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It is possible to reduce the number of forming machines, commissioning and maintenance personnel and the number of moulds and increase the output per unit of time with the same output. The fast energy-saving intelligent cavity insulation forming machine consists of frame structure, hydraulic system, servo and control system, feeding system, heating system, energy-saving mould cavity insulation system, high-performance vacuum-assisted cooling system, and unmanned quick-change system.
The frame is designed with high strength and high stability structure, welded with torsion resistant thick-walled hollow section steel and famous factory steel plate, with high overall strength and low deformation. High temperature annealing failure heat treatment is used; the overall structure is sandblasted to remove rust, and the surface is sprayed with zinc and then sprayed with plastic/paint process to form an orange pattern protective layer, making it have high anti-corrosion performance and anti-corrosion cycle.
The feeding system is configured in the form of vertical barrels, each barrel is equipped with 16 discharge ports and the interface size is DN25. photoelectric sensors are used to control the height of the material level and the storage of material in the barrels, and the pressurisation pressure is adjusted proportionally using the barrel pressure figures to control the feeding rate within 2-3 S/ cycle. Compressed air is used to automatically shield the quick coupling lance from the air, and the quick clutching lance hose coupling is used to achieve a quick connection, while ensuring a ±3% weight tolerance of the product.
In order to ensure stable production and normal heating system of the equipment, the heating system adopts pressure proportional sensor for pressure decompression to ensure that the steam pressure into the mould is stable at 0.15~0.25MPA and the flow rate is stable; its mould cavity pressure control adopts digital proportional control energy distribution system, which is composed of German Gemi steam angle valve and Italian Cosys digital proportional valve, with the cooperation of Siemens control system, it can With the support of low-pressure moulding process, the steam consumption can be greatly reduced and costs can be saved.
The energy saving mould cavity insulation system is an innovative design for our company in the field of energy saving. Due to the low utilisation of heat energy in EPS moulding, most of the heat is dissipated into the air due to the heat transfer effect. By optimising the mould cavity structure, the internal insulation system is made of a new polymer insulation material inside the standard mould cavity, thus reducing the heat loss during the heating process and the waste of repeated heat due to the rapid drop of the mould cavity temperature during the demoulding process, thus achieving its energy saving purpose. The use of insulation systems can save approximately 10-30% of energy.
High performance vacuum assisted cooling system, which consists of cooling water piping, separate large condenser and control system. The high performance cooling effect is achieved by water-air-liquid conversion under high vacuum, ensuring rapid cooling and high temperature demoulding of the product. Thanks to the large condenser, the working environment of the vacuum system is greatly improved, ensuring the pressure and pumping capacity of the vacuum pump, bringing the result that the mould water cooling time can be greatly reduced, resulting in models with very low water content, reduced drying time and lower energy consumption.
