Cut out the shaped parts of the ventilation. Industrial ventilation and its features

Modern building– enterprise, industrial facility, a private house– it is impossible to imagine without an air exchange complex. Ventilation is a key component of any building engineering communications. Without timely supply, treatment and removal of air flows, it is extremely difficult to maintain an optimal climate for technical personnel and conditions for the correct operation of production equipment. Cutting the shaped parts of industrial ventilation is an extremely important stage in the installation of an air exchange complex. A number of activities for the production of ventilation pipe components require exclusively vocational training and implementation.

Industrial air exchange system

Brief information about ventilation

The purpose of any air exchange is the uninterrupted supply and processing of air flows with their subsequent removal outside the premises. Natural method ventilation is hardly suitable for an industrial facility.

Most often, ventilation is associated with filtration cleaning, as well as cooling/heating of the air mass.

Industrial ventilation is a forced process that is only possible thanks to specialized climate control equipment.

There are three types of forced ventilation:

1. Supply;
2. Exhaust;
3. Combined (supply and exhaust ventilation).

Ventilation of an industrial facility

It is the combined air exchange scheme that is considered as the most optimal method of organizing air movement in a room. The supply part of such a complex is responsible for access and processing of fresh air flows, and the exhaust component is responsible for their timely and effective removal from a given area.

The organization of such a complex air exchange system includes a number of important stages, each of which is a guarantee successful implementation project. One of these important stages is design, during which the most suitable units and equipment for a given room are determined.

Sample project documentation

A modern industrial air exchange system is impossible without:

1. Air ducts;
2. Fans;
3. Heaters (devices for air exchange);
4. Cooling devices;
5. Supply systems responsible for timely access of air;
6. Various filters for purifying air from harmful impurities and gases.

It’s not for nothing that we mentioned air ducts first. If the fan can be defined as the “heart” of any forced air exchange system, then the air ducts are “arteries” through which strictly given direction air moves.

Air duct pipes

Purpose and features of air ducts

A properly designed duct network is the basis of an effective ventilation system. That is why modern air exchange systems require a variety of shapes and characteristics of these products.

It can be mentioned that there are more than 10 different types of metal pipes for moving air alone. These “arteries” must have high levels of fire resistance, anti-corrosion, resistance to acidic environments, etc. Sheet metal (copper, aluminum, titanium alloys), plastic, fiber cement are all materials from which air ducts are made. There are also round and rectangular sections of such pipes, each of which has its own individual characteristics. Let us also mention flexible, rigid, and semi-rigid air duct pipes. And so on.

Plastic air duct box

In other words, the choice of air duct products depends on the wishes of the customer, the engineering features of the industrial premises, the purpose and installation of the air exchange network.

Air duct pipe manufacturing technology

Production ventilation ducts and shaped parts (read – part, element) must provide highest quality connections and connections. This will help mitigate possible losses in the future. air circulation and install the air exchange network more efficiently and without significant time costs. The accuracy of the production of pipe components depends on properly adjusted automated control of devices and machines.

Shaped elements of the ventilation system

The qualifications of specialists are also extremely important; how efficiently they will be able to make markings, as well as cutting sheet material (we are considering the most common material - low-carbon steel) for “patterns” of shaped parts of air ducts. Workers must have knowledge of various connections of network elements and parts, the design functionality of automation, as well as the key requirements for both material and equipment specified in SNiP.

Selection of material and methods of work

The practical implementation of cutting begins with the selection of the appropriate material. It is necessary to take into account the factors of saturation, cooling/heating, yoke rigidity, vibration characteristics, as well as a number of other operational nuances.

Example of shaped components layout

The most common method of processing sheet metal for cutting air duct network elements is oxy-fuel cutting. In this way you can implement:

1. Directly cut the steel;
2. Trimming profile metal;
3. Cutting out various gussets, flanges, and other blanks.

Connecting shaped components to each other - welding - also has a number of features:

1. The usual (manual) welding method is butt joints, excluding metal allowances;
2. The seam or spot method involves electric welding automation and allows for material allowances.

Seam welding technology

Shaped elements of the air exchange network should be cut using combined templates. In addition to welding, connecting them together into a single complex is possible in the following ways:

1. Bells;
2. Flanges;
3. Crimping bands.

All these methods of fastening pipe elements are essentially not much different from each other, but they have their own individual characteristics. For example, a socket connection considers a ring that, when heated, is put on the end of the air duct, and after cooling, it is welded to the pipe. The same procedure is carried out in relation to the air duct itself. After this, the rings are fastened together by welding.

Sample engineering calculation tables

To prevent clogging, fittings must be manufactured with smooth turns, according to the standard template.

It is necessary to take into account the fact that not all elements of the air duct network are the same in terms of wear resistance. The cutting of some parts that fall into such a “risk zone” must be done so that these components can be replaced in the future without threatening the entire complex.

The most labor-intensive and responsible operation is considered to be marking tees, transitions, crosses, etc. The cutting of such ventilation segments (up to 900 mm) must be carried out according to the inventory combined templates. Parts whose diameter is over 900 mm should be manufactured based on special engineering tables that provide markings along coordinates.

Manufacturing of air ducts

One of the main conditions for creating comfortable workplaces in industrial premises is the arrangement effective system ventilation. It provides an influx fresh air and elimination of contaminated air masses. In this article we will look at how industrial ventilation functions, as well as the main types and features of ventilation systems.

Types of industrial ventilation systems

Depending on the conditions of industrial premises and the requirements for ventilation systems, they can be implemented according to the following schemes:

Natural ventilation

Natural air exchange is allowed in those industrial premises where production is not associated with the release of harmful substances into environment. Such systems imply the presence, which are located at different heights.

The working principle of the natural system is as follows:

• As cold air descends, fresh air masses enter the room through openings located at the top.
• Next, the air currents mix with old air and heat up.
• Rising upward, the air flow exits through the exhaust hole.

Ventilation holes allow you to regulate air exchange using valves or vents. The advantages of such a system include the fact that it does not require additional energy costs. However, despite this, such ventilation is extremely rarely used in industrial premises, which is due to their low efficiency.

Even if the calculation of natural industrial ventilation has been professionally carried out, it will not be enough to ensure a favorable microclimate in a room where emissions of harmful substances are constantly occurring.

Forced ventilation

Industrial ventilation and air conditioning systems are most often performed using special equipment.

This solution has a number of advantages, such as:

• Large range of action, since the air masses are supplied under pressure created by the fan.
• The efficiency of air exchange, as mentioned above, does not depend on wind speed and air temperature outside.
• The ability to heat the supply air flows, as well as subject them to cleaning, humidification, or, conversely, drying.
• The ability to organize optimal distribution of air masses, for example, with the supply of fresh air directly to workplaces.
• The ability to capture harmful gases directly at the point of their release, preventing them from spreading throughout the entire space of the room, as well as the ability to clean air flows of contaminants before releasing them into the atmosphere.
• Installation of industrial ventilation of a forced type can be carried out after the construction of a building, while natural ventilation is installed at the stage of its construction.

Of course, along with their advantages, these systems also have some disadvantages, the most serious of which are the following:

• The high price of the equipment, in addition, the operation of the system is associated with certain costs.
• Noisy operation, which requires some measures to combat noise.

There are several types of forced ventilation systems:

As a rule, the volume of incoming air is equal to the volume of outgoing air. However, sometimes there is a need to violate this equality. In this case, the inflow is greater than the outflow, which makes it possible to create some excess in the room, for example, to prevent dust from entering the “clean” workshops from other rooms.

In addition, forced ventilation of industrial facilities differs in the principle of air supply. It happens:

As mentioned above, the choice of air exchange scheme depends on the conditions in the room and production needs.

Ventilation equipment

Industrial ventilation equipment, in fact, differs from domestic equipment only in power.

At the same time, all the main elements of the system are the same:

• Ventilation ducts– are pipes of different sizes and cross-sections that provide transportation of air flows to the distribution point.
• Shaped parts– allow you to make turns and branches of ventilation ducts.
• Fans– are the main element of forced systems, as they ensure their movement in the desired direction under a certain pressure.

• Filters– provide cleaning of air flows. They differ in the degree of cleaning - from coarse, which traps large impurities, to complete, which eliminates even unpleasant odors.
• Recuperators– provide heating of the supply air with warm exhaust flows. This device allows you to save on space heating.
• Heaters– designed to heat incoming flows during the cold season.
• Air conditioning systems– provide cooling of incoming flows.

Advice! Recuperators are expensive equipment, so it makes sense to use them when servicing large premises.

It should be noted that often industrial systems ventilation chambers are used. In fact, these are combined devices that combine everything in one housing necessary equipment for ventilation. In particular, industrial ventilation manufacturers supply them with fans, filters, heat exchangers, etc.

As a result, for the system to function, all that remains is to connect such a device to the ventilation ducts.

Advice! In some cases, when installing air ducts, non-standard shaped elements may be required. In this case, you can make them yourself. The most important thing is to correctly cut the shaped parts of industrial ventilation, after which the parts must be cut out of tin, bent according to the pattern and welded.

Design Features

Ventilation design industrial enterprises consists of several main stages:

• Determination of the basic conditions of the premises (their area, configuration features, equipment used, etc.).
• Accounting climatic features(air temperature, pressure and wind speed).
• The intended purpose of the room - for example, local ventilation may be required along with a general supply and exhaust system.

Based on the data obtained, a calculation is made, which includes:

• Determination of the cross-section of air ducts;
• Calculation of air exchange rate;
• Determining the area of ​​ventilation holes;
• Calculation of equipment power;
• Determining the amount of materials needed.

It should be noted that designing ventilation for industrial premises is an extremely important and at the same time quite complex task. Therefore, without certain knowledge, you should not take on this work with your own hands.

Selection of materials and installation

In addition to design, it is very important to choose the right duct materials. For example, in fire and explosion hazardous facilities it is necessary to use non-combustible materials, for example, galvanized steel, for the installation of channels. It can also be used in rooms with high temperatures.

If the main requirement is resistance to corrosion, for example, when the air duct is to operate in an aggressive environment or in rooms with high humidity, then it is better to use PVC pipes the required diameter.

In areas with complex pipeline configurations, flexible corrugated pipes are used. However, if it is possible to install rigid elbows, it is better to give preference to them.

The advantages of the latter are strength and durability. The corrugation allows you to assemble the system even in the most inaccessible places.

Advice! When choosing corrugated pipes, it is better to give preference to steel products, as they are more heat-resistant and have greater strength.

The photo shows corrugated steel pipes

Of course, installation of the system is not limited to the assembly of ventilation ducts. In addition, installation and connection of equipment is carried out.

The assembled system must be tested and adjusted before operation. The instructions for performing these works are also quite complex, so they must also be carried out by specialists. These are, perhaps, all the main features of ensuring air exchange in industrial conditions.

Conclusion

Industrial ventilation is no different in operating principle from domestic ventilation, however, its design and installation require a much more careful approach. In addition, to install such systems, special powerful equipment is used, which is able to provide effective air exchange over large areas.

From the video in this article you can glean some Additional information on this topic.

If loading is slow, the drawings and drawings of this page can be opened and viewed in the “Drawings, diagrams, drawings of the site” catalogue.

90 degree bend.

Pattern of a five-link bend. Marking the interface line of the outlet links.

Transfer the pattern of the left side of the tap link pattern to the right one, or draw it on the right according to the same pattern and dimensions. Formula for calculating the width of the pattern: 3.14D + seam allowances. The width of the allowance for a folded joint is taken, for example, 14 + 14 = 28 mm with a folded edge of 7 mm.

Transition from rectangular to round, confuser, diffuser.

The pattern of a direct symmetrical transition consists of two identical parts.

Cut the circular section line from small reserve; in the finished transition, clarify and mark it along the circular cross-section of the attached pipe or along the flange; and finally cut with an edge allowance for the connecting rebate or flange.
In some cases, L~h can be accepted: if the difference in the transition cross sections is not very large, or if the accuracy of its height is not significant. The deviation from the given height can be compensated by the length of the next shaped part attached to it.

Transition from a round section to a round of a different diameter.

Construction of a pattern (development) of a straight confuser, a diffuser with a circular cross-section.

In some cases, L~h can be accepted: if the difference in the transition cross sections is not very large, or if the accuracy of its height is not significant. The deviation from the specified transition height can be compensated by the length of the next shaped part attached to it.

Transition from one rectangular section to another rectangular section.

Transition pattern in two parts:

When calculating the length of the pattern, take into account the material allowances for attaching the lower and upper rectangular flanges.

Tee. Pattern drawing and manufacturing sequence.

The proposed method of constructing a pattern is less accurate than that set out in a special or educational literature, but is successfully used in practice in the manufacture of parts for ventilation, aspiration and gravity transport.

The length of the tee can be taken according to the dimensions of standard tees with a central angle of 30 degrees. The size table shows the minimum length of a standard tee - depending on the diameter of the straight trunk of the air flow duct d. To make a tee using the proposed approximate method, it is recommended to take a slightly longer pattern length, for example, depending on the diameter of the base D. If it is necessary to make a tee, the length of which differs from those indicated in the table, then the dimensions “a” and “b” should be clarified by calculation. Calculation formulas for a 30 degree tee:

a=0.5l tr ; b=0.87l tr.

As you accumulate practical experience The length of the part and its pattern will be determined independently, taking into account the installation location in the air duct network and the method of connection with other shaped parts of the ventilation system.

Dimensions of straight asymmetrical tees with a central angle of 30 degrees:

On a separate sheet of iron or thick paper, make a drawing of a side view of the tee. A complete drawing is not necessary - those drawing lines that are needed to determine the "C" size are sufficient.

The figure shows a straight asymmetrical tee with an angle of 30 degrees and a drawing of its side view:

Drawing of the pattern of the pass-through shaft and the side branch of the tee:

Sequence of making a tee.

Prepare connecting folds for long sides both parts of the pattern. Bend the 7 and 14 mm edges on the inner line of the joint of the trunks. Combine the pattern pieces, placing the smaller one on top of the larger one. Connect the branch pattern with the straight trunk pattern along the joint line with a one-and-a-half folded fold. The joint connection sequence is shown in the figure:

Bend both barrels of the tee in round shape, fasten the folds, seal the folded seam. Fill the beginning of the internal connecting seam at a length of 3 - 5 cm, sufficient for installing a flange or connecting to a round pipe. The base, through and side trunks of the tee are evenly marked out and cut along the flange or round pipe of the appropriate diameter, leaving allowances for flanging for connection with the next part. The result is a symmetrical pants-shaped tee. It can be made asymmetrical by cutting the base perpendicular to the through-duct, or left pant-shaped by cutting the base perpendicular to the “C” line. If a wide collar (clamp) is used for connection, then the main section of the tee must be supplemented with a straight pipe of the same diameter.

A tee with a different central angle is drawn and made in the same way, but the dimensions “a”, “b” and “C” are determined for the corresponding joining angle. In a 45 degree tee, the dimensions "a" and "b" are the same.

Automated production system PractiCAM™ is focused on the production of products for ventilation systems from sheet and coil metal, as well as from pipe blanks. PractiCAM™ works with plasma and laser CNC machines program controlled(CNC), as well as with stamping, spiral and coordinate-cutting machines. The program has great functionality for cutting sheet metal, i.e. It is focused not only on the production of air ducts, but also flat parts, signs, weather vanes, roof elements, etc.

Main advantages of the PractiCAM™ system:

	Creation of air ducts of any type, as well as any other elements from sheet and rolled metal, and pipe blanks
	System libraries PractiCAM™ very extensive and unparalleled. They contain over 4000 fittings and over 1600 parameterized flat parts. Despite such diversity, the system libraries PractiCAM™ are still increasing (each time you download a new version of our program, new elements will be waiting for you). In addition to existing libraries, we can create for you as many different fittings, flat parts and other elements as you wish. We will make the parts you need and send them to you as soon as possible (as a rule, the development of a new part, depending on its complexity, takes from one to three working days).
	Compatible with any equipment
	System PractiCAM™ Supports many models of plasma and laser CNC machines. It can also work with punching machines, spiral punching machines, jig punching machines, tube cutters and bar code readers. If your machine model is not yet in our library, then we will quickly write a post-processor for you completely free of charge, which will connect our program with your equipment.
	Instant and accurate cost estimates
	During your work, the system PractiCAM™ continuously creates an accurate cost estimate of all parts manufacturing costs. The full calculation takes into account the cost of material, labor costs for manufacturing parts, the cost of all fastening elements (bolts, screws, tires, rivets, etc.), as well as the cost of various accessories (blades, rods, flaps, etc.). As an example, given American tables standard SMACNA, but you can create your own regulatory tables for accounting for labor costs at your enterprise, taking into account the specifics of your production.
	Export and import of information in generally accepted formats.dxf, dwg and.csv for communication with software products of 1C, Microsoft, Autodesk companies
	All information about the metal spent, consumables and components contained in the system PractiCAM™ can be translated into a .csv file format, which is supported by 1C: Accounting and Microsoft Excel programs. This makes it possible to calculate the cost of all your products using accounting programs. System PractiCAM™ can work with .dxf and .dwg files, which allows you to import drawings from AutoCAD and Compass programs, as well as export cutting maps, fitting patterns and flat parts to these programs.
	Importing orders from 1C:Accounting program
	In the 1C: Accounting program, you can create orders for cutting fittings, indicating the names of fittings, their quantity, the material from which they should be made, technological parameters, names of allowances, etc., and send them to the system PractiCAM™. Having received the order, the system PractiCAM™ automatically finds the specified fittings in its libraries, applies the specified parameters to them and lays out the fitting patterns on sheets of metal. After automatic installation, control commands for your equipment are generated, as well as various reports and labels.
	Metal saving
	It is possible to use leftover sheet metal suitable for cutting out any products from them, and maximum use leaf area. For this purpose, the “Warehouse” functional module has been added, which allows, after laying the main work parts on metal sheets, to automatically add flat parts from a pre-created list to unused space.
	Possibility of automatic stacking of products using a combined cut
	IN PractiCAM™ There are two options for automatic stacking of products: regular stacking and stacking with a combined cut for products that can be combined on one side.
	Fully Russified
	In addition to the Russian language, the system PractiCAM™ translated into English, French, Spanish, Chinese and Korean.
	Various types of allowances
	Allowances (connectors, locks, joints, seams) and notches contained in large quantities in system libraries PractiCAM™ can be created in any geometric shape, fully parameterized and editable. Graphics editor provides ample opportunities for creating and editing allowances and notches.
	Generating reports
	System PractiCAM™ provides you with a wide selection of standard report templates. In addition to this, you can create your own reporting forms in any convenient format and with any type of layout. The main thing is that in the report you can report any information contained in the system PractiCAM™.
	Creating Labels
	Mark parts in the system PractiCAM™ easy and convenient. Various label templates are provided for your attention, but if they do not suit you for some reason, then you can create your own template. Add any information to your labels: your organization’s logo, barcodes, 3D images of parts, any part parameters you are interested in; edit these inscriptions in any style and font size. You can make a label for any fitting and flat part.
	Useful Specifications
	Specifications (SNiPs) of the system PractiCAM™ allow you to define all the features of your production standards when working with different products, allowing you to unify production, automate the entry of products for production and reduce the number of errors during entry, thereby increasing your productivity, and with it your profit. You can create your own rules for the production of products that are used in your enterprise.
	Availability of libraries of double-wall fittings
	In system PractiCAM™ Libraries of double-wall fittings are available. They are used in cases where it is necessary to increase the level of heat and noise insulation. For each double wall fitting, insulation can be cut to fit between its walls.
	Possibility of manual and automatic segmentation for large products
	System PractiCAM™ allows you to segment (break into separate components) products big size, which do not fit on a sheet of metal. You can set segmentation rules for each product yourself or entrust this process to the program.

Benefits of our technical support:

• The best product support - at the request of users, we develop and add new software modules, create new fittings and parametric flat parts (within 1 - 3 days depending on the complexity of the product), add new methods of cutting fittings to existing ones.
• Free education working with the program.
• Regular update PractiCAM™— a new release comes out at least once every 2 weeks.
• Development and addition of new labels and reports, placing on them the information necessary for the user.

Currently, a new version of the program has been developed PractiCAM™. Its main difference is that the program is now divided into many functional modules that can be turned on and off in various combinations, reducing or increasing the set of functions performed by the program. Depending on the number of included modules, the price of the program is determined. PractiCAM™ It is still possible to purchase the entire program with all its capabilities, but you can also buy one of the standard program packages (each of which is a truncated version of the system PractiCAM™), or a standard package with additional options.

Standard packages PractiCAM™:

PractiCAM™ for typical parts.

• Use libraries of parametric flat (two-dimensional) parts, create flat parts using a graphic editor.
• Work with a graphic model of the part, specify dimensions, material and thickness.
• Use multiple layers when creating a part.
• Import files with the extension .dxf, .dwg (AutoCAD, Compass, etc. systems).
• Use automatic placement of parts on sheets of metal using various algorithms, including combined cutting.
• Lay parts on sheets of metal manually.
• 
  at the exit).

PractiCAM™ for ventilation.

This package allows the user:

• Use libraries of shaped products (fittings).
• Work with a three-dimensional graphic model of a fitting, set dimensions, allowances, material, determine the method of cutting the fitting.
• Work with the library of fittings accessories, specify dampers, stiffeners, couplers, rotary blades.
• Use various marking notches, automatically generate bend lines, create marking lines.
• Create a library of materials used, indicating the material thickness and type (sheet, roll).
• Create a library of used allowances (connectors, locks, joints).
• Apply automatic laying of product patterns on sheets of metal using various algorithms, including combined cutting.
• Lay product patterns on sheets of metal manually.
• Based on the installation results, generate and print installation maps.
• Based on the laying results, automatically generate a sequence of control (CNC) commands for the cutter.
• Set cutter parameters (table dimensions, table positioning and orientation, size and shape of cut at entry and cut
  at the exit).
• Determine the method of transmitting control commands to the cutter (via a file or COM port).
• Automatically segment (cut into pieces) large patterns.
• Automatically add allowances when segmenting patterns.
• Create and edit seam allowances connecting segmented parts of patterns.
• Create tables for recalculating fitting section parameters and apply them when creating fittings.
• Import/export files with the .pmx extension (PractiCAM™ program files).

PractiCAM™ Classic.

This package combines the PractiCAM™ for Generic Parts and PractiCAM™ for Ventilation packages and provides all the features listed for these packages.

The list of additional options (program features) for packages is given in the table.

If you want to learn more about PractiCAM™, then we can conduct a demonstration of the program at a time convenient for you, completely free of charge using Skype or TeamViewer, and at the same time answer all your questions. Also, specifically for your machine controller, completely free of charge, at your request, we can write a post-processor and activate PractiCAM™ for you for 1 month so that you can evaluate all its capabilities directly in your work. All you need to do is call us or write a message to our email, or leave your contact information by filling out the following form.