Push-pull welding ventilation for 10 manual welding stations and a separate system for robotic welding
For the metalworking workshop, we designed two separate welding ventilation systems: a push-pull solution for 10 manual welding stations and a separate filter system for the robotic welding area, each with its own airflow rates and control logic. In the manual welding area, welding fumes are directed in a controlled manner towards the central part of the building, with air exchange in the 10-station area ranging between 12,000–18,000 m3/h. A strip curtain limits the spread of fumes outside the work area, and a heat recovery ventilation unit keeps heat loss under control in winter (heat recovery ~80%).
Project Challenge
In the manual welding area, welding fumes had to be directed towards the central part of the building, where the truss area was open and the risk of fume spread across the entire production area was high. The ventilated area covered only half of the production hall, which meant that air movement had to be kept under control throughout the entire work area.
- the nature of manual welding was more mobile than robotic welding
- fume spread had to be kept under control throughout the entire work area
- extraction had to operate evenly across the entire ductwork
- robotic welding required a system with separate control logic
How We Built the Solution
Since manual welding and robotic welding cannot be optimally solved with a single system, we designed two separate systems. We solved the 10-workstation manual welding area using the push-pull method with directed extraction towards the central part of the building, and the robotic welding area received a filter system with its own control logic. In addition, a strip curtain limits the spread of welding fumes out of the work area, and a temporary demo "Airtower" welding tower was used for testing.
- Push-pull system – for 10 manual welding stations, directed extraction towards the central part of the building
- Air exchange in the 10-workstation area 12,000–18,000 m3/h
- Filter system – separate solution for the robotic welding area, with its own control logic
- Strip curtain – limits the spread of welding fumes out of the work area
- Demo "Airtower" welding tower – temporary rental solution for testing and adjustment
- FL type filters – space-saving "Plug & Play" filtration unit with an integrated fan
- ACF cyclone filter – filter with optimised capacity for larger filtration tasks
Automation
The robotic welding area received a separate system, because robotic work differs from manual welding in the nature of fume generation, the location of the work area, and control. In robotic welding, fumes are generated in a specific and repeating work area, which allows extraction to be dimensioned more precisely and linked to a specific work process. The separate solution ensures that the operation of the robotic area does not depend on the load of the manual welding area, enables more precise configuration, more stable operation and simpler maintenance.
Result
The result was not merely air removal, but a solution with controlled air movement that directs welding fumes into the correct zone and reduces their spread to the rest of the production area. Properly designed filters clean the air of residues and return it to production, the ventilation unit's heat recovery is around 80%, which keeps winter heat loss under control. The entire project takes 2–4 months in total with minimal production downtime.
- heat recovery ~80%
- 10 manual welding stations in the push-pull system
- air exchange 12,000–18,000 m3/h
- project duration 2–4 months, phased installation
Galerii
FAQ
Frequently asked questions
How many welding stations does this push-pull system cover?
Why were separate systems built for manual and robotic welding?
What is the system's air exchange rate?
How high is the heat recovery and how does it help in winter?
How long does the project take and does production have to stop?
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