How To Operate The PU Sandwich Panel Machine

Polyurethane sandwich panel machine is a professional equipment used for producing insulation sandwich panels for construction, and its operation requires strict process flow and safety regulations.

sandwich panel machine

The pu sandwich panel line mainly consists of the following core components:

• Uncoiler: used for unfolding and tension control of metal coils, with manual centering function to prevent coil deviation.

• Preheating roller conveyor: Preheating metal coils, aluminum foil and other substrates to improve foaming and bonding effects.

• Foam machine:
  Divided into BLC (R) type low-pressure continuous foaming machine or PH (R/F) high-pressure foaming machine
  Equipped with resin (A) tank and curing agent (B) tank
  Control flow through variable frequency motor driven metering pump

• Mobile fabric machine: achieve uniform arrangement of core materials, with adjustable height.

• Double track machine:
  The length is usually 24 meters, and the heating temperature is 60 ℃
  Complete online foaming and shaping of polyurethane
  Using a precision hydraulic lifting system to adjust the thickness of the sheet metal

• Compression molding machine: for various shape processing of metal coils.

• Fixed length sawing machine: Saw the formed sheet according to the set size.

Preparation before production

• Raw material inspection:
  Ensure that black and white materials are stored in an environment of 15-25 ℃
  Check that the raw materials are free of sediment and impurities
  Confirm that the raw material ratio meets the process requirements

• Equipment preheating:
  Start the foam machine circulation system
  Set the temperature of the material tube at 35-45 ℃
  The mold head temperature is set at 40-50 ℃
  Preheat the dual track machine to 60 ℃

• Mold preparation:
  Clean the mold cavity to ensure no dust or oil stains
  Check if the positioning of the upper and lower plates is accurate
  Confirm that the gap between the mold cavity is uniform and consistent

Production operation steps

• Loading:
  Load the metal coil into the unwinding machine
  Adjust the tension control device to ensure smooth material transportation

• Substrate processing:
  Metal coil is formed by a press molding machine
  Preheat the roller conveyor to a suitable temperature

• Foam preparation:
  Set parameters in the control panel:
  Injection pressure: 100-150bar
  Injection time: calculated based on the thickness of the board
  Raw material ratio: set according to process requirements
  Start the metering pump circulation system

• Mixed casting:
  Align the mixing head of the foaming machine with the injection hole
  Start high-pressure injection
  Raw materials are subjected to high-pressure atomization, collision, and mixing within the mixing head
  The mixture is evenly poured onto the lower surface material

• Laminated molding:
  The upper layer material is fed into the double track machine together with the casting material
  Foam and solidify between the upper and lower chain plates
  Accelerating solidification through a hot air circulation system

• Shaped cutting:
  The formed sheet is cooled by an unpowered roller conveyor
  The fixed length sawing machine automatically cuts according to the set length
  Side trimming machine for processing board edges

• Finished product processing:
  Automatic palletizing or manual stacking
  The finished product needs to be left for at least 24 hours to complete maturation

Safety precautions

• Personal protection:
  Operators are required to wear protective clothing, goggles, and gas masks
  Avoid direct skin contact with chemical materials

• Equipment safety:
  Regularly inspect high-pressure pipelines and joints
  Open flames are strictly prohibited near the foaming machine
  The emergency stop button must remain available

• Process safety:
  Strictly control the temperature and proportion of raw materials
  Prohibit arbitrary changes to process parameters
  Immediately stop the machine for inspection upon discovering any abnormalities

• Electrical safety:
  The total power of the equipment is about 120-240KW
  Ensure good grounding
  Regularly inspect cable insulation

Common problem handling

• Insufficient filling:
  Check if the temperature of the raw materials is too low
  Confirm if the injection volume is sufficient
  Check the mixing effect and exhaust condition

• Cracking of foam:
  Detecting the moisture content of raw materials
  Check the catalyst ratio
  Adjust the mold temperature

• Holes/voids:
  Improve exhaust design
  Adjust injection speed
  Ensure uniform temperature of the mold

• Difficulty in demolding:
  Check if the release agent is sprayed evenly
  Appropriately increase the mold temperature
  Extend curing time

Maintenance and upkeep

• Daily maintenance:
  Clean the surface of the equipment
  Check all lubrication points
  Clean the residue of the mixing head

• Regular maintenance:
  Monthly inspection of hydraulic system
  Calibrate the measurement system quarterly
  Annual comprehensive maintenance of the electrical system

• Key component maintenance:
  Foam machine: regularly replace seals
  Double track machine: check the wear of the chain plate
  Cutting machine: keep the saw blade sharp

By following the above operating procedures, the safe and efficient operation of the polyurethane sandwich panel production line can be ensured, producing high-quality sandwich panel products with high flatness and uniform core material density. Different types of equipment may have differences in details. It is recommended to read the equipment manual carefully and receive professional training before operation.