Grid Configuration

Clean Air Matrix

RoboVent engineers are experts in every category of air filtration and ventilation. The four categories below represent the major options for treating your contaminated air. RoboVent has designed solutions for each of these categories and has manufactured air filtration systems of unrivaled quality.

For more information about these categories, see Indoor Air Quality 101.

Ambient_Filtration

Large blowers and air filtration equipment draw contaminated air from the plant (typically at the ceiling level), filter it and return it to the plant. This is a proven solution in plants welding large parts with overhead cranes. It reduces the haze in the air, resulting in a cleaner working environment, with no negative pressure or heat loss.

SourceCapture_Filtration

Air in the immediate area of the welding activity is captured in a hood system, then filtered and returned to the plant. This is the best solution whenever possible. It allows for a more flexible system and removes the smoke directly from the operator's breathing zone. There are many types of source capture, including overhead hoods, crossflow hoods, fume arms and fume guns, some of which work better than others.

Ambient_Exhaust

Large exhaust fans draw contaminated air from the plant and exhaust it directly into the environment, typically through the roof or walls. This is a traditional method and often results in negative air pressure. Also, it is very difficult to climate-control your plant and the system may not work well in the winter.

SourceCapture_Exhaust
Air in the immediate area of the welding activity is captured in a hood, sent through ductwork, and exhausted directly into the environment. This is a lower capital cost alternative to filtration, but tends to result in high operating costs and large, unsightly ducting systems that work less efficiently with modifications. It also results in negative pressure problems.

A modular, flexible and future-proof solution

When you want the efficiency and energy savings of a centralized ducted system, but with flexibility to move components if needed, consider RoboVent's Grid Configuration.

Grid gives you the flexibility of mobile source capture systems with the efficiency of a centralized ducted system. It's a whole-facility solution consisting of modular, standardized ductwork and components that can be easily reconfigured as your needs change. The Grid system is:

  • Energy efficient: The ducted grid system only needs 70% of the airflow used by individual units, delivering significant energy savings over time.
  • Modular: We use standardized, modular components to make installation of your custom system fast and easy.
  • Low-maintenance: Our Smart Gate™ Auto Cleaning system directs airflow to clear debris from the system automatically, reducing manual cleaning requirements.
  • Flexible: Move components around, expand or reduce capacity, and adjust your system to your new requirements. Modular components and QuickClamp ductwork make it easy to change your configuration as your needs change.

grid-how-it-works

How It Works

APrimary Grid Duct System The Grid system is designed using the same principles as a compressed air loop system for optimal efficiency. QuickClamp ductwork snaps together for fast and easy setup and endless configuration options—similar to your kids’ favorite snap-together toy bricks.

BGrid Fusion Connectors Modular Grid Fusion Connectors are the same size as the ductwork section, so you can place them anywhere on the Grid.

CStandardized One-Size RoboVent Grid Collector RoboVent produces the most powerful, effective and energy-efficient dust collectors on the market. The Grid system uses standardized collectors for maximum flexibility. A typical configuration would place the collectors indoors attached to various production equipment; however, outdoor confirgurations can be used when floorspace is at a premium indoors. Read further about Outdoor Grid Configurations below.

DGrid Process Connectors Smaller Grid Process Connectors drop down to connect to the suction hoses for the collectors. They easily connect anywhere along the Grid system, so you can add or subtract collectors and move them to wherever they are needed.

EDelta Gate The Smart Gate™ system is a proprietary connector for the ductwork within the Grid system. We combine our proprietary Delta3 spark arrestance technology with a system of automatic gates to control airflow in and out of each cell. Airflow can be increased or decreased in specific areas as needed, and directed to clear debris out of the system. Delta Gate can be integrated into the cell prior to set up and delivery, so it’s ready to go as soon as the cell is assembled on site.

outdoor-grid-circle

Outdoor Grid Configuration

The Outdoor Grid Configuration uses the same principles the as the indoor configuration; however, collectors are typically placed outside the building and are usually larger in size.  Production equipment can be added and reconfigured inside in based on production needs.

Often times, it's several collectors placed side-by-side or perhaps one larger unit that will be placed outside the facility.  And, while there are benefits to both Indoor & Outdoor configurations – managers will like the ability to service equipment and not disturb production lines; however, maintenance staff will have to deal with the elements outside.

grid_energy-savings

Built for Energy Savings

With the Grid System, efficiency and energy savings are built right in.

Many facilities simply exhaust dirty air outside, which drives heating bills sky-high during winter months. With the RoboVent Grid system, air is returned to the plant after being cleaned in our highly efficient filtration units. This eliminates a significant loss of energy for manufacturing facilities.

In addition, Grid comes with automated controls that reduce energy consumption automatically. Arc-on time for most robotic welding stations is between 45% and 75%. For manual stations, arc-on time may only be between 20% and 40%. So why pay for the power to run your dust collection system 100% of the time?

With RoboVent’s automated controls, your system is on when you need it, and off when you don’t—delivering significant energy savings.

The DeltaGate system is tied to welding activity. The gates open when the welding arc is on and automatically close a few seconds after the arc turns off. When the gates close, pressure on the system increases and airflow is automatically increased in other areas to compensate.

The proprietary eDrive Automated VFD comes standard with the Grid System. It works with the DeltaGates to control airflow and adjust the motor speed up or down based on system requirements. That means your system draws power only when it is needed—typically we see an average of a 30% reduction in overall airflow and horsepower required.

 

RoboVent Grid Running with 70% of the stations welding: The RoboVent Grid simulation illustrated on the left shows 5 of 17 stations with their DeltaGates closed. The system includes 6 RoboVent Grid collectors. Using the data on RoboVent savings seen in the graph, and assuming an average arc-on time of 71%, the total savings per 8-hour shift would be 1,718.8 KWHs!

A Flexible, Modular System

The Grid System uses the same size ductwork components and collectors throughout, working together on the same ductwork system. This allows you to easily configure and reconfigure for your unique needs.

grid001

Initial Plant Layout

This image shows a plant with an initial layout and floor plan design with multiple stations and collectors. This scenario depicts what your plant layout might look like in normal working and production conditions. As production needs fluctuate and facility-specific manufacturing processes change, the system can be easily altered to accommodate needs.

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Production Changes

As your needs change, the system could change right along with you. For example, consider a scenario where you add six new welding stations, as seen here. In order to accommodate the additional welding fume output, you simply add two additional collectors to your configuration.

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Station Reconfiguration

Now, imagine you have moved two robotic welding stations to the other side of the plant. With the Grid system, the collectors can be easily moved to wherever they are needed. The system will automatically self balance to optimize the new configuration.

Components

Fusion™ Series

A dust collector on the cutting edge of air filtration. The Fusion Series delivers exceptional performance and cost savings in a powerful, simple package.

QuickClamp Ductwork

A flexible system of ductwork whose components clamp together without tools, RoboVent's QuickClamp Ductwork is flexible, easy to use and reconfigurable.