Fully automatic horizontal annular foam cutting machine

1 Overview

1.1 Basic situation

Sponge (trade name is polyurethane flexible foam) is widely used in industrial production, infrastructure construction, and people's life. Because it is soft, flexible, easy to process, it is widely used. Insulation, heat insulation, sound absorption, shockproof, padding, etc., are more popular building materials, industrial finished packaging materials, furniture cushion materials and refrigeration equipment.

With the wide application of plastic products and the rapid growth of its output, plastic machinery has become an important technical equipment in the building materials, packaging, electrical and electronic, automotive, petrochemical, machinery and other industries. In recent years, China's demand for plastic machinery has grown at an average annual rate of about 6%, but the annual growth rate of domestic plastic machinery is around 30%, which is one of the fastest growing industries. In 2001, China's plastic machinery industry only The output value is 8.1 billion yuan. Among the 194 industries in the national machinery industry, the main economic indicators of the plastic machinery industry are in the forefront. At present, there are nearly 400 major plastic machinery manufacturing enterprises in China, most of which are distributed along the southeast coast. In recent years, the plastic machinery industry in Shantou has developed rapidly. It has formed a plastic industry chain system with complete product categories, mutual support and close structure, and possessing the advantages of high technology, technological innovation and system innovation. There are large and medium-sized enterprises in the region. Yu Jia, the scale of the enterprise group is constantly expanding, and a series of great changes such as technology development and innovation, management system, reform and innovation have attracted the attention of the same industry at home and abroad.

Ring-shaped polyurethane flexible foam cutting machine is one of the important equipments for plastic processing machinery. It belongs to plastic polyurethane sponge deep processing equipment. At present, domestic sponge cutting machine has flat cutting machine, angle cutting machine, pressing machine, profile machine and straight cutting machine. Cutting machines and other Models, but due to its short output, low degree of automation, narrow coverage, and so on, it is far from meeting the requirements of the domestic market. Most domestic companies only spend a lot of foreign exchange to introduce foreign equipment. The horizontal ring cutting machine is still in the blank in China. Because of its high efficiency, good performance and high accuracy, it has received great attention from the industry.

1.2 Current status in China

Although the plastics industry in China has achieved certain results after several years of rapid development, from the perspective of overall strength, it is still in the initial stage of development. At present, China's plastic machinery technology and technology level are not high, basically staying at a lower level. Grades are mainly characterized by low variety, low efficiency, high energy consumption, low control level and unstable performance. On the whole, the strength of China's plastic machinery is constantly increasing and the level is increasing. However, compared with foreign countries, its industrial structure is very unreasonable, and there are very few large-scale enterprises. Most of the domestic plastic machinery enterprises are small township enterprises or other enterprises. Industry transformation and concurrent enterprises, small-scale joint ventures and private enterprises, most of which lack the technical strength, lack of equipment and management, can only produce ordinary products. With the wide application of plastic products and the rapid growth of its output, it is imperative to research and develop plastic machinery with high technology content, high performance, high quality and high output.

2 The necessity of research and development

2.1 The significance of research and development

Sponge is a veritable multicellular organism composed of several different types of cells that are closely coordinated in a specific function. When the sponge is shredded and the parts are squeezed through enough mesh to break all the cell bonds. These isolated cells can still reassemble them into a complete organism. Due to the special properties of the sponge, it has brought many difficulties to the processing of the sponge. Sponge cutting machine must be based on the characteristics of its elastic body easy to compress and deform. At present, domestic cutting machines, whether it is a flat cutting machine, a corner cutting machine, a press machine, a profile machine or a straight cutting machine, rely on the concave toothed wheel to compress the sponge. Therefore, the formation error is large, and the processing size and the like are limited. China's plastic machinery started late, has been following the foreign market, forming a model to introduce imitation equipment, and then put into production. There are too few institutions specializing in plastic machinery research in China, especially in the joint development with enterprises. The level of equipment research and development is directly related to the variety of products and technical performance, so we must take the road of grouping and develop high-tech, high-performance, high-quality products. Plastic machinery must develop in the direction of automation, intelligence and integration. Advanced plastic machinery manufacturing industries in Europe, America, Japan, etc. have emerged a new trend of miniaturization and large-scale, flexible and flexible coexistence, automation and intelligence, networking and virtualization, personalization and scale management. Plastic machinery must keep up with this trend if it is to achieve its due status internationally.

The successful research of this project will break the situation that the plastic deep processing of cutting-edge equipment has been monopolized by foreign countries for many years and will promote the rapid development of China's plastic deep processing industry. After the project is industrialized, it will replace imports, saving a large amount of foreign exchange for the country, so that the level of China's plastic deep processing technology is close to the international level of the same industry.

2.2 The importance of research and development

At present, there are nearly 700 domestic manufacturers of polyurethane foam sponges in China. There are only three or four manufacturers of foam sponge ring cutters nationwide, and all of them are purchased by a large amount of foreign exchange, each of which is about 600,000. US dollars, companies without strength are not reliable to spend huge sums of money to introduce such expensive equipment. The circular cutting machine, which was researched by the Xi'an Mechanical Design Institute of Light Industry, is about one-third of the cost of imported equipment and can completely replace imported equipment. . The successful research of the ring cutting machine will also break the monopoly of this technology for many years abroad, and strive for a place in this industry, and promote the development of China's sponge deep processing industry, filling the domestic gap.

3 Technical feasibility

3.1 Research content

The fully automatic knife cutting and cutting machine is mainly used for effectively and economically cutting the foam of higher density (up to 200kg/m3) and foam of similar materials such as Basotect foam into thin products. On the viscous conveyor belt, when moving forward, the ring belt cutter cuts the blister into slices of the required thickness. The length of the cut blister product depends on the length of the conveyor belt, and the cut product is taken directly from the production line or The product is processed into a roll by a winding device. The main research content of this project is to fix the plastic polyurethane sponge elastomer on the ring bracket according to the principle of deformation, and then continuously cut out the required sheet products according to the production needs. In order to ensure that the block is not deflected, a special correcting device is designed to compensate the dimensional change in the longitudinal direction, which ensures that the conveying system can adapt to the change of the material length direction. The conveyor belt system is provided with a vertical guide roller, and the gear mechanism is adjusted through the console to ensure a proper width during the cutting process of the block and an accurate die size.

The ring sponge cutter consists of three parts, one is a 30-meter-long guide rail to ensure the effective working range of the machine. The cutting part is the key research content of this project. The cutting machine realizes the automatic control man-machine interface. All parts are designed with automatic and manual two parts. For example, the machine has two cutting parts, which are adjusted by screw drive. The required width of each block, and the position of each cutting point, the center of the track, and the gauge of the two cutters are displayed by the calculation equipment.

Each cutting part is equipped with 4 blades with a width of 3mm (300m in diameter). If the cutter is found to be pure for a period of time, there is also a ring-shaped friction driving wheel on the machine, which can grind the blade to ensure cutting. The knife is in good working condition.

The horizontal circular cutting machine mainly completes the continuous cutting of the large height of 1000mm and the width of 2400mm, and the cutting part is trimmed and cut. The oblique cutting part mainly completes the cutting of the inclined surface to ensure the flat joint of the material block.

3.2 Technological advancement

1 The machine adapts to the bulk of the foam material up to 1000mm, the width of the Zui is 2400mm, the production efficiency is 4-5 times of the domestic horizontal cutting machine, and the processing precision can reach 0.05mm.
2 At present, domestically produced sheet processing machinery and products require manual bonding, which affects the appearance of the surface, affects the production efficiency, and cannot guarantee the quality of the product. Compared with the foam material, the sponge processed product can be considered infinitely long. .
3 Through horizontal cutting, edge trimming, bevel cutting and other series of actions, the quality of the product can be guaranteed. The product can be continuously formed, automatically rolled, automatically counted, automatically discharged, and stable in performance.
4 The equipment fully realizes the automatic control, the man-machine interface directly talks, and the data setting and modification can be completed at any time through the automatic control system, which can be automatically and manually changed with the conversion.
5 With the knife, the wear will occur during the cutting process, so that the A point will retreat to different extents, the cutting edge will be purified by the cutting heat, the cutting effect will be reduced, the cutting surface precision and the surface quality will be affected, in order to keep the cutting edge sharp. The consistency of the origin return of the cutter during the cutting process (this is the guarantee of the quality of the cutting machine sheet). The machine has designed two special mechanisms: â—‹A. Automatic grinding mechanism; â—‹B. Automatic compensation mechanism. The two mechanisms allow the bubble cutter to remain in an ideal state from start to finish through the automatic control system, so that the cutting does not change with time and the amount of the foam.
6 Correction mechanism, during the transportation process, due to the comprehensive factors such as mechanical aspects, self-control, and the error of the foam itself, it is inevitable that there may be a deviation phenomenon. The correction mechanism can be found at any time and corrected at any time to ensure no downtime. In the case of production of qualified products.
7 The import price of imported circular horizontal cutting machine is 600,000 US dollars (400,000 main engines and 200,000 guiding frames). The market price of domestically produced ring cutting machines is about 1/3 of imported equipment.

Advantages of horizontal annular polyurethane flexible foam cutting machine:

1 AUTOCAD programming and control integration software, no need to generate processing code, only need to generate processing route, select processing workpiece can be processed, convenient, fast, and save the time to prepare a large number of processing code, greatly reducing your labor intensity;
2 Support automatic nesting and nesting work, and save a lot of graphics processing time and raw material cost;
3 Support digitizer input function;
4 The CNC machining software developed by the motion control card is simple and intuitive, and supports unattended;
5 User-friendly parameter setting window, you can set the processing speed, running processing speed, etc. Processing conditions and work efficiency have been greatly improved;
6 The mechanical structure is reasonable and compact, the imported electronic frequency converter is used to control the running motor, and the high-precision straight guide rail makes the whole system run balanced;
7 Sponge conveyor adopts imported high-quality non-slip conveyor transmission to ensure the transmission accuracy;
8 The processing status is easy to display and monitor in real time;
9 With automatic correction mechanism to ensure the quality of the product;
10 With automatic knife grinding mechanism, the knife can be ground at any time to ensure the sharpness of the knife;
â—‹11 The comprehensive safety system guarantees no accidents during operation. The system consists of four safety plexiglass doors with interlocking switches and broken wire protection brakes. Once entering the danger zone, the safety door cutter motor and stepper motor will stop running. There is also a limit switch that prevents malfunction of the equipment.

3.3 Technology Innovation

1. The ring cutter is equipped with two different modes, which can be used to complete the production requirements of different products: â—‹ A. Direct cutting mode (can be used for trimming or cutting the same thickness of foam); â—‹ B. Program operation mode ( Can be used for periodic data reduction to achieve a high production efficiency).
2. Adjust the cutting mechanism to make the bubble width from 800mm to 2400mm.
3. The gap between the knife and the knife box is only 0.01mm, and the outer diameter of the knife extends out of the box length ≤10mm. In order to ensure that the L value does not change during the operation, an automatic compensation mechanism is specially designed for the belt cutter. Automatic grinding mechanism. Under the action of the automatic compensation mechanism, the belt cutter is kept at the required value to ensure that the accuracy of the bulb after cutting does not change with time. Due to the special nature of the foam, the belt cutter should always be kept in a very sharp state, and under the action of the automatic grinding mechanism, the production requirements of the belt cutter are guaranteed.
4. There are two correction stations on the conveyor belt, which usually can solve the error that the bubble can cause in the transmission speed.
5. The device is designed with a sharpening dust collection system. The user can perform modular assembly to collect metal dust in the sharpening process. The collection of sharpening dust is advantageous for stable equipment performance and machine life.
6. The circular frame of the bubble ring cutting machine can automatically replenish the change of the size caused by cutting each layer of foam material according to the calculated automatic mode, and ensure that the cutting piece of the cutting material is cut by the cutting knife every week. The same tightness ensures the quality of the cut product. The automatic compensation of the moving mechanism of the rack is directly related to the density and performance of the foam.

4 Industrialization prospects

Because of its good cushioning performance and vibration absorption performance, foam plastic has become a buffer material widely used in modern times. Because of its light weight, easy processing, good protection performance, wide adaptability and low cost, foam plastics have developed rapidly in recent years. The relevant information introduces only PP foam. The annual consumption in the United States is 35,000 tons, in Europe is 17,000 tons, in Japan is 10,000 tons, and in other Asian countries, it is 0.7 million tons. It can be seen that foam consumption is amazing.

4.1 Market significance

After China joined the World Trade Organization (WTO), foreign machinery manufacturing industry accelerated the transfer to China. Some well-known plastic companies in the world, such as Germany, Japan and other countries, have successively "entered" China, and some have further set up technology centers. The entry of foreign plastic machinery manufacturers has brought development vitality to China's plastic machinery industry, and at the same time, it has filled Chinese plastic machinery manufacturing enterprises with opportunities and challenges. The successful research of this project will be a bright spot in China's plastic machinery industry. It not only improves the technical content of the industry, but also increases the conditions for competition with foreign companies. In addition, the project can replace imports, *, saving a lot of foreign exchange for the country, creating greater economic benefits for the enterprise.

4.2 Market capacity

In recent years, the average annual growth rate of demand for plastic machinery in China is about 6%. In 2001, the total output value of plastic machinery industry was 8.1 billion yuan. Among the 194 industries in the national machinery industry, the main economic indicators of the plastic machinery industry were in the forefront. . There are more than 700 polyurethane foam sponge production enterprises in China, but most of them are small enterprises. The technology is backward, the equipment is outdated, the output is small, the precision is low, and the product variety is monotonous. To change the backward situation of the domestic polyurethane sponge deep processing, it is necessary to And the equipment is catching up, and the current situation of China's sponge processing machinery enterprises started late, and has always followed the foreign market. There are too few institutions specializing in plastic machinery research in China, especially in joint development, and there is a big gap with foreign countries. The structure leads to low levels of plastic processing machinery, poor performance, and low production efficiency. High-level, high-performance products are in short supply, or even blank. Based on the above analysis, the market prospect of horizontal annular polyurethane flexible foam cutting machine will be very broad.

5 Benefits and Risk Forecast

5.1 Market prospects

Some developed countries in Europe and the United States have predicted that the material field in the 21st century is the world of plastics, while the plastics industry in China in the 21st century is a large market (including the plastic machinery industry). At present, the output value of China's plastic machinery industry is about 10 billion yuan/d. The market demand is about 20 billion yuan / d, there is still a lot of market space, experts predict that the next decade will be a period of rapid development of the domestic plastic machinery industry.

The production of polyurethane foam in China began in the 1950s. The polyurethane foam industry has been developed for more than 40 years. In 2001, the output of polyurethane foam in China was 550,000 tons. In 2003, the output reached 800,000 tons. The rapid development of plastics analysis, the market for plastic processing machinery must be very broad, so the development space of the horizontal circular cutting machine market I developed is huge.

5.2 Social benefits

1 The successful development of horizontal annular polyurethane flexible foam cutting machine will mark the synchronization of China's plastic foam deep processing technology with international advanced technology. At the same time, it is a bright spot in China's plastic foam deep processing industry, and will gradually become the market leader in the future.
2 Save a lot of foreign exchange, strongly support and promote the development of China's plastic deep processing industry, and improve China's competitiveness in the industry.
3 Improve the quality of foam plastic products and promote the development of China's plastics industry.
4 Economic benefits: Importing a cutting machine requires 600,000 US dollars (RMB 4.92 million), and the price of the domestically produced cutting machine is about 1.64 million yuan. If the cost of spare parts, spare parts and maintenance is added, it can be a society every year. Save a lot of money with the company.

6 Conclusion

With the deepening of people's understanding of polyurethane foam, the application of foam plastic products will be further broadened. Foam plastics bring huge economic benefits to the society with its unique advantages, which bring great convenience to people's lives. Although it is a big consumer of foam products, the current status of the foam industry is traditional ingredients, low starting point and lack of competitiveness in product structure. The world's plastic machinery is developing in the direction of unmanned and intelligent. The new products of advanced plastics manufacturing enterprises in industrialized countries and regions such as Europe, America and Japan are moving towards miniaturization, large-scale, flexible and flexible, and automation. The direction of intelligence is developing, so China's plastic machinery manufacturers should take the road of grouping in order to participate in market competition.

If Chinese plastic machinery wants to occupy the market and win a place in the international market, it must solve the following problems:

1 Increase technical imitation. There are too few institutions specializing in plastic machinery research in China. The weak research and design of plastic machinery products leads to low technical content of plastic machine products, expands the research institute of plastic machines, develops new technologies, and creates its own patented products to improve the presses. Value."
2 Utilize the results of international plastic presses. Utilizing the achievements of the existing plastic presses in the world, we will renovate China's plastic machinery without taking the road of repeated research and development, so that the grades of its products will be improved as soon as possible.
3 Adopt advanced technology equipment. Only advanced process equipment can improve efficiency, ensure quality and reduce costs.
After China's accession to the WTO, it has further improved the international market environment of China's plastic machinery industry. Therefore, we must seize the opportunity to make full use of relevant policies and give play to the advantages of low labor costs and social stability and sustained GDP growth in the local (domestic market). . Adopting effective measures has made a new development in plastic machinery.