PU sandwich panel production line

 

 

Production speed	About 5m/minute (50mm T standard)
1 hour production capacity	300 m2
1 day production volume (with 8 hours working time)	2 400 m2
1-year production capacity (with 300 working days)	720 000m2
Efficiency 80%	576 000m2
Annual production volume	About 600,000 m2 (with one shift working time)
With two shifts	1 000 000 m2

 

The size of the land area required for the installation of this line (Minimum)	Min. 100m (length)*30m (width)*7m (height)
Number of workers needed	6-8 workers
Product production volume	About 6 m per minute Maximum 10 m (this indicator is for a product with a thickness of 50 mm)
Factory temperature	15°C ~ 25°C
Relative humidity	60~70%
Total electricity consumption	About 300kw without heating system
Voltage	380V/50Hz or 440V/50Hz
Stress resistance	±5%
Control cabinet lighting voltage	220 or 110V AC

Outline drawing of the line:

Technical parameters of the line:

Roll (raw material)	Color steel
Roll (steel sheet) thickness	Outer layer surface: 0.4mm-0.7mm Inner layer surface :0.4mm-0.7mm
Roll theft	Maximum 7 tons
Roll width	1070, 1200(1207), 1220mm (3-4 types of steel)
Equipment length	Around 40 m
Inner diameter of the roll	Æ508mm
Outer diameter of the roll	Maximum Æ1,100mm
Rotation speed	0 m ˜ 8 m/min
Hydraulic pressure	Maximum 150kg/cm2
Pneumatic pressure	Around 4~9 kg/cm2
Electric power source	380V or 440V*50Hz
Transition line (height)	1,250 mm above the ground
Panel type	Boltless panel, roof panel
Panel length	Minimum 2,000mm~Maximum 15,000mm
Panel width	1,000mm
Panel thickness	35~150mm
Features of foaming equipment	PU/PIR-digital equipment
Foam density	About 35~50 kg/m3
Unit of measurement	High pressure pump system (2 or 4 comp)
Foaming pressure	Maximum 0.5 bar/cm2
The size of the plant	Minimum 100m(length)*30m(width)*7m(height)
Production rate	Approximately 6m/minute at a maximum of 10m/minute at a thickness of 50mm
The length of two belts	24,000mm(24m)
Height required for work	Minimum 7 m
Air compressor	Minimum 10Hp
Air pressure	About 4~10 bar
Factory temperature	150C ~ 250C
PU tank storage temperature	220C ~ 250C
Relative humidity	60-70%
Total electricity consumption	Except for the heating system of about 300KW
Power	380V/50Hz or 440V/50Hz
Stress resistance	±5%
Frequency (tolerance)	50Hz (±1%)
Control panel Lighting voltage	220 or 110V AC
Valve and Sensor voltage	24V DC
PLC	Siemens or Mitsubishi PLC
Emergency transmitter	Minimum of 7 transmitters on a common line

Roll forming (profiling) line

Main points : This line consists of roll car, unwinder and upper/lower roll forming equipment. The most important features in this line are roll quality and electrical synchronization, including a dual belt conveyor.

The coils must go through several heat treatment and precision machining processes, and then the hard chrome plating process guarantees more than 10 years of service. If this is not the case, the rolls will wear out easily and the service life will be much shorter, resulting in a lower quality of the panel. The hard chrome coating provides a high level of durability and protects the colored coil (steel layer) paint from peeling during roll forming. Electric synchronization is designed to ensure the same speed in steel sheet opening, roll forming and double transport. In addition, the rotation speed of the upper and lower rollers should be the same. Otherwise, the panel production will not be completed successfully and the production facilities themselves may be damaged.

This is a package designed to transport and deliver a bundle of coiled steel sheets (coils) to the quenching device. Lifting up and down is done by 4 wheels on the rail and a hydraulic cylinder that moves right and left supported by 4 wheels. Two units are required to operate the upper coil and lower coil.

Technical data:

Equipment type	4-wheel equipment with hydraulic power
Roll weight	Maximum 7 tons
Roll width	Maximum 1,255mm
Main part material	Welded iron construction

Roll spreader, 2 sets

The steel sheet (slat) is installed on the opener by the roller carriage, in which 4 pins are expanded, then 4 wedges are expanded, fixed by hydraulic power, and then driven by a motor. A rubber roller is mounted on the opener to prevent the reel (steel plate) from twisting suddenly and over-twisting in motion.

Load capacity	Maximum 7 tons
Slinder opening and closing distance	Æ482 ~ Æ517mm
Mil	Æ260mm
Slinder drive	A.C 2.2kw gear motor
Snub roll	Æ200mm × 400mm (rubber coated)
Drum brake	Æ400mm × 100mm wheel handbrake
Lifting the upper roll	Air cylinder

Cutting device

It consists of a blade driven by a compressed air cylinder, which is designed to set the M/C cutting pattern that initially forms the roll, and then cuts the steel sheets to the same panel length. It is also designed for cutting without interrupting the production line.

This machine is designed to protect the panel skin by sticking the protective film while controlling the tension of the protective film, 1 roll must be installed and each one is connected without stopping the line.

Cutting speed	0.5sec
Size	1.0mm(T)*1,250mm(L)
Cutting type	Air cylinder
Main frame	Welded steel construction
Roller shaft	Æ70mm × max. 1,300mm(L)

 

Top steel plate corona device for bottom component
● High frequency corona device

 

Top Roll Forming Machine – Fixed Width Type (1000mm)
The upper roll forming machine is primarily responsible for forming the shapes of both sides of the lower coil (steel plates) to use the joining parts of the roof and wall (including interior) panels.
It has an easy-to-change setting in case different panel shapes are required for production.
The stationary reduction device is conveniently located on the undercarriage frame, which allows quick replacement of roll forming units.

Bottom Steel Roll Forming Blocks, Roof 4 Compartment and Boltless, SS (Cold Room) Panel

Installation type – moving rail type

Roller Conveyor — 3 sets (roller-ø60mm×1,200mm(L)

Electric control system
This device is installed separately on the upper and lower forming line.
The main control panel next to the PU foam block controls the speed (whole line when in manual mode)
The roll former has a small manual control panel to test the roll former unit.

— Main: 2 sets / operation panel: 2 sets
Electricity 380v or 440v × 50Hz

Preheating system with electric heater
This device is used for moderate heating of upper and lower steel plates
temperature after the roll forming process.
Since polyurethane undergoes a chemical reaction at moderate heat, the process of heating steel
the sheet activates the PUR and forms an adhesive bond between the steel sheet
polyurethane foam flooring is stronger.
The heating mechanism is a flow of air heated by a gas or electric heater and directed to it
upper and lower steel plates.
The temperature sensor is mounted on the upper and lower brackets, which make the installation
the actual temperature can be adjusted to any desired temperature.
The housing is tunnel type and heated air to prevent heat loss
supplied directly to the tunnel.
The temperature of the steel plates after preheating is on average 40 ~ 60 ° C. Higher
temperature can cause the PUR to react earlier and produce a lower quality panel.
Temper. Circulation air: Max. 90 ° C, adjustable

Steel plate temperature: 40°C ~ 60°C

Type of temperature control: Automatic. management
Warming room size: About 4 m (L) × 3 m (W) × 3.5 m (H)
Heating capacity: 40 kW

Heating method: Electric heater

Chiller (30RT)

The distribution pressure is maximum 200 bar/min

Production volume for each pump – Max. 32l/min at 50 Hz

Required viscosity level-Max. 2,000 mPas

 

 

The sleeper system through the steel panels for the bottom roll forming machine:

 

 

 

Hardware function:

 

The oscillating action of the stirring part is important for optimal results
It is applied to the bottom coating layer of the PUR-compound.
This equipment is driven by an AC servo motor and its toothed belt, providing free programmable oscillating motion across the entire width of the panel. There is almost no noise during the operation of this part, which greatly affects the stable operation of the equipment.
When moving, the speed, width and level of the vibrating movement can be adjusted.
You can also select a separate speed for each type of panel to be produced when displaying the speed status graphically on the monitor.
This system ensures that the production of each panel type has a constant quantity and quality after the optimal vibration characteristic has been determined.
In particular, for roofing panels with deep compartments, the vibration speed can be selected, the speed of the stirring part decreases as it moves through the deep compartments. In this case, more foam is applied (poured) to the deep sections to prevent differences in density, as well as to prevent the panel from sticking together.

Double belt conveyor system — 24m:

The PU component mixture applied to the bottom coating layer is transferred inward and synchronized with the facing layer across the double-sided panel for activation. This device is the most basic part and plays a key role in ensuring that the sandwich panel meets the highest standards. plays
This equipment is mainly composed of a driving motor, upper and lower slats, a hydraulic cylinder containing increased pressure, and a side panel and side block to prevent PUR.
The most important parts of this device are the lamellas, which require precise metal processing
requires the most precise degree of equality and change of process and units.
Lateral sealing chains on both sides seal the foam and contain the lateral pressure of the foam. Because PU foaming pressure is very high, multiple hydraulic cylinders are needed to control the foam.
The hydraulic cylinder is designed to move the upper belt conveyor up and down for the desired panel thickness.

The length between the wheel axles	24 000 mm
The height of the lower chain belt	About 1 250 mm
Plate width	220 mm
Plate length	1 350 mm
Plate thickness	About 10~12 mm
The number of plates between each division	About 500 of them
The lifting distance of the upper chain belt (required during repair	Maximum 300 mm
Panel thickness	Minimum 35~maximum 220 mm
Lifting time of upper chain belt (to maximum height)	About 1 minute
The power required to move	About 2*7.5kw
Power requirement for screw connector device	About 7.5kw
Maximum speed	8m/min

Heating system for two-belt conveyor:

 

The PU adhesive spread between the upper and lower panels has excellent chemical reaction and has the ability to process at a constant temperature. This device is designed to maintain a constant temperature and provide heated air during such a process.
An electric heater is the ideal power for a heater that needs to supply heated air to the upper and lower conveyors separately.
There is also an automatic temperature control unit with an overheat protection device for a safe and quality panel
An insulated panel is required for enclosures to maintain the overall temperature.

Device	Air circulation system by electric heating or gas
Amount of circulating air	About 18,0003m/h
Type of temperature control	Automatic control
Cold/noise protection part	50mm glass panel
Heating part	By electric heater or gas
Ventilation system motor	15kw,A.C motor
Ventilation capacity	420m3/minute
Plate temperature	+400C~+700C
Maximum air circulation temperature	+1200C

 

 

The side guide device is installed on the left and right side, which prevents the PU component with strong uplift pressure from being pushed out of the panel by the side blocks.
When adjusting the width of the panel, it is necessary to fasten one of the two side guide devices, then the other side guide device. The two belts are transferred to the inner side of the conveyor.

Side welding part:

This device is designed to prevent the PU component from flowing through the stack from the side of the panel, and when the double-belt conveyor presses the PU foam and conveys the PU panel, the plastic blocks carry out this process.
An automatic temperature controller with an overheat protection device should also be included. The control device for the stack of plastic blocks is synchronized with the two-belt conveyor, so they move at the same speed.

Tape and saw cutting equipment for PU sandwich panels for roof:

 

The cutting speed must be synchronized with the panel transport. This cutting device can be controlled manually or with automatic control.
The gantry is installed at the rear, and the sawing unit is located on the right side of the production line. In this case, it can also be a band saw blade. The cross cutter is designed so that the saw band can be changed, and the production stops at this time, because the change only takes 1~2 minutes. The two band line transmits the sandwich panel at a preset speed.
An incremental encoder is installed on the turning shaft of the two-band conveyor. Impulses are transferred to the microprocessor control of the saw.
The cut-off saw waits for a start signal based on the length of the panel and then accelerates the X-axis to maximum speed.
After both speed and offset controls are synchronized, the clamps are pneumatically actuated to clamp the front and back of the panel, and then the bandsaw makes the first cut from left to right on the front.

The saw blade is turned at an angle of +90. The saw unit is in motion until the second blade part is also out of the cut. The cut panel lies on an unguided roller conveyor and is pushed by the panel coming from the saw’s work area.
The cutting saw returns to the starting position at maximum speed and rotates approximately 180 degrees. In this case, the cutting saw waits for the next start signal (depending on the length of the sandwich panel) and the procedure described above starts again.
Now the cutting direction changes from right to left. The control panel is equipped outside the housing and provides automatic cutting, the length and quantity of the panel are set by the workers.

Equipment cutting speed	10~50 m/minute
Cutting width	Maximum 1 300 mm
Cutting thickness	Maximum 200 mm
The diameter of the lower wheels	About 2 000 mm
The width of the cutting saw	16~25 mm
Cutting saw length	About 7,300 mm
Cutting accuracy	±2mm
Angle accuracy	±1 mm wide on a 1000 panel
Minimum cutting width	2 000 mm 6 m/minute
Panel thickness	35~200 mm
The maximum production speed of the equipment	10m/minute

Cutting device for roof panel:

 

 

Safety control panel and sensor                           Gas absorption system

 

Panel template for a cold room:

Panel Template for Walls— SS Type:

Pentane storage tank system:

Part names	Amount	Price
Device for automatic distribution of upper and lower rolls (max. 7 tons)	2	53 000$
3 sets of machines for top and bottom 1- Roll cutting equipment 2- Film equipment for top and bottom coating 3- 2 grooves for upper and lower roll.	2	53 000$
Upper roll forming device	1	46 000$
Bottom roll forming device Panel for cold rooms Roof panel(4 RIB/35-250) Boltless panel	3	173 000$
Heating system	1	30 000$
High pressure sprayer for polyurethane (PU) A and B components	1	80 000$
Double belt conveyor system (24m)	7	750 000$
Cross cutting device	1	106 000$
Electric control system	1	105 000$
Shipping costs	About 20 containers	200 000$
	Total	1 596 000$