Hi-Vac 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 Hi-Vac Grid Configuration.

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

 

hivac_grid-how-it-works

How It Works

APrimary Grid Duct System The Hi-Vac Grid system is designed using the same principles as a compressed air loop system for optimal efficiency. Component ductwork is configured in a grid across your facility so that welding stations can be added or rearranged easily.

BHi-Vac Grid Connectors Modular Hi-Vac Grid Connectors are the same size as the primary Grid ductwork sections, so you can place RoboVent FlexPro hi-vac air filtration units anywhere on the Grid.

CStandardized One-Size RoboVent Hi-Vac Grid Collector RoboVent produces the most powerful, effective and energy efficient dust collectors on the market. The Hi-Vac Grid system uses standardized hi-vac collectors for maximum flexibility.

DGrid Process Connectors Grid Process Connectors can be placed anywhere on the primary grid duct system for maximum flexibility. These Process Connectors are used to connect the stations in your process to the primary grid ductwork that is connected to the dust collectors.

EDelta Gate The DeltaGate is a proprietary connector for welding stations to connect to the RoboVent Hi-Vac Grid system. We combine our proprietary Delta3 spark arrestance technology with a system of automatic gates to control airflow at each cell.

hivac_grid_energy-savings

Built for Energy Savings

With the Hi-Vac 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 balanced throughout the system.

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 Hi-Vac Grid Running with 70% of the stations welding: The RoboVent Hi-Vac Grid simulation illustrated on the left shows 7 of 24 stations with their DeltaGates closed. The system includes 6 RoboVent FlexPro 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 434.1 KWHs!

hivac_grid001

Initial Plant Layout

This image shows a plant with an initial layout and floor plan design with multiple stations and hi-vac 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.

hivac_grid002

Production Changes

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

hivac_grid003

Station Reconfiguration

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

Components

FlexPro™ Hi-Vac Series

A plug-and-work smoke-collection system that collects fumes at the source. This powerful air filtration system is perfect for manual and robotic welding applications.

Hi-Vac Fume Gun Source Extraction: The RoboVent Extractor

The RoboVent Extractor™

A welding gun with built-in extraction module to remove weld fumes at the source. The RoboVent Extractor is a lightweight, flexible and powerful tool to protect workers.

QuickClamp Ductwork

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