A manufacturing facility in Shenyang faced a persistent air quality challenge across two distinct welding zones and Dual-System Solution. The first zone housed six manual welding stations handling oversized workpieces up to 6.5 meters in length. The second zone operated three carbon arc gouging stations, which generate significantly heavier fume loads than standard welding. Conventional extraction methods simply could not keep up. Workers complained of poor visibility, and accumulated dust settled on equipment throughout the workshop. Meanwhile, the company struggled to pass environmental compliance inspections without a proper fume management system.
After a thorough site assessment, we proposed a two-pronged centralized dust collection strategy — one system optimized for manual welding, and three independent units dedicated to the more demanding carbon arc gouging operations.
Six manual welding stations sharing one 8,000 m³/h fume extractor. The biggest challenge was accommodating 6.5-meter workpieces that extend well beyond typical station boundaries. We solved this with a 4-meter crossbeam paired with a 3-meter articulated suction arm. The crossbeam offers 180° free suspension, while the suction arm rotates a full 360°. Together, they provide unrestricted reach across the entire welding envelope, ensuring fume capture regardless of workpiece orientation.
Carbon arc gouging produces far more smoke and dust than conventional welding. Therefore, we assigned each of the three gouging stations its own dedicated 6,000 m³/h extraction unit. Each station is equipped with a side-suction dust hood measuring 2.2 m × 0.8 m × 1.7 m. This large-format hood creates a powerful capture zone directly at the fume source, preventing heavy particulate from dispersing into the workshop. Individual units also allow each station to operate independently, avoiding unnecessary energy consumption when not all stations are active.
表格
| Parameter | Manual Welding Zone | Carbon Arc Gouging Zone |
|---|---|---|
| Luftmenge | 8,000 m³/h (×1) | 6,000 m³/h (×3) |
| Collection method | Crossbeam + suction arm | Side-suction dust hood |
| Reach / Coverage | 4m beam (180°) + 3m arm (360°) | 2.2m × 0.8m × 1.7m hood |
| Stations served | 6 | 3 (1 unit each) |
First, the crossbeam-and-arm combination solves the oversized workpiece problem entirely. Welders no longer need to reposition themselves or the workpiece to stay within the extraction zone — the arm comes to them. Second, dedicated units for carbon arc gouging deliver the high-airflow performance that this process demands. Shared systems often underperform under heavy fume loads, but independent units maintain consistent extraction power.
Third, the side-suction hood design targets fumes at the source before they spread. This is critical for carbon arc gouging, where dust volume can overwhelm overhead extraction in seconds. Additionally, independent station control reduces operating costs, as only active stations consume power.
The Shenyang Huaze project demonstrates how a customized dual-system approach delivers superior results when different welding processes coexist in one facility. Rather than forcing a one-size-fits-all solution, we matched each system to the specific fume characteristics and workflow of each zone.
Dealing with mixed welding fume challenges in your workshop? Contact our engineering team for a free site assessment and tailored solution. We help facilities across industries achieve cleaner, safer, and fully compliant work environments.
