main Causes of Insufficient Air Volume
Troubleshooting insufficient air volume needs to start from three aspects: the equipment itself, the pipeline system and the use environment. Common causes include: first, serious dust accumulation on the exhaust fan impeller. The ventilation area decreases after the blades are covered by dust, resulting in reduced air flow driving force; second, blockage, deformation or air leakage of the air inlet and exhaust pipelines. The dust and debris accumulated in the pipelines will hinder air circulation, and pipeline damage will lead to air leakage, reducing the actual exhaust air volume; third, motor failures, such as reduced motor speed, bearing wear, poor line contact, etc., resulting in insufficient motor output power and inability to drive the impeller to reach the rated speed; fourth, decreased sealing performance of the air shower. Air leakage from gaps in door frames and glass leads to air flow diversion, affecting the actual effective air volume of the exhaust fan; fifth, improper selection of exhaust fans. In some scenarios, the rated air volume of the exhaust fan does not match the size of the air shower and the cleanliness requirements of the workshop, and it operates at full load for a long time, gradually leading to air volume attenuation.
III. Effective Solutions
1. Regular Cleaning and Maintenance of Equipment: Formulate a regular cleaning plan, regularly disassemble the exhaust fan housing and impeller, use high-pressure air flow to blow or special cleaning agents to clean the dust and debris on the impeller and the inner wall of the housing, ensuring that the blades are clean and unobstructed; at the same time, clean the motor radiator to avoid affecting motor performance due to poor heat dissipation. It is recommended to clean at least once a month, and shorten to once every two weeks in dusty environments.
2. Overhaul of Pipeline System: Conduct a comprehensive inspection of the air inlet and exhaust pipelines, clean the dust and debris in the pipelines, repair damaged and deformed pipeline parts, seal the pipeline interfaces and flanges, replace aging gaskets to prevent air leakage; if the unreasonable pipeline layout leads to excessive air flow resistance, optimize the pipeline direction, reduce elbows and diameter changes, and reduce ventilation resistance.
3. Troubleshooting of Motor and Electrical System: Check whether the motor speed meets the rated standard. If the speed is insufficient, it may be due to bearing wear and insufficient lubrication. The bearing should be replaced in time and special lubricating oil should be added; at the same time, check electrical components such as lines, contactors and frequency converters, repair poor contact and aging damaged components to ensure stable operation of the motor. If the motor is severely aged, it should be replaced with a motor of the same power and suitable model in time.
4. Strengthen the Sealing Performance of the Air Shower: Check the seals at the connections of the air shower door frame, glass and cabin, replace aging and damaged sealing strips, adjust the closing gap of the door frame, ensure that the air shower is in a good sealing state, and avoid air flow diversion affecting the air volume of the exhaust fan.
5. Optimization of Equipment Selection and Configuration: If insufficient air volume is caused by improper selection after troubleshooting, it is necessary to recalculate the required air volume based on parameters such as the size of the air shower, the level of the clean workshop and the operation frequency, and replace the exhaust fan with a matching rated air volume; at the same time, configure air pressure and air volume monitoring devices to real-time monitor the operation status of the exhaust fan and timely detect and handle air volume abnormalities.
IV. Summary
Insufficient air volume of the air shower exhaust fan seems to be a small problem, but it will actually affect the operation stability of the entire clean workshop and product quality. To solve this problem, we must adhere to the principle of “prevention first, troubleshooting supplemented”. Through regular cleaning and maintenance, regular inspection of equipment and pipelines, optimization of selection and configuration, we can ensure that the exhaust fan is always in the best operating state. At the same time, establishing an equipment operation account to record maintenance and inspection conditions can effectively reduce the incidence of insufficient air volume and provide a reliable guarantee for the clean production environment.
