Full-auto PU Sandwich Panel Line With PLC Control System

Polyurethane (PU) sandwich panels as a high-performance building material, have been widely used in the field of modern architecture due to their excellent thermal insulation performance, lightweight and high strength, and fire resistance. To meet the growing market demand, a full-auto PU sandwich panel line equipped with a PLC (Programmable Logic Controller) control system has become an industry standard configuration, achieving a transition from traditional manual operation to intelligent manufacturing.

sandwich panel line

The fully automatic PU sandwich panel manufacturing line is a complex system that integrates mechanical, electrical, hydraulic, pneumatic, and computer technologies. It can continuously complete all processes of metal panel feeding, cleaning, gluing, foaming, curing, cutting, stacking, etc. The PLC control system, as the "brain" of the entire production line, ensures the coordinated operation of each process through precise program control, producing PU sandwich panel products with precise dimensions and stable quality.

The main components of the fully automatic PU sandwich panel production line

• Metal panel pretreatment system
  Pre treatment of metal panels is the first step in a fully automated production line, including:
  Dual station automatic feeding device: using a hydraulic lifting platform and a vacuum suction cup robotic arm to achieve automatic loading and positioning of the coil material
  Panel unwinding leveling unit: eliminates coil stress through a multi roll leveling machine to ensure panel flatness
  Surface cleaning system: using high-pressure ion air cleaning and electrostatic precipitator technology to improve the bonding strength between the panel and the core material
  Automatic glue coating device: precise control of glue amount (± 5g/㎡) and coating position, using infrared drying technology to accelerate glue curing

• PU foam molding system
  The core foaming area adopts a fully enclosed design, and the key components include:
  High pressure foaming machine: working pressure up to 150 bar, mixing accuracy ± 1%, equipped with temperature PID control (± 0.5 ℃)
  Double track laminating machine: segmented heating control (60-80 ℃), pressure adjustable range 0.1-0.3MPa
  Online density detector: Real time monitoring of core material density (usually 38-45kg/m ³), data automatically fed back to the control system
  Exhaust gas treatment device: activated carbon adsorption+RTO incineration system, VOCs removal rate>95%

• Post processing and packaging system
  High speed CNC cutting saw: cutting accuracy ± 0.5mm, maximum cutting speed 30m/min
  Automatic stacking robot: Six axis robotic arm, maximum load 200kg, positioning accuracy ± 0.1mm
  Intelligent packaging line: automatic film wrapping machine+corner protection device, packaging speed can reach 15 boards/minute
  Quality Inspection Station: Integrated infrared thermal imaging (detecting foam uniformity) and laser thickness measurement (accuracy ± 0.2mm)

The key controls implemented by the PLC system include:

• Synchronous motion control: By using electronic gears and cam curve algorithms, ensure the synchronization of upper and lower plate conveying speeds (deviation<0.1%)
  

• Foaming process control: temperature pressure flow multi parameter closed-loop control based on reaction kinetics model
  

• Adaptive cutting optimization: Automatically calculate the optimal cutting plan based on order requirements, with material utilization rate>98%
  

• Energy management system: Real time monitoring of water, electricity, and gas consumption, automatic alarm for abnormal usage

The full-auto PU sandwich panel line with a PLC control system, through highly integrated and intelligent design, not only significantly improves production efficiency and product consistency, but also reduces labor costs and energy consumption.