Dây chuyền sản xuất panel PU 2 + 2

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SUBJECT: PU PANEL DIS-CONTINUOUS LINE

I.             HP100 HIGH PRESSURE INJECTOR

 

Máy phun PU áp cao

Technical Configuration

Nguyên lý hoạt động của máy phun PU áp cao


1. PROFILE:

HP100-type two-component high pressure pouring machine, using a polyether polyol feed tank (POLY.), 1 Pcs polyisocyanate (ISO.) feed tank; two measurement units were used frequency convert to control the output of metering pump flow rate,

2. EQUIPMENT, MAIN TECHNICAL PARAMETERS AND DESCRIPTION:

2.1 Equipment Type: HP100

2.2 The application of foam:

2.3 for viscosity: (22 )

Polyether polyol: ~ 2000mPas

Polyisocyanate: ~ 2000mPas

2.4 Injection volume (mixing ratio 1:1) :400-1500g / s (60HZ, increase flow rate 20%, about 1200g / s)

Mixture ratio adjustment rang: 2:1 ~ 1:1

2.5 Injection time: 0.5 ~ 99.99s (accurate to 0.01s)

2.6 Injection programme quantity:

Manual injection: 20      Auto-injection: 99

2.7 Measurement Unit:  Measurement accuracy of 0.5%

Components of raw materials POLY ISO.    Number 11

Pump Model A2F12(Rexroth) from Shanghai

Frequency Motor Power (kw) 5.5  

Inverter motor speed (rpm) 1450

Shaft Seal Lubrication DOP

Used for the measurement of components, including those with anti-vibration pad bracket, drive motor, coupling, axial piston pumps and safety valves,

Electronic pressure switches.

2.8 Pressure limit and control system

Polyether polyol and isocyanate groups working pressure were controlled at 6 ~ 22MPa, if the working pressure beyond this range. Machine will stop injecting, alarm and display the "work pressure is not normal" fault information.

Group were the limits of safe pressure metering pump is set to 25MPa, and equipped with dual protection, to ensure that the metering pumps and systems to enable with security. Electrical Protection: When the pressure of 25MPa, the device automatically shut down, alarm and display the "super-pressure pump" and fault information.

Mechanical protection: When the pressure of 25MPa, the overflow valve;

Group were the lowest pre-pressure metering pump to protect pump is set to polyether polyol 0.25MPa, isocyanate pump set to 0.15MPa. When the pressure is below the pre-set value, the device automatically shut down alarm and display the "pre-pressure is too low," the fault information.

2.9 component flow control and test unit

According to pump output flow and process requirements component mixing ratio in the casting process to set the two groups, respectively, copies of the relevant parameters;

Component flow rate through the frequency converter to adjust the motor speed from the surface pump output flow to meet the metering pump adjustment hand wheel and the respective

Flow test device, respectively 2-component parameters of flow and mixing ratio testing, calibration in order to achieve flow regulation and components

Control. .

2.10 component filter

A, B groups were equipped with a net-type filter. One POLY.1, ISO filter 4 inches, filtering accuracy of 330μm. Set period of change and regular sewage.

2.11 Hydraulic Unit

Pump flow (L / min): 15

Motor Power (kw): 5.5

Motor speed (rpm): 1450

1 Pcs 80L oil tank installed above the supporting plate;

install the driver to install on-board motors, pumps, buffer coupling, hydraulic manifold block, integrated block is installed on the booster valve, an

All valves, pressure gaupcss, pressure switches and manual vent valve load, etc.;

1 Pcs 10L high-pressure accumulator, in order to ensure rapid mixing and to absorb the vibration of the first switch;

1 full precision back to the oil filter;

1 set of oil cooler, valves, etc. to ensure the hydraulic system will not work in a continuous temperature rise is too high ( 60 );

1 set of level display, indicating the oil level inside the tank;

2 Pcs NG10 solenoid valve control L were mixed the first two mixing chamber and the main piston to open or close.

2.12 high-pressure mixing head

Mixing head 1 pcs

With South Korea DUT technology to produce high-pressure self-cleaning linear mixing head, using needle adjustable nozzle. In order to ensure mixed

Effect of raw material respectively from two different directions of collision mixing nozzle in order to ensure adequate mixing component.

2.13 mixing head cantilever

Be used to support piping system and installation of mixing head and procedures for the button box, from the rotation center to the ends of arm length 2200mm. an electric lifting equipment to mix the first freely up and down movement; the level of 160 ° rotation range

2.14 high and low voltage switch cell cycle

So that the formation of low-power cycle components. Control the various components of the respective high and low pressure cycle switch.

2.15 polyether polyol feed tank: 1

 effective volume: 250 liters;

 sandwich-style, SUS304 stainless steel;

 Maximum working pressure: 0.06MPa;

 1 Pcs jacket water safety valve, set the working pressure of 0.30MPa;

 1 Pcs safety valve set pressure 0.60MPa;

 1-band gauge of the pressure reducing valve set pressure of 0.35 ~    0.40MPa control the feed of compressed air into the gas tank high pressure;

 automatic feeding installation of one-way exit valve;

 output by three to manually install the two cut-off valve (bypass valve which   be used for sewage);

Level Meter: high limit, high feeding level, low four overall control, with visual level

heat exchangers: tubular;

Temperature probe: PT100

mechanical seal agitator, power 1.5KW, speed 46rpm; airtight enough to meet the technical requirements;

outer zone insulation.

2.16 isocyanate material tank 1

effective volume 250 liters;

jacket type SUS304 stainless steel;

Maximum working pressure: 0.06MPa;

1 Pcs jacket water safety valve, set the working pressure of 0.30MPa;

1 Pcs safety valve set pressure 0.60MPa;

1-band gaupcs of the pressure reducing valve set pressure of 0.35 ~ 0.40MPa control the feed of compressed air into the gas tank high pressure;

 automatic feeding installation of one-way exit valve;

 output by three to manually install the two cut-off valve (bypass valve which  be used for sewage);

 Level Meter: high limit, high feeding level, low four overall control, with visual  level

heat exchangers: tubular;

Temperature probe: PT100

mechanical seal agitator, power 1.5KW, speed 46rpm; airtight enough to meet the technical requirements;

outer zone insulation.

2.17 Temperature Control Unit:

Heating power: 2X3KW

Cooling unit cooling capacity (Kcal / h); 3600;

Two heating modules are expected to control two tank heating, cooling unit is equipped with 7.5HP compressor, pressure 0.25MPa,

The temperature of raw materials to achieve automatic control foaming process requirements. Compressor imported brands, with a special refrigeration temperature control device, operating

Switch to imported pieces.

2.19 metering pumps self-lubricating

Is used to polyether polyol isocyanate metering pumps and metering and hand axle shaft seal for regular self-lubricating and clearing

Washing, lubricating medium for the DOP.

2.20 Automatic Feeding Unit

Polyether polyol feeding gear pump (Taiwan) 1

Polyisocyanate feeding gear pump (Taiwan) 1

Flow rate: 8L/min, feeding level control can be realized manual / automatic feeding in two ways.

2.21 Electrical Control System

Electric control system adopts OMRON PLC, input, output modules, touch-OP Speaking manipulator with a strong

Menu function, easy operation. The main electrical components of imported brands, to ensure safety and reliability of the control system.

Equipment manual, automatic features, dry / wet injection of choice function, auto-loop function, equipment, hand function and stem injection function

Is mainly used for debugging the device. Under normal operating conditions, opt for wet-injection auto-functional state. Auto-circulatory function is mainly to be Longer period of time for equipment to maintain the system does not produce Ershi normal process conditions. Parameters of various functions to operate on the Actions menu.

Control system failure alarm has a strong functions of the various test points of failure on the information display device in operation, with sound and light alarm, Device to automatically shut down when necessary.

Include control cabinet;

  South Korea's LG Series PLC controller;

  Taiwan and Taiwan reached inverter controller;

  Omron relay;

  Schneider contactor;

  French Schneider switches, buttons;

  External Tongxun interface;

  system software and control procedures.

2.22 Pipeline System

Covers all types of pipes and hydraulic control components, respectively, were used to transport materials and hydraulic oil group.

2.23 Power Supply and equipment weight, area:

Control voltage: 3 × 380V/50HZ

Input power: 25KW

Equipment weight and area:

Weight: 2600KG

Area: 2800 × 3100 × 2800 (L × W × H)

2.24.  ACCESSORIES, SPARE PARTS AND SPECIAL TOOLS LIST

1. A2F28 pump bearing ring (wearing parts)   4set

2. Needle of adjustable nozzle               2sets      

3. material mixing tank seal (graphite)        2 sets

4. material tank valve Air TAC              (Taiwan brand) 1sets

5. Installation tools                         1sets

 

3. DEVICE CONFIGURATION LIST AND RANDOM LIST OF SPARE PARTS

No.

Name

Original from and brand

Qty.

1

Machine frame

Henghui

1set

2

POLY. Metering unit

Metering pump:Shanghai

Magnetic coupling: China

Speed adjustable motorSiemens

1set

3

ISO. Metering unit

Metering pump:Shanghai

Magnetic coupling: China

Speed adjustable motorSiemens

1set

4

Pressure display and controlling system

Material outlet low pressure switchSchniledWith digital display);

Material out high pressure transferUSA Sensna

2set

5

Material flow automatic ratio checking unit

Made in germany

2 Set

6

Material flow manual ratio checking unit

Mixing head check

1Set

7

Polyol net filter

Shanghai Tongji330μm

1 set

8

ISO net filter

Shanghai Tongji330μm

1Set

9

Hydraulic system

High pressure pumpMade in italy

Hydraulic high pressure switchSchneiderwith digital display);

MotorSiemens

1 set

10

Mixing head DHV-1218-2K

Henghui

1set

11

High pressure magnetic sensor

Swiss made

1 set

12

Mixing head cantilever

Henghui

1 set

13

High/low pressure shift unit

Taiwan made

2set

14

250L Polyol material tank/Lay pipe heating exchanger/liquid meter/stirring motor

Tankhenghui

Heating exchangerhenghui

Liquid meterFeishun

Stirring motorShanghai shuanglian

1 set

15

250L Polyol material tank/Lay pipe heating exchanger/liquid meter/stirring motor

Tankhenghui

Heating exchangerhenghui

Liquid meterFeishun

Stirring motorShanghai shuanglian

1 set

16

Temperature controlling system

Omron

2set

17

Electrical controlling system

PLCIP/OP Mould unitSiemense S7-200

Touch screenSiemens 7.5"

Frequency inverter: Siemens

Low voltage electrical partsschnilder

Button switchschnilder

1 set

18

Pipe line

High pressure pipecoupling china

Air system relief valvesolenoidYadeke Taiwan

1 set

 

II.   PU FOAMING PRESS MACHINE


I.              APPLICATION AND PROPERTIES:

MJS2+2-6.3-type non-continuous PU sandwich panel machine, also called PU press machine. On working, two template make foam injection and curing , at the same time, the other two for product disassembling. So two going inside, two going out. The equipment characteristics is small body compared with continuous PU sandwich panel production line, but more suitable for cold storage rooms of sandwich panel and other high-insulation building polyurethane sandwich panel production.


II. MAIN CONFIGURATION
1. Laminating machine frame
    1Pcs.
Laminating machine frame is welded steel, strength
is sufficient for foam demand.

2. Fixed press disk               1Pcs.
Fixed
press disk is from whole piece process, with water cycle channel inside. The fixed plate  as the main part of the press machine. Its designing and manufacturing process for a number of process indicators inspection to ensure the maximum foam power machine power requirements. Template flatness is 0.5mm, the surface roughness Ra = 3.2um

 

3. Template                      4pcs.
Template is the main parts of the press machine, up and down template used simultaneously, The template is from process of whole piece solid steel plate, with water cycle channel inside. The template designing and manufacturing process for a number of process indicators inspection to ensure the maximum foam power machine power requirements. Template flatness is 0.5mm, the surface roughness Ra = 3.2um.
   Each template has independent motor, moving on the rail. Every template has handling chain, and drive cables inside , heating pipes and so on.


4. Synchronization,
  The process of template has synchronized structure composed of gear bar, which will ensure a smooth synchronization on rise

5.Electrical control system

Applying PLCfor controlling every unit motion and press machine open and close

l  Emergency reset and return button

l  Stop and recycle button

l  Template temperature controlling system

l  Signal light

l  Heating timer and water level limit

6.Hydraulic system: Split flow pump control the template open and close

7.Heating system: Heating water tank adjust working temperature from 30-60.

8.Safety : Photo sensor protection in case to enter dangerous area

 

IIITECHNICAL SPECIFICATION:

l  Template size                 6300mmX1500mm

l  Table plate thickness           40mm

l  Table surface flatness more than 3.2um

l  Table surface plan is less        0.5mm

l  Table plate temperature         30-60

l  Max. Product size              6000mmX1200mmX200mm

l  Max. Clamping force            200T

l  Thickness range of              20-220mm

l  Hydraulic station pressure        6-15Mpa

l  Machine size                   18mX1.9X1.8(L/W/H)

l  Machine weight                 around 48ton

l  Power                         3P/50Hz/380V

l  Water heater power             36KW

l  Hydraulic station power          11KW 

IV. MAIN PARTS LIST

 

No.

Name

Model

Brand

Qty.

1

Press machine

Main structure

HPE

1Set

2

Fixed pressure disk

Fixed for press

HPE

1Set

 

3

Moved pressure disk

Driving gear motor

Zhengjiang shuanglian

4Set

Driving wheel

HPE

4Set

Moved wheel

HPE

4Set

Template

HPE

4Set

Track rail

HPE

2Set

 

4

Control box

PLC

Siemens

1Set

Touch screen

Siemens

1Set

Electrician parts

Schneider

1Set

5

Hydraulic station

Hydraulic cylinder

Taiwan chaotian

16Set

Solenoid

Taiwan chaotian

1Set

Hydraulic soft pipe

China

1Set

Hydraulic pipe fitting

China

1Set

Motor

Siemens

1Set

Hydraulic pump

Taiwan chaotian

1Set

Pressure switch

Taiwan chaotian

1Set

Pressure hold accumulator

Nanfang Hydraulic

1Set

6

Heating system

Water tank

(Inside stainless steel)

HPE

1Set

 

Một số hình ảnh tại xưởng sản xuất Panel bên Thượng Hải:

 


Mr Pham Tan Vietnam Mobile: +84978700123


 

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