Annual output of 5000-1000,000 square light composite
wall panel production line equipment?
1. Characteristics and uses
This production line by programmable control of electromechanical hydraulic integration of special hydraulic forming machine, randomly equipped with various specifications of the mold, the production of light composite wall panel. Based on the comprehensive requirements of light and high strength, thermal insulation, sound insulation and fire prevention, the current non-asbestos fiber cement board with light and high
strength and good stability is used as the external structural panel, and the styrene particle light concrete is used as the core material. Through systematic and in-depth research, the composite structure and splicing structure, the ratio of panel and core material and the preparation process parameters of the strip wall are further optimized, and the mechanical, thermal, sound insulation, fire protection and durability of the composite strip wall panel are improved. It is a new type of wall material with development prospect.
二、the composition and function of the equipment
1, equipment composition: by mixer, grouting machine, wall panel forming machine, stripping and turning table, hydraulic system, electrical system and other six parts.
1.1 Mixer is composed of cement silo, metering system, mixer, mixing building and other parts to measure and mix raw materials. (as shown below)
2.2 The grouting machine is composed of mobile car, storage and irrigation, hydraulic system and other parts to inject the stirred slurry into the mold. (as shown below)
2.3 The wall panel forming machine is composed of frame, fixed plate, intermediate plate, movable plate, hydraulic system and other parts, and the mold is clamped and fixed. (as shown below)
2.4 Demolishing and turning table is composed of moving frame, turning platform, hydraulic system, etc., to demolishing the molded wall panel. (as shown below)
2.5 The hydraulic system is composed of hydraulic station, pipeline and cylinder, which has reliable performance and accurate control. The hydraulic station is composed of oil tank, motor high pressure pump group, integrated valve block group, cooler and oil inlet and return filter. At the same time, the oil tank is equipped with temperature measurement and level meter and filter element alarm clogging device. When the filter element is blocked, the alarm device notifies to replace the filter element.
三、Machine layout, inspection, installation and preparation
The installation plane layout of the machine should be determined according to the production site and product process requirements. In principle, it is required that mixing, mobile grouting, wall panel molding, demoulding and maintenance turnover do not interfere with each other. It is recommended to arrange according to the installation foundation diagram.
Before installing the device, the installation and operation personnel should read the relevant documents carefully, make the installation plan, and make necessary preparations. Check the size of the foundation according to the foundation drawing. The levelness of each part of the plane should meet the requirements of the drawing. The foundation surface should be cast with cement.
Note: the position of the embedded parts and guide rails should be accurate and firm, and the foundation should meet the design requirements to achieve the allowed installation strength.
四、Production process flow
The different required ratios of raw materials are measured and then placed in the mixer for mixing. At the same time, the grouting machine is moved to the floor below the mixing to wait and store the materials. The wall panel molding machine is equipped with the mold, and the grouting machine moves to the side of the wall panel molding machine along the guide rail to grouting the wall panel molding machine, and the grouting completes the resting of the wall panel molding machine. The stripping and turning platform is moved to the other side of the molding machine, and the product is demudded. The turning platform is rotated 90 degrees and stands upright. The forklift is moved to the back of the turning platform to fork the wall panel.
1, the entire production process of the board
Clean the mold → spray release agent → Install the mold → pouring → shaping (appropriate heating) → constant temperature steaming → cooling → mold opening → mold exit → inspection → storage
2. Detailed explanation of flow chart
2.1 Cleaning mold: mainly clean the surface of cement blocks, foreign bodies, etc., so that the surface of the mold is clean without debris, the overall flatness is high, and pay attention to not leaving dead corners when cleaning.
2.2 Spray film removal agent: the amount of spray should be small and uniform, and too large film removal dose will affect the surface quality of the wall board, mainly pores. After drying, the film removal agent is easy to form dirt, and it should be regularly removed to ensure product quality.
2.3 Mold closing: after the core is installed, the mold must be closed in place, and the plate spacing must be measured one by one after the mold closing, which is a necessary means to ensure the thickness of the plate, and to ensure that the front mold is just stuck in the limit slot.
2.4 Mixing ingredients: strictly in accordance with the mixing process, the error of various materials shall not exceed 2%, the mixer should be watered and moistened before mixing, and the mixing consistency should be moderate.
2.5 Pouring: The pouring of the plate should be divided into uniform pouring, and special attention should be paid to vibration when pouring, and automatic vibration should also be set.
2.6 Shaping: After pouring, the top should be shaped. The closing must be flat and no individual protruding points are allowed. After shaping, the size error should be less than 2mm.
2.7 Constant temperature steaming: pay attention to the temperature control at 25℃/ hour, the high temperature control at 40-50℃ steaming covered with insulation, to prevent cracks, heating and constant temperature steaming for 150 minutes.
2.8 Cooling, mold opening, mold out: to open the mold after cooling, the temperature difference between the mold opening temperature and the ambient temperature of the plate should not be greater than 20℃, and the protection of the end of the wall board should be strengthened during the lifting process to prevent damage due to lifting, and measures should be taken for light defects and can be remedied to improve the quality of the product.
2.9 Inspection and warehousing: The wall panels after the mold should be vigilant, inspected and marked, and classified into the warehouse according to the quality level.
1.1 Before starting, check whether the strong parts are loose (especially the transmission motor bolts)
1.2 Check whether the electrical circuits and electrical signals are sensitive and reliable. (especially for measuring scale sensors)
1.3 Close the inlet valve of the air compressor and the gate valve of the pressure air pipeline, and then start the machine; At this time, pay attention to whether the sound of the machine running is normal, if found abnormal should immediately stop the check; If there is no abnormality, the air inlet valve of the air compressor should be slowly opened at this time to allow the machine to work normally.
(1) Listen to the machine sound is normal;
(2) the rise of the machine pressure gauge;
(3) Whether the oil observation hole is oiled;
(4) Whether the safety valve of the machine and the safety valve of the gas storage tank are working normally.
1.4 Be sure to close the discharge port of the metering and mixer before starting.
2. Grouting machine
2.1 Before starting, check whether the solid parts are loose. There are no obstacles in each running part and moving surface, and whether the limiting device and safety protection device are perfect.
2.2 Check whether the valve of the opening pump is opened within the scope of the hydraulic system. After opening the pump, check whether each automatic device reaches the specified value, whether the action meets the technical and complete detection requirements, and check whether the system pressure can be automatically stopped when it rises to the upper limit of the pressure gauge of the electric contact.
2.3 In the event of loss of pressure, prohibit all cylinder movements, and then shut down the liquid according to the liquid shutdown procedures to deal with related faults. In case of power failure, all valves should be closed.
2.4 Lubricate the moving parts.
2.5 Check whether the motor route is normal.
3. Wall panel forming machine
3.1 Before starting, check whether the solid parts are loose. There are no obstacles in each running part and moving surface, and whether the limiting device and safety protection device are perfect.
3.2 Check whether the valve of the opening pump is opened within the scope of the hydraulic system. After opening the pump, check whether each automatic device reaches the specified value, whether the action meets the technical and complete detection requirements, and check whether the system pressure can automatically stop when it rises to the upper limit of the pressure gauge of the electric contact.
3.3 Check whether the motor route is normal.
3.4 When encountering loss of pressure, prohibit all cylinder block action, and then shut down the liquid according to the liquid shutdown procedures to deal with related faults. In case of power failure, all valves should be closed.
4. Release and flip platform
4.1 Before starting, check whether the solid parts are loose. There are no obstacles in each running part and sliding surface, and whether the limiting device and safety protection device are perfect.
4.2 Check whether the valve of the opening pump is opened within the scope of the hydraulic system, check whether each automatic device reaches the specified value after opening the pump, whether the action meets the technical and complete detection requirements, and check whether the system pressure can be automatically stopped when it rises to the upper limit of the electric contact pressure gauge.
4.3 Lubricate the moving parts.
4.4 Check whether the motor route is normal.
4.5 Flipping Platform Do not stand behind the platform when flipping. When encountering loss of pressure, prohibit all cylinder movements, and then shut down the liquid according to the liquid shutdown procedures to deal with related faults. In case of power failure, all valves should be closed.
6, the production of raw materials reference mix
Reference data: The weight ratio of various materials of a single board is: cement 54.77%, foam particles 0.53%, water 44.62%, rubber powder 0.08%
七、Maintenance and inspection
1. Check and maintain the air compressor regularly
1.1 Frequently look at each indicator, such as pressure gauge, oil level, pressure controller.
1.2 Listen to the sound of the machine, such as air valve, piston, crankshaft, bearing and other parts.
1.3 Touch the parts frequently, detect the temperature changes and vibration of the air compressor, such as the temperature and vibration of the crankcase, intercooler, cylinder, exhaust pipe, early detection of abnormal temperature rise and the fastening of the parts, be sure to pay attention to safety.
1.4 The drain valve of the gas storage tank is opened once a day to remove oil and water.
1.5 Piston air compressor maintenance basic rules, operation and maintenance personnel must do a good job of the corresponding operation records, even if there is a failure, but also easy to judge and take measures.
2. Check and maintain the hydraulic system regularly
2.1 The hydraulic station should often check the use of hydraulic oil, it is important to ensure that the working environment of the hydraulic station is clean, and do not enter any stolen goods into the hydraulic system. If the oil is found to be deteriorating, replace it with new oil immediately. Usually, the oil in the hydraulic station should be filtered and replaced regularly. Generally, it is filtered once every six months. Special note: New oil is not really clean oil. Because the oil drum is rarely cleaned, there may also be stolen goods on the pump used when the oil is loaded. Even the new oil is contaminated. Therefore, the oil that is required to be injected into the tank must be filtered. If conditions permit, the user can add an oil filter.
2.2 After the adjustment of the hydraulic station, in the use or stop state, any personnel shall not arbitrarily twist the handle of the relevant valve parts to ensure the normal use of the hoist.
2.3 When wiring each solenoid directional valve, it should be connected strictly according to the specified voltage and current value, and operate several times through the corresponding switch on the operating platform to check the flexibility, correctness and reliability of the action.
2.4 The valves on the safety brake device should be regularly checked for the link of each screw.
2.5 Check the operation of the solenoid directional valve.
3. Regular lubrication of rotating bearings and friction parts is manual lubrication of grease, with ZG-2 or ZG-3 calcium-based grease.
4, often check the working condition of the whole machine is normal, find problems in time to solve.