lightweight composite wallboard production line features and uses

[Hongfa Heavy Industry] The light composite wallboard production line is composed of a programmable control electromechanical hydraulic integration special hydraulic forming machine, randomly equipped with various specifications of the mold, the production of light composite wallboard. Based on the comprehensive requirements of light weight and high strength, thermal insulation, sound insulation and fire prevention, the non-asbestos fiber cement board with light weight and high strength and good stability is used as the external structural panel, and the new energy-saving and environment-friendly solid light composite wall board with styrene particle light concrete as the core material. Through systematic and in-depth research, the composite structure and splicing structure of the strip wall, the ratio of panel and core material and the preparation process parameters are further optimized to improve the mechanical, thermal, sound insulation, fire protection and durability of the composite strip wall panel. It is a new wall material with development prospects.

lightweight wallboard production line equipment

1. Equipment composition: it is composed of six parts: mixer, grouting machine, wallboard forming machine, demoulding and turning table, hydraulic system and electrical system.

1.1 mixer is composed of cement silo, metering system, mixer, mixing building and other parts, measuring and mixing raw materials. (as shown below)

2.2 grouting machine is composed of mobile trolley, storage material filling, hydraulic system and other parts, and the stirred slurry is injected into the mold. (as shown below)

2.3wall panel forming machineconsists of a frame, a fixed plate, an intermediate plate, a movable plate, a hydraulic system and other parts to clamp and fix the mold. (as shown below)

2.4 demoulding and turning table is composed of mobile frame, turning platform, hydraulic system and other parts, and demoulding the formed wallboard. (as shown below)

2.5 is composed of hydraulic station, pipeline and oil cylinder, which has reliable performance and accurate control. The hydraulic station consists of an oil tank, a motor high-pressure pump group, an integrated valve block group, a cooler and an oil inlet and return filter. At the same time, the oil tank is equipped with a temperature measurement and level gauge and a filter element alarm and blocking device. When the filter element is blocked, the alarm device notifies the replacement of the filter element.

Machine layout, inspection, installation and preparation

The installation plane layout of this machine shall be determined according to the production site and product process requirements. In principle, stirring, moving grouting, wall panel forming, demoulding and turning, and maintenance turnover shall not interfere with each other. It is recommended to arrange according to the installation foundation drawing.

equipment, the installation and operation personnel should carefully read the relevant information, make the installation plan and necessary preparations. Check the foundation size according to the foundation drawing, the levelness of each part of the plane shall meet the requirements of the drawing, and the foundation surface shall be poured with cement.

Note: The positions of embedded parts and guide rails should be accurate and firm, and the foundation should meet the design requirements to achieve the allowable installation strength.

production process

, the different required ratios of raw materials are measured and then placed in a mixer for mixing. At the same time, the grouting machine is moved to the bottom of the mixing building to wait and store the materials. The wallboard forming machine is equipped with a mold, and the grouting machine moves along the guide rail to the side of the wallboard forming machine to conduct grouting to the wallboard forming machine, and the grouting completes the resting of the wallboard forming machine. The demoulding and turning platform moves to the other side of the molding machine to demoulding the product. The turning platform rotates 90 degrees to stand up. The forklift moves behind the turning platform to fork the wallboard away, thus completing a working cycle.

1. The whole production process of plate making

Clean up the mold & rarr; Spray mold release agent & rarr; Install the mold & rarr; Pouring & rarr; Shaping (properly heated) & rarr; Steaming at constant temperature & rarr; Cooling & rarr; Mold opening & rarr; Mold exit & rarr; Inspection & rarr; Storage

2. Detailed explanation of flow chart

2.1 cleaning the mold: mainly clean the cement blocks, foreign objects, etc. on the surface, so that the surface of the mold is clean and free of debris, and the overall flatness is high. Pay attention to no dead corners when cleaning.

2.2 spray remover: spray when the amount is small and uniform, the amount of remover is too large to affect the surface quality of the wallboard, mainly pores, remover is easy to form dirt after drying, to be removed regularly to ensure product quality.

2.3 mold clamping: mold clamping shall be carried out after the plate core is installed, and the mold clamping shall be in place. After mold clamping, the plate spacing shall be measured one by one. This is a necessary means to ensure the plate thickness, and the front mold shall be just stuck in the limiting groove.

2.4 ingredients mixing: strictly according to the proportioning process, the error of various materials shall not exceed 2%, the mixer shall be watered and moistened before mixing, and the mixing consistency shall be moderate.

2.5 pouring: the pouring of the board should be evenly poured in stages, and special attention should be paid to vibrating during pouring, and the automatic vibrating should also be set to vibrate in stages.

2.6 reshaping: after pouring, the upper edge shall be reshaped, and the closing shall be smooth and no individual protruding points are allowed. after reshaping, the size error shall be less than 2mm.

2.7: when heating up, pay attention to controlling the temperature at 25 ℃/hour, and when controlling the high temperature at 40-50 ℃, cover the heat preservation quilt to prevent cracks, and heat up and steaming at constant temperature for 150 minutes.

2.8 cooling, mold opening and mold outlet: the mold opening temperature of the plate shall not be greater than 20 ℃ after cooling. During the hoisting process, the protection of the end of the wallboard shall be strengthened to prevent the end from being damaged due to hoisting. Measures shall be taken for light defects and can be remedied to improve the quality grade of the product.

2.9 inspection and warehousing: for the wallboard after the formwork is released, it shall be inspected and marked, and shall be put into storage according to the quality grade.

product commissioning

1. Mixer

1.1, and check whether the fasteners are loose (especially the bolts of the drive motor).

1.2 check the electrical circuits and electrical signals are sensitive and reliable. (especially for gauging sensors)

1.3 close the air inlet valve of the air compressor and the gate valve of the air pressure pipe, and then start the machine; At this time, pay attention to whether the sound of the machine is normal. If any abnormality is found, stop the machine immediately. If there is no abnormality, slowly open the air inlet valve of the air compressor to let the machine work normally. Attention should be paid at this time:

(1) whether it is normal to listen to the sound of the machine;

(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 is turned on.

2. Grouting machine

2.1 and check whether the fasteners are loose. Whether there are obstacles on each running part and moving surface, and whether the limit device and safety protection device are perfect.

2.2 check whether the pump opening valve is open within the scope of the hydraulic system. After the pump is started, 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 electric contact pressure gauge.

2.3 encounters pressure loss, prohibit all cylinder movements, and then close the liquid according to the liquid closing procedure to deal with related faults. In case of power failure, all valves shall be closed.

2.4.

2.5 check whether the motor route is normal.

3, wallboard forming machine

3.1 and check whether the fasteners are loose. Whether there are obstacles on each running part and moving surface, and whether the limit device and safety protection device are perfect.

3.2 check whether the pump opening valve is open within the scope of the hydraulic system. After starting 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 electric contact pressure gauge.

3.3 check whether the motor route is normal.

3.4 encounters pressure loss, prohibit all cylinder body actions, and then close the liquid according to the liquid closing procedures to deal with related faults. In case of power failure, all valves shall be closed.

4. Demoulding and turnover platform

4.1 and check whether the fasteners are loose. Whether there are obstacles on each running part and sliding surface, and whether the limiting device and safety protection device are perfect.

4.2 check whether the pump-opening valve is open within the scope of the hydraulic system. After the pump is started, 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 electric contact pressure gauge.

4.3 to lubricate the rotating walking parts.

4.4 check whether the motor route is normal.

4.5 flip platform. In case of pressure loss, prohibit all cylinder movements, and then close the liquid according to the liquid closing procedure to deal with related faults. In case of power failure, all valves shall be closed.

production

reference data: the weight ratio of various materials of a single board is: cement 54.77% , foamed particles 0.53%, water 44.62%, rubber powder 0.08%.

Maintenance and Inspection

1. Regular inspection and maintenance of air compressor

1.1 check the indicating instruments, such as pressure gauge, oil level and pressure controller.
1.2 frequently listen to the sound of the machine, such as air valves, pistons, crankshafts, bearings and other parts.

1.3 frequently touch various parts, detect the temperature changes and vibration of the air compressor, such as the temperature and vibration of the crankcase, intercooler, cylinder, and exhaust pipe, and detect abnormal temperature rises and tightening of mechanical parts as soon as possible., Be sure to pay attention to safety.
1.4 the drain valve of the gas storage tank is opened once a day to drain the oil and water.

1.5 the basic procedures for the maintenance of piston air compressor, operation and maintenance personnel must make the corresponding operation records, even if there is a failure, it is easy to judge and take measures.

2, regular inspection and maintenance of the hydraulic system

2.1 hydraulic station should always check the use of hydraulic oil, it is important to ensure that the working environment of the hydraulic station clean, do not enter any stolen goods into the hydraulic system. If the oil is found to be deteriorated, the new oil should be replaced immediately. Usually, the oil of the hydraulic station should be filtered and replaced regularly. It is usually filtered once every six months. Special note: New oil is not really clean oil. Because the oil drum used to tie the oil is rarely cleaned, there may also be stolen goods on the oil extractor used to load the oil. Even the new oil is contaminated. Therefore, it is required that the oil injected into the oil tank must be filtered. If conditions permit, the user can add an oil filter.

After the adjustment of the 2.2 hydraulic station, in the use or stop state, any personnel are not allowed to twist the handle of the relevant valve parts to ensure the normal use of the hoist.

2.3 the electromagnetic directional valve wiring, should be strictly in accordance with the provisions of the voltage and current value of the matching, and through the corresponding switch on the operating table repeated operation several times, check the flexibility of action, correctness, reliability.

the valves on the 2.4 safety brake, the linkage of each screw should be checked regularly.

2.5 check the action of the solenoid directional valve.

3. Regularly lubricate the rotating bearings and friction parts with grease. Use ZG-2 or ZG-3 calcium-based grease.

4. Check frequently whether the working condition of the whole machine is normal, and solve any problems found in time.