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90 degree bend.

Pattern of a branch of five links. Marking the line of conjugation of the branch links.

The pattern of the left side of the pattern of the branch link is mirrored to the right, or drawn on the right according to the same pattern and dimensions. Pattern width calculation formula: 3.14D + seam allowances. The width of the seam allowances is taken, for example, 14 + 14 = 28 mm with a folded edge of 7 mm.

Transition from rectangular to round section, confuser, diffuser.

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

Cut off the circular section line with a small margin; in the finished transition, clarify and strike it out along the circular section of the connected branch pipe or along the flange; and cut off completely with an edge allowance for the connecting seam or flange.
In some cases, you can take L~h: if the difference in the cross sections of the transition is not very large, or if the accuracy of its height is not significant. Deviation from the given height can be compensated by the length of the next fitting attached to it.

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

Construction of a pattern (sweep) of a straight confuser, a circular diffuser.

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

Transition from one rectangular section to another rectangular.

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 for 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 from the dimensions of standard tees with central corner 30 degrees. The size table shows the minimum length of a standard tee - depending on the diameter of the straight shaft of the free-flow duct d . For the manufacture of a tee according to 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 tee 30 degrees:

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

With the accumulation of practical experience, the length of the part and its pattern will be determined independently, taking into account the installation location in the 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:

Diameter	Lengthl tr	A	b
	1072
	1184		1027
	1316		1142

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

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

Drawing of a pattern of a through shaft and a side branch of a tee:

Tee manufacturing sequence.

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

Bend both stems of the tee into a round shape, fasten the folds, seal the seam seam. Fill the beginning of the internal connecting seam at a length of 3 - 5 cm, sufficient to install a flange or connection with a round section pipe. The base, through passage and side shafts of the tee should be evenly marked and cut along the flange or round nozzle of the appropriate diameter, leaving allowances for the flanging for connection with the next part. The result is a symmetrical pant-shaped tee. It can be made asymmetrical by cutting the base perpendicular to the duct, or left trouser-shaped by cutting the base perpendicular to the "C" line. If a wide cuff (clamp) is used for the connection, then the main section of the tee must be supplemented with a straight branch 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, dimensions "a" and "b" are the same.

One of the main conditions for creating comfortable workplaces in industrial premises is the arrangement of an effective ventilation system. It provides an influx of fresh air and the elimination of polluted 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 emission of harmful substances into environment. Such systems imply the presence, which are located at different heights.

The principle of operation of the natural system is as follows:

• As cold air descends, fresh air masses enter the room through openings located at the top.
• Further, the air flows are mixed with the old air and heated.
• Rising up, the air flow exits through the exhaust hole.

Ventilation openings allow you to regulate air exchange using valves or vents. The advantage of such a system is that it does not require additional costs for electricity. However, despite this, such ventilation is rarely used in industrial premises, due to their low efficiency.

Even if the calculation of industrial ventilation of a natural type is professionally performed, it will not be enough to provide a favorable microclimate in a room where emissions of harmful substances constantly occur.

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 radius of action, as 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 vice versa drying.
• The possibility of organizing the optimal distribution of air masses, for example, with the supply of fresh air directly to the workplace.
• The ability to capture harmful gases right at the point of their release, preventing them from spreading throughout the space of the room, as well as the ability to clean air flows from pollution before they are released into the atmosphere.
• Installation of industrial ventilation of forced type can be carried out after the construction of the building, while natural ventilation is laid at the stage of its construction.

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

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

Forced ventilation systems are of several types:

As a rule, the volume of incoming air is equal to the volume of the outgoing flow. However, sometimes there is a need to violate this equality. In this case, the inflow is made larger than the outflow, which allows you to create some excess in the room, for example, to prevent dust from other rooms from entering the "clean" shops.

In addition, forced ventilation of industrial facilities differs in the principle of air supply. She 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 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 sections, which provide transportation of air flows to the distribution point.
• Shaped parts- allow you to perform turns and branching of ventilation ducts.
• Fans- are the main element of forced systems, as they ensure their movement in the right direction under a certain pressure.

• Filters- provide air purification. They differ in the degree of purification - from coarse, retaining large impurities, to complete, eliminating even unpleasant odors.
• Recuperators- provide heating of supply air with warm exhaust flows. This device allows you to save on space heating.
• heaters- designed to heat incoming flows in the cold season.
• Air conditioning systems- provide cooling of incoming streams.

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 all necessary equipment for ventilation. In particular, manufacturers of industrial ventilation supply them with fans, filters, heat exchangers, etc.

As a result, for the functioning of the system, it remains only to connect such a device to the ventilation ducts.

Advice! In some cases, when installing air ducts, non-standard fittings 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 scheme and welded.

Design Features

Ventilation design industrial enterprises consists of several main steps:

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

Based on the received data, a calculation is carried out, which includes:

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

It should be noted that the design of industrial premises ventilation is an extremely responsible and at the same time quite a difficult task. Therefore, without having certain knowledge, you should not take on this work with your own hands.

Material selection and installation

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

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

In areas with a complex configuration of highways, 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.

In the photo - corrugated steel pipes

Of course, the installation of the system is not limited to the assembly of ventilation ducts. In addition, equipment is installed and connected.

The assembled system must be checked and adjusted before operation. The instructions for performing these works are also quite complicated, so specialists should also deal with them. Here, perhaps, are all the main features of ensuring air exchange in industrial conditions.

Conclusion

Industrial ventilation by the principle of operation does not differ from domestic, however, its design and installation requires a much more careful approach. In addition, for the construction of 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 get some additional information on this topic.

A modern building is an enterprise, an industrial facility, a private house- it is impossible to imagine without an air exchange complex. Ventilation is a key component of any building engineering communication. Without timely supply, processing and removal of air flows, it is extremely difficult to maintain an optimal climate for technical staff and conditions for the correct operation of production equipment. Cutting shaped parts of industrial ventilation is an extremely important step in the installation of an air exchange complex. A number of measures for the manufacture 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. The natural method of 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, which is possible only thanks to specialized climate 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 the movement of air in the room. The inlet part of such a complex is responsible for the access and processing of fresh air flows, and the exhaust component is responsible for their timely and effective removal from the specified 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 the design, during which the units and equipment that are most suitable 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 complexes responsible for timely air access;
6. Various filters for air purification from harmful impurities and gases.

It was not in vain that we mentioned air ducts in the very first place. If the fan can be defined as the "heart" of any forced air exchange system, then the air ducts are the "arteries" through which air moves in a strictly specified direction.

Air pipes

Purpose and features of air ducts

A properly designed air duct network is the basis of an effective ventilation complex. That is why modern air exchange systems need 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. These "arteries" must have high fire resistance, anti-corrosion, acid resistance, etc. Sheet metal (copper, aluminum, titanium alloys), plastic, fiber cement - all these are the 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's also mention flexible, rigid, as well as semi-rigid air pipes. And so on.

Plastic air duct

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.

Manufacturing technology of air pipes

The production of ventilation ducts and fittings (read - detail, element) must ensure the highest quality of joints and connections. This will allow leveling possible losses of air circulation in the future and more efficiently and without significant time costs to install the air exchange network. The accuracy of the production of pipe components depends on a properly tuned automated control instruments and machines.

Shaped elements of the ventilation system

The qualification of specialists is also extremely important; how rationally they will be able to make markings, as well as cutting sheet material (we are considering the most common material - mild steel) for "patterns" of shaped parts of air ducts. Workers must have knowledge of various connections of elements and parts of the network, the constructive functionality of automation, as well as the key requirements for both material and equipment, enshrined in SNiP.

Selection of material and methods of work

The practical implementation of nesting begins with the selection of the appropriate material. Saturation, cooling/heating factors, yoke stiffness, vibration characteristics, and a number of other operational nuances must be taken into account.

An example of the layout of shaped components

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

1. Directly cutting steel;
2. Cutting profile metal;
3. Cutting various scarves, flanges, as well as other blanks.

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

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

Seam welding technology

The shaped elements of the air exchange network should be cut using combined templates. In addition to welding, their connection to each other into a single complex is possible in the following ways:

1. Bells;
2. flanges;
3. Crimp bandages.

All these methods of fastening pipe elements essentially differ little from each other, however, they have their own individual characteristics. For example, a socket connection considers a ring that, when heated, is put on the end of the duct, and after cooling, it is connected to the pipe by welding. The same procedure is carried out in relation to the air duct itself. After that, the rings are fastened together by welding.

Sample engineering design tables

In order to prevent clogging, fittings must be made with smooth turns, according to a standard template.

It should be taken into account the fact that not all elements of the air duct network are the same in terms of wear resistance. Open some parts that fall into such a "risk zone", you need to produce so that these components can be replaced in the future without endangering the entire complex.

The most time-consuming and responsible operation is the marking of tees, transitions, crosses, etc. The cutting of such ventilation segments (up to 900 mm) must be performed according to the inventory combined templates. Parts whose diameter is more than 900 mm should be manufactured based on special engineering tables that provide markings by coordinates.

Production of air ducts

System automated production PractiCAM™ is focused on the production of products for ventilation systems from sheet and rolled metal, as well as from pipe blanks. PractiCAM™ works with plasma and laser machines with numerical program management(CNC), as well as with stamping, spiral and coordinate punching 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, signboards, weather vanes, roof elements, etc.

The 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 this diversity, the system libraries PractiCAM™ are still increasing (every time you download a new version of our program, new items will be waiting for you). In addition to existing libraries, we can create as many different fittings, flat parts and other elements for you 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 punch, scroll, jig punches, pipe cutters and barcode readers. If your machine model is not yet in our library, then we will write a postprocessor for you free of charge in the shortest possible time, which will connect our program with your equipment.
	Instant and accurate cost estimates
	During your work, the system PractiCAM™ continuously creates an accurate estimate of the cost of all costs for the manufacture of parts. The full calculation takes into account the cost of the material, labor costs for the manufacture of parts, the cost of all fasteners (bolts, screws, tires, rivets, etc.), as well as the cost of various accessories (blades, rods, dampers, etc.). As an example, the American SMACNA tables are given, but you can create your own standard tables for accounting for labor costs in your enterprise, taking into account the specifics of your production.
	Export and import of information in common .dxf, dwg and .csv formats for communication with software products of 1C, Microsoft, Autodesk companies
	All information about the spent metal, consumables and accessories contained in the system Practicam™, can be converted to a .csv file, which is supported by 1C: Accounting and Microsoft Excel. 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 nesting plans, fitting patterns and flat parts to these programs.
	Import orders from the program 1C: Accounting
	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™. After receiving 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 metal sheets. After automatic laying, control commands for your equipment are generated, as well as various reports and labels.
	metal saving
	It is possible to use the rest of the sheet metal, suitable for cutting out any products from them, and to maximize the use of the sheet area. For this, 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 an unused place.
	Possibility of automatic stacking of products using a combined cut
	IN PractiCAM™ There are two options for automatic stacking of products: normal stacking and stacking with a combined cut for products that can be combined along one of the sides.
	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 a large number in the 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.
	Report creation
	System PractiCAM™ provides you with a wide range 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™.
	Create 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, then you can create your own template. Add any information to your labels: your organization's logo, barcodes, 3D parts images, any part parameters you are interested in; edit these captions with any font style and size. You can make a label for any fitting and flat piece.
	Useful specifications
	Specifications (SNiPs) of the system PractiCAM™ allow you to set all the features of your production standards when working with various products, allowing you to unify production, automate the input of products for manufacturing and reduce input errors, 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™ there are libraries of double wall fittings. 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) large-sized products that do not fit on a sheet of metal. You can set the segmentation rules for each product yourself or entrust this process to the program.

Benefits of our technical support:

• Better 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 ways to cut fittings to existing ones.
• Free education working with the program.
• Regular update PractiCAM™— a new release comes out at least 1 time in 2 weeks.
• Development and addition of new labels and reports, placing on them the information required by the user.

A new version of the program is currently being developed PractiCAM™. Its main difference is that now the program is 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 formed. PractiCAM™ can still be purchased in its entirety with all its features, but it is also possible to buy either 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 generic parts.

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

PractiCAM™ for ventilation.

This package allows the user to:

• Use libraries of fittings (fittings).
• Work with a 3D graphical model of a fitting, set dimensions, allowances, material, and determine the fitting cutting method.
• Work with a library of fittings accessories, set flaps, stiffeners, ties, rotary blades.
• Use different marking recesses, automatically generate bending lines, create marking lines.
• Create a library of used materials indicating the thickness of the material 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 a combined cut.
• Lay patterns of products on sheets of metal manually.
• Based on the laying results, generate and print laying maps.
• Based on the laying results, automatically generate a sequence of control (CNC) commands for the cutter.
• Set the cutter parameters (table dimensions, table positioning and orientation, size and shape of the cut at the input and cut
  at the exit).
• Determine how control commands are sent to the cutter (via file or COM port).
• Automatically segment (cut into pieces) patterns of large size.
• Automatically add allowances when segmenting patterns.
• Create and edit seam allowances connecting segmented parts of patterns.
• Create tables to recalculate fitting section parameters and apply them when creating fittings.
• Import/export files with .pmx extension (PractiCAM™ program files).

PractiCAM™ Classic.

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

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

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