DecorationSandwich Panel Production Line

1.Purpose of the line:

Decoration sandwich panel production line is used to makecustom-made decoration sandwich panels with aluminum sheet on the one side andaluminum foil on the other side and the middle layer of polyurethane.

2.Main technical parameters:

3.Constituents of the line

The decoration sandwich panel production line is consistedof one double-head foil decoiler, one hydraulicclipping machine and one film-covering installation, one forming machine, oneflexible sheet deliverer, one PU foaming machine unit, one mobile injector, onepre-heating installation, one double-belt laminator, one hot-air circulator ,one automatic cutting machine, and roller conveyors, etc.

4.Functions of each equipment and its main parameters :
1) Double-headfoil decoiler

It is mainly consisted of decoiling mechanism, rotator, and angle/position adjustor and so on, which is to fix and decoil foil coil.
The decoiling mechanism includes the steel frame,spindle rotator and coil expander, etc.
Frame with plate welding structure is mainly used for supporting and installingother parts on the decoiler. Spindle rotator isequipped with driving system and expander is to fix the coil and support itsweight and rotation. Foil coil is moved to the expander by crane and a magneticbrake is used to damp decoiling process.

Main technical parameters:

2)Hydraulic clipping machine and film-covering installation

This part easily operated is a kind of machine toolhydraulically and pneumatically to shear and cover film to steel sheet. It usesthe 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 lowercutting blades as well as steel frame.
Usually, two film-covering installations, one put before the top former and theother before the bottom former, are fixed with the clipping machine.
Each of them include air cylinders, two gripping rubber rollers and bracket to,under the pulling of relevant former, pneumatic clamp film and colored steelsheet together. Number of this installation can be custom made.

Main technical parameters:

3)Forming machine (Refer to panel drawing)
The former is consisted of steel frame, forming rollers and driving mechanism,which has plate like structure, welded frame and gear-chain transmission.

Main technical parameters

4)Flexible sheet deliverer:

It is put on the top platform of laminator, which canhandle flexible facings like foil in terms of delivering, deviation correcting, automatic positioning, and controlling aluminum foilsuperficial tension force.
Main technical parameters:

Aluminum foil position correctionto be done manually.

5)Low-pressure PU foaming machine unit

This machine is equipped to meter and agitate two differentliquid raw materials in accordance with technically required ratio. The foamingmachine has devices of cooling and temperature-controlling designed to make theraw material reach the temperature required by the technical process. Besides,the pressure and metering are controllable and actions of injecting, cleaningand air-jetting could be controlled by computer programming.

Constituents and main technical parameters:
Tank assembly
Including four 300L tanks with a jacket, two layers of stainless steel wall,and scrape-type self-cleaning filters; mixing power: 0.55kw4; mixingrevolution: 60r/min.

Pump unit assembly
Two internally-engaged gear pumps with two gear motors infinitelyspeed-adjustable by way of frequency change (one is 1.5kw in power, the other1.1kw), revolution and pressure digitally displayed, auto controllable andadjustable.
Throughput is between 30 to 120g/s when the mixingratio is 1:1.
Two sets of pipes are equipped.

Mixing head assembly
One high-speed mixing head with the mixing revolution of 4500r/min and themixing power of 1.5kw, revolution adjustable by frequency variation; twopneumatic ball valves; automatic-cleaning installation with a 25L detergenttank made of stainless steel; and relevant cleaning valves and solenoid valves.

System of cooling materials
One water-chilling machine of 5HP; suitable hydraulicsolenoid valves and pipes and other valves; material temperature digitallydisplayed and adjustable through a changeover switch; one water-heating tank of6kw is included.

Auto material-supplementing installation
Two pneumatic diaphragm pumps with level control switches.

Main electric control
One control panel adopting a PLC controller except the electromotor, aircylinders, electric heating pipe and solenoid valve and other executivecomponents; the following parameters can be preset: injection time (setting atusers will), cleaning time, air-jetting time, alarming time and injection,cleaning and air-jetting actions.

6)Mobile injector

The injector here comprises steel base, frame, servo driverand slider, etc.
Main steel frame is installed on rails fixed on the base. Adjustors attached tothe base can regulate the height of injector and its distance from thelaminator. Mixing head put on a sliding plate can be driven by a tooth-shapedbelt to distribute materials reciprocally on a track. Driving power is from ahydraulic motor. The heads reciprocating stroke and position are variable.

Main technical parameters:

7)Pre-heating installation

To optimize the properties of products, the surface ofmetal sheet shall be first heated up to the appropriate temperature beforefoaming gets started.

8)Technical parameters

9)Double-belt laminator

This part fixed on the continuous production line is usedfor the foaming, hardening, ripening and shaping of core materials of sandwichpanels being laminated.

1. 1. Constituents and specifications

The press comprises top and bottom conveyor belts,hydraulic lifting and pressure-keeping installations, etc.

) Top and bottom conveyor belts
Laminating conveyor belts in the shape of acaterpillar include the driving chain belts, chain planks, rails and the boxframes welded up by good quality steel removed from stress. Hi-precision railsare installed to support the rolling bearings holding chain belts. Thesewear-resistant rails are made of GCr15 alloy steel with the surface hardened toHRC50~55.
Boxlike chain planks are finely made of good-quality aluminum alloy. They arehighly rigid and strong and are fixed onto big-pitch industrial chain belts bymeans 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. Devicesequipped on the sides of conveyor belts allow operators to tighten or loosenthe left or right chain belt.

) Hydraulic lifting and pressure-keeping installations
Installations here are composed of hydraulic system and devices to guide, raiseor lower, locate and sustain top conveyor belt.
The bottom conveyor belt is fixed on the press\'s base with multiple pairs ofvertical rails to raise or lower the top conveyor with the help of oilcylinders. Thickness of sandwich panels depends on the clearance between topand bottom belt conveyors. On the vertical rails, locators and spacing blocksare arranged to position the top belt conveyor.
Hydraulic system includes the hydraulic station, pairs of oil cylinders andrelevant hoses.
It works with low pressure to raise or lower the top conveyor belt and highpressure to sustain the belt. The system adopts an integrated design with all valvesfixed on one hydraulic station.

2. Main technical parameters:

10)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-burningfurnace and electric heaters as the heating source. Air circuit is enclosed bythe blower and air ducts as well as the conveyor belts of the press. Thermalsensors are put at the air outlet of furnace and within the top and bottomconveyor belts, which can control the temperature in positions mentioned by adigital thermal instrument. The oil-burning hot-air furnace is a kind ofindirect heating installation with the capability of fast heating and highworking efficiency.

Main technical parameters:

11)Automatic tracking cutter

The cutter is consisted of five basic mechanisms, viatraverse, protrude, cutting unit, dust collector, and steel frame. Protrudeincluding pinch rollers, castors, and necessary frame can passively go togetherwith the sandwich panel moving forward while it presses the panel withcylinders. Air cylinders are used to draw protrudeback to the original position. Traverse can be driven on a rail to move thecutter traversal, moving speed being infinitely adjustable. Cutting unit mainlycomprises upper and lower disc saws, vertical position adjustor and aircylinders, etc.. It is adaptable to cut differentthicknesses of panels via regulating the stroke of air cylinder concerned.Rotation speed of cutter will be infinitely adjustable by using a frequencyinverter. Dust collector with enclosure structure is to collect the PU and irondust. To guarantee the regular working of pneumatic devices, the client has toprovide an air compressor on his own with the output of 0.9cu.m./min andminimum compressed pressure of 1.2Mpa.

The cutter is controlled both electrically andpneumatically. The electric components send out instructions first andpneumatic valves automatically turn auto control system into originalcondition. Multiple restrictors in the air circuit aims to control the movingspeed of pistons of air cylinders as required.
Cutter moves along with the panel in the cutting process.

12)Powered roller conveyor.

Made up of steel pipe rollers, brackets, and driving units,etc.

The powerless roller conveyors shall be arranged accordingto the layout drawing.

13)Auto control

Whole production line speed-variable by frequency conversionis controlled by closed-loop auto-feedback system in a concentrated way, eachpart of which is adjustable.
Control panel position & functions during manual & automatic mode:

. The panel should control the rollformer,laminator, chemical output and chemical flush operations individually in manualor auto mode.
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 to control the overall speed of the line.

Manual Mode Buttons:
3. Running control of former
4. Running control of laminator
5. Interlinked movement of former and laminator
6. Polyol Flush - 5 seconds.
7. MDI Flush - 5 seconds.
8. Polyol and Isocyanate Bag Shot together - with variable timer set on main panel.

Automatic Mode Buttons
9. Start Mixing Head Traverse.
10. Stop-Mixing Head Traverse.
11. Start Roll former, Laminator and Pre-heater together.
12. Start - Polyol and Isocyanate Flow.
13. Stop - Polyol and Isocyanate Flow and retract Mixing Head to home position, then provide automatic Polyol Flush for 5 seconds when home.
14. Stop - Former, Laminator and Pre-heaters together.

B. Saw cross cutter
The saw should function automatically when thelaminator 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.

5.Price terms, after sales service and delivery time.

a. Price: USD500000 FOB Shanghai.
30% as deposit by T/T; 65% before shipment by T/T or L/C; 5%by T/T within 10 days since commissioning in buyers factory.

b. Guaranty and technical and after-sales service:
The seller shall be responsible for the equipment installation andcommissioning. The buyer shall bear the expenses of the plane tickets for thetesting staff dispatched by the seller side. Quality guaranty is valid for oneyear since finishing the installation and commissioning of the equipment.

c. Delivery time:
Delivery shall be made within 6 months after contract takes effect.

Kangda Polyurethane Machinery Co., Ltd. is a professional manufacturer and supplier of decoration sandwich panelproduction line. With 24 years of experience in production, sales and service,the products have exported to worldwise, like: the United Arab Emirates, Iran,India, Indonesia, Russia,Brazil, South Africa, Egypt,Sudan, Albania andother countries.

If you need decoration sandwich panel production line andother products, please contact us!