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PU Sandwich Panel Forming Machine

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Product Details

Place of Origin:	Liaoning in China

Specifications

Continuous production line of rigid polyfoam PU color-steel-sided sandwich panels

Purpose of the line The line is used to continuously make PU-cored sandwich panels with the facing layers of steel or aluminum sheet or PU-cored sandwich panels with one side of color steel and the other side of flexible sheet. It is also able to make panels of different profiles if the roll-forming machine is changed.

Main technical parameters

Specification of the panel	700~1000mm (width)
	30~150mm (thickness)
	Length to be custom-made
Production speed	3~8m/min
Length of belt laminator	24m
Max temperature of hot-air circulation	70℃
Dimensions of the line	about 86,000×7,000×3,800mm(L×W×H)
Total electrical capacity	about 207kw
Power of hot-air furnace	200000 kcal

Constituents of the line

The line is consisted of two decoilers, two hydraulic clipping machines, two forming machines, two film-covering installations, one PU foaming machine unit, one mobile injector, one pre-heating installation, one double-belt laminator, one set of plastic blocks supporting corrugation skin, one hot-air circulator, one set of side chemical stopper, one automatic cutting machine, roller conveyor, steel platform, powered roller conveyor and auto control etc..

Functions of each equipment and its main parameters

· Decoiler It is mainly consisted of decoiling mechanism, coil-loading trolley, hydraulic system, infrared measuring device and so on, which is to fix and decoil colored steel coil. The decoiling mechanism include the steel frame, spindle rotator and coil expander, etc.. Frame with plate welding structure is mainly used for supporting and installing other parts on the decoiler. Spindle is to hydraulically draw and expand steel blades so as to fix a steel coil. Spindle rotator is equipped with driving system for coil rotation. Coil-loading trolley aims to hydraulically raise a steel coil to a certain height and then move it to spindle’s blades along with rails. When the coil is in position, steel blades on the spindle will be expanded to tighten it. Linear rotation speed of the spindle is usually slightly higher than panel production speed, which can be automatically controlled in real time by way of using an infrared sensor. Main technical parameters: Inner diameter of steel coil 508mm Max. Coil weight 9000kg Max. Coil width 1250mm Power 4.8kw (2) Hydraulic clipping machine and film-covering installation This part easily operated is a kind of machine tool hydraulically and pneumatically to shear and cover film to steel sheet. It uses the same hydraulic station for decoiler. The clipping machine can use hydraulic force to shear colored steel sheet, which is basically made up of hydraulic cylinders, levers, upper and lower cutting blades as well as steel frame. Film-covering installation including pneumatic cylinders, gripping rubber rollers and steel supporters adopts pneumatic force to grip steel sheet and covered film lead forward by forming machine. Two such installations usable according to requirement are given, one for the top steel sheet of sandwich panel, the other for the bottom one. Main technical parameters: Max. Shearing thickness 1.0mm Max. Shearing width 1280mm Max.Film covering width 1250mm Inner diameter of film coil 72-80mm (3) Forming machine This machine is configured in accordance with panel form drawing given (refer to the drawing). The same is used to form color-steel facings with platelike structure, welded frame and gear-chain transmission. Specification of color-steel facings for wall panels and inside roof panels: 1,000mm in width and 0.4~0.7mm in thickness. Specification of color-steel facings for outside roof panels: 1,200mm in width and 0.4~0.7mm in thickness. The unit includes: I. One set machine for top sheet forming It is put on a high platform, which is used to press and form inside roof skins and wall skins. The machine, which is infinitely speed-variable by way of changing frequency, shall be with 11 forming rollers of 75mm in diameter and with the power of 4kw and maximum forming speed 8m/min. Ii. One set machine for bottom sheet forming It is installed on the ground, which is used to press and form corrugating roof skins and wall skins. As to outside roof skins, the machine shall be with 21 forming rollers of 75mm in diameter and maximum forming speed 8m/min. For wall skins, the infinitely speed-variable machine shall be with 11 forming rollers of 75mm in diameter and with the power of 7.5kw and maximum forming speed 8m/min. (4) Hi-pressure PU foaming machine unit and material-supplementing installation (no(4) Hi-pressure PU foaming machine unit and material-supplementing installation t applicable for explosive or flammable foaming agent such as pentane) 1,Tank assembly Producing tank: Two 300L jacketed tanks with insulation layer on the outside, maximum allowable pressure 0.4MPa. Each tank is with a 0.75kw agitator assembly and the safety valve, pressure-reducing valve, pressure gauge, magnetic liquid-level indicator and fitting valves and pipes as well as two 1.3m2 condensers of pipe type. Preparatory tank: Two 2000L jacketed tanks with insulation layer on the outside, maximum allowable pressure 0.1MPa. Each tank is with a 1.5kw agitator assembly and the safety valve, pressure-reducing valve, pressure gauge, liquid-level control switch, fitting valves and pipes as well as the ladder, platform and fence rail. Temperature control system with a 18000kcal. Water-chiller, a 12kw heater, and 5 sets of digital temperature control instruments. Automatic material-supplementing installation: two material-loading tanks included; material loading done either in an automatic or a manual way; power: 1.5kw×2. Material filtration part includes two wire-type filters. 2, Pump assembly Two hi-pressure flowrate-variable plunger pumps: 12m3 displacement; nominal pressure at 25Mpa; motor power being 5.5kw, revolution at 1450r/min; with pressure sensor and alarm to limit maximum and minimum pressure. Flowrate sensor: instantaneous flowrate indication. An switcher between high pressure and low pressure is equipped. Two magnetic-driving connectors to prevent material’s dripping. 3, Hi-pressure mixing head One mixing head: continuous injection; co-jetting pressure adjustable. One head cleaner: one 25L stainless steel tank with the air-blowing valve, hydraulic cleaning valve, fitting pipes, electromagnetic valve, safety valves, etc. 4,Electrical control One control cabinet, on which pressure, temperature, flowrate, alarm and digital display are given. PLC and contact screen are equipped. (5) Mobile injector The injector here comprises steel base, frame, servo driver and slider, etc.. Main steel frame is installed on rails fixed on the base. Adjustors attached to the base can regulate the height of injector and its distance from the laminator. Mixing head put on a sliding plate can be driven by a tooth-shaped belt to distribute materials reciprocally on atrack. Driving power is from a servo motor given with a speed reducer of star connection. PLC and contract screen are used to control mixing head’s reciprocating stroke, position, and frequency. Main technical parameters: Power 1.5kw Max. Reciprocating speed 1200mm/s Max. Distribution width 1200mm Max. Vertical adjustment 800mm Max. Horizontal adjustment 100mm (6) Pre-heating installation To optimize the properties of products, the surface of metal sheet shall be first heated up to the appropriate temperature before foaming gets started. Pre-heating oven Technical parameters Temperature of air circulation: 80℃ ( adjustable) Temperature control auto with digital display Temperature of steel sheet 35℃, when moving speed is 5m/min Heating power 32kw Air-circulating fan 0.5kw×3 Pre-heating platform Technical parameters Temperature control: Temperature control switch Temperature: 40℃ Heating power: 7.2kw (7) Double-belt laminator This part fixed on the continuous production line is used for the foaming, hardening, ripening and shaping of core materials of sandwich panels being laminated. 1. Constituents and specifications The press comprises top and bottom conveyor belts, hydraulic lifting and pressure-keeping installations, etc. A. Top and bottom conveyor belts Laminating conveyor belts in the shape of a caterpillar include the driving chain belts, chain planks, rails and the box frames welded up by good quality steel removed from stress. Hi-precision rails are installed to support the rolling bearings holding chain belts. These wear-resistant rails are made of GCr15 alloy steel with the surface hardened to HRC50~55°. Boxlike chain planks are finely made of good-quality welding structural steel removed from stress. They are highly rigid and strong and are fixed onto big-pitch industrial chain belts by means of special roller bearings at the pitching points.Chain belts are driven by the frequency-variable motor through a speed-reducer, transmission speed infinitely adjustable by a frequency inverter. Devices equipped on the sides of conveyor belts allow operators to tighten or loosen the left or right chain belt. B. Hydraulic lifting and pressure-keeping installations Installations here are composed of hydraulic system and devices to guide, raise or lower, locate and sustain top conveyor belt. The bottom conveyor belt is fixed on the press’s base with multiple pairs of vertical rails to raise or lower the top conveyor with the help of oil cylinders. Thickness of sandwich panels depends on the clearance between top and bottom belt conveyors. On the vertical rails, locators and spacing blocks are arranged to position the top belt conveyor. Hydraulic system includes the hydraulic station, pairs of oil cylinders and relevant hoses. It works with low pressure to raise or lower the top conveyor belt and high pressure to sustain the belt. The system adopts an integrated design with all valves fixed on one hydraulic station. 2. Main technical parameters Usable length of top conveyor belt [ effective] 24m Usable length of bottom conveyor belt [effective] 24.6m Length of chain plank 1200mm Foaming width adjustable 700~1000mm Width of chain plank 200mm Total thickness of chain plank frame 60mm Number of sprocket teeth 8 Pitch of sprocket 200mm Clearance between top and bottom conveyors 300 mm (max.) Foaming pressure bearable 0.6bar/cm2 Number of hydraulically raising cylinders 16pcs Diameter of oil cylinder ∮80 mm Power of hydraulic station 7.5kw for raising top belt; 1.1kw for sustaining top belt Conveying speed 3～8 m Power of conveyor motor 11kw×2(speed-adjustable by frequency inverter) Precision rails 3pcs×2

8) One set of plastic blocks supporting corrugation skin Used to support outer roof skin by means of engineering plastic blocks. These blocks are arranged in 254 groups, several pieces, in one group, fixed onto one connection sheet. The connection sheet includes heat-resistant magnetic steel and location pins and thus can be attached onto chain planks by magnetic force. (9) Hot-air circulator To meet the technical requirement of chemicals’ foaming, one set of hot-air circulator is to heat the chain planks of conveyor belts. 1.Constituents and specifications The circulator takes a oil-burning furnace and electric heaters as the heating source. Air circuit is enclosed by the blower and air ducts as well as the conveyor belts of the press. Thermal sensors are put at the air outlet of furnace and within the top and bottom conveyor belts, which can control the temperature in positions mentioned by a digital thermal instrument. The oil-burning hot-air furnace is a kind of indirect heating installation with the capability of fast heating and high working efficiency. Main technical parameters Capacity of hot-air furnace 200000 kcal. Temperature at the air outlet of furnace 60~200°, adjustable Max. Circulation temperature 70℃ Power of air-circulating blower 5.5kw Power of furnace’s blower 3kw Volume of air circulation 12000m3/h (10) Side chemical stopper Two side stoppers driven by chain belt are respectively placed on the left and right sides of the press of continuous production line to keep foaming raw materials from leaking out at sandwich panel’ sides. 1. Constituents and specifications This installation is made up of the chain belt, plastic stoppers and the mechanism for adjusting the distance between stoppers on the left and right sides of press. A. Chain belt The industrial chain belt with the pitch of 100mm is horizontally installed on a steel frame, which is driven by an AC motor through a gear reducer. It can move simultaneously with the conveyor belts, moving speed adjustable by a frequency inverter. A magnetic powder clutch is arranged at the chain-driving position to play the roles of delaying startup, overload protection and speed variation. Two sprockets are placed at the ends of each chain belt so as to tighten or loosen the belt. B. Plastic stoppers 100mm-wide plastic sealing blocks connected to chain belts can form an enclosed space together with the top and bottom facing steel sheet (or other flexible facing materials like aluminum foil, paper ,etc.) and sealing paper so as to prevent chemical’s leakage and they move in the speed same as that of facing sheet being fed into the press. Details of stoppers are as follows: ·One set of plastic sealing blocks for roof panels Thickness of base blocks: 30mm (not including corrugation height) Including stacking plastics with the thickness of 10mm, 20mm and 30mm Max. Stacking thickness: 150mm. · One set of plastic sealing blocks for wall panels Thickness of base blocks: 30mm Including stacking plastics with the thickness of 10mm, 20mm and 30mm Max. Stacking thickness: 150mm C. Mechanism for adjusting the distance between stoppers on the left and right sides of press To meet the requirement of making panels with different width, this mechanism is included in the side stopper installation. Its adjustment devices comprise rails, sliders, and locking parts. Rails are joined with multiple sliders locked on plates. When locking parts are loosened, the sliders and rails can be moved to adjust the distance between stoppers on the left and right sides of press. 2. Main technical parameters Length of side stopper about 18m Pitch of chain belt 100mm Width of side stopper 150mm×2, adjustable Power required 1.5kw×2(speed variable by frequency inverter) Speed of chain belt movement to be same as the belt conveyor Width of plastic block 100mm Shape of plastic block in accordance with panel profile · Automatic tracking cutter The cutter is consisted of five basic mechanisms, viz traverser, protruder, cutting unit, dust collector, and steel frame. Protruder including pinch rollers, castors, and necessary frame can passively go together with the sandwich panel moving forward while it presses the panel with cylinders. Air cylinders are used to draw protruder back to the original position. Traverser can be driven on a rail to move the cutter traversely, moving speed being infinitely adjustable. Cutting unit mainly comprises upper and lower disc saws, vertical position adjustor and air cylinders, etc.. It is adaptable to cut different thicknesses of panels via regulating the stroke of air cylinder concerned. Rotation speed of cutter will be infinitely adjustable by using a frequency inverter. Dust collector with enclosure structure is to collect the PU and iron dust. To guarantee the regular working of pneumatic devices, the client has to provide an air compressor on his own with the output of 0.9cu.m./min and minimum compressed pressure of 1.2Mpa. The cutter is controlled both electrically and pneumatically. The electric components send out instructions first and pneumatic valves automatically turn auto control system into original condition. Multiple restrictors in the air circuit aims to control the moving speed of pistons of air cylinders as required.

Cutter moves along with the panel in the cutting process. Saw-cutting power 2.2kw×2 Diameter of disc saw φ300mm Clamping cylinder φ63×50mm×2 Resetting cylinder φ80×1500mm Cutter traversing power 1.5kw Cutting speed 150mm/s, infinitely adjustable Minimum cutting length 3m Cutting length measured by digital device Lengthwise cutting precision ±2mm Cutting precision in diagonal direction ±2mm (12) Steel platform Used to place the decoiler, hydraulic clipper and top forming machine and other single machines. Ladder and fence are given. (13) Power roller conveyor Made up of steel pipe rollers, brackets, and driving units, etc.. Diameter of roller φ76mm Length of roller 1100mm Gap between two rollers 300mm Length of roller conveyor 7000mm The powerless roller conveyors shall be arranged according to the layout drawing. (14) Auto control Whole production line speed-variable by frequency conversion is controlled by closed-loop Auto-feedback system in an concentrated way, each part of which is adjustable. Screen monitor Is provided to watch over four important sections on the line. Control panel position & functions during manual & automatic mode: A. The control remote panel should be situated on the side foaming gantry, as shown above. The panel should control the two rollformers, laminator, chemical output and chemical Flush operations individually in manual mode and all four functions simultaneously during Automatic mode, as follows: List of control switches and buttons: 1 Selection Switch – Manual Mode/Automatic Mode. 2 Speed Control Potentiometer – operational in both Manual and Automatic Mode. This is situated on the foaming station remote panel and controls the overall speed of the line, Including de-coiler rollformer and laminator. As you speed up or slow down the laminator, The de-coiler and rollformer speeds are matched. The rollformer remote panel should have a Speed indicator. Manual Mode Buttons 3 Jog - Top Rollformer Forward or Reverse. 4 Jog - Bottom. Rollformer Forward or Reverse. 5 Jog - Laminator Forward or Reverse. 6 Jog Top - Rollformer, Bottom Rollformer and Laminator together- Forward or Reverse. 7 Run Laminator Forward or Reverse. 8 Stop Laminator. 9 Polyol Flush - 5 seconds. 10 Solvent Flush - 5 seconds. 11 Polyol and Isocyanate Bag Shot together - with variable timer set on main panel. Automatic Mode Buttons 12 Start – Mixing Head Traverse. 13 Stop Mixing Head Traverse. 14 Start - Top Rollformer, Bottom Rollformer, Laminator and Pre-heaters together. 15 Start - Polyol and Isocyanate Flow. 16 Stop - Polyol and Isocyanate Flow and retract Mixing Head to home position, then Provide automatic Polyol Flush for 5 seconds when home. 17 Stop - Top Rollformer, Bottom Rollformer, Laminator and Pre-heaters together. B. Saw cross cutter The saw should function automatically when the laminator operates in the automatic mode. 1 Selection Switch - Manual Mode/Automatic Mode. 2 Manual Cut Button in Manual Mode. 3 Manual Cut Button in Automatic. Optional equipment: 1. Lifting and parallel moving installation with vacuum suckers (USD38000) Mainly used to move the finished sandwich panel from the production line onto powered roller conveyors for packing machine and then stack the panels to a certain height. This installation is consisted of steel frame, crane, traveling mechanism, vacuum lifter, vacuum pump and electrical control system, etc.. All of its actions-lifting, lowering and horizontal movement-are done by manual control. If need be, PLC system can be used to perform all these actions by presetting programs. Main parameters: Max. Horizontal-moving distance 8m Max. Lifting height 2m Max. Lifting weight 250kg Max. Panel length 12m Total power 7.5kw 2. Flipper (USD6000) To turn over the sandwich panel in 180 degrees for the convenience of stacking. This machine includes a main frame, a flipping mechanism, and powered rollers. The flipping mechanism includes both flipping and take-over installations. Its operations are actuated by two independent powered systems while flipping action is controlled by electrical parts like limit switch, etc. Main parameters: Max. Length of panel to be flipped 12m Max. Width of panel to be flipped 1.1m Total power 2×1.5kw 3. Packing machine of winding type (USD28000) Suitable for horizontally packing bar-shaped products by the use of thin plastic film or paper. This machine is made up of the packer and conveyors in front of and behind the packer. An oscillating arm is equipped to grip and cut packing materials. Before packing, if plastic film and padding are needed to put at the cutting ends and the bottom of panels to be packed, this process shall be done manually. Main technical parameters: Specification of panels to be packed 12000mm (max. Length) 1200mm(max. Width) 1100mm(max. Height) Packing speed 0~4m/min, adjustable Film specification 250~500mm wide; inner diameter Of paper core: 76mm. Total power 5.5kw Attachment : Panel drawing

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