1.     Features

EMM081 series high pressure foaming machine is high-tech model combined with international technology and after market research for polyurethane industry application. Main parts are imported and the whole equipment has reliable performance and high safety standard.

1.1 Principle

It has three tanks (two for POLY. and one for ISO), three independent metering equipment to supply raw material (change by one automatic valve). It is equipped mixing head L-shape, with two mixing rooms, pouring one exit. This makes two different formula or different color’s material system to use in one or different molds

1.2 Advantages

Easy maintenance and operation

Eliminate limitation of use single prescription/color produces (like double hardness crafts products-cushion & seat pad). Main parts are imported and assembly in China so that with high cost-effective

EMM081-A40/20-C three components ，adopt 2 tanks for POLY.Y.、one tank for ISO.；Three metering units separately adopt variable-frequency governor control output flow of metering pump，use separate flow gauge to control materials’ open-loop/close-loop, change density by different mixing

2. Technical capacity

2.1 Model： EMM081-A40/20-C      

2.2 Foam type：self-tegument、soft foaming、half-hard foaming

2.3 Viscosity： (22℃)

        POLY.：~3000mPas

ISO：~1000mPas

2.4 Pouring output: 50-410g/sec (1:1), adjust range of mix ratio：5：1~1：1

2.5 Injection time：0.5~99.99 (accuracy reach 0.01s)

2.6 Program No.：

Hand-injection：20

Auto-injection：99

2.7 Measure unit：measure accuracy ≤0.5%，for metering components，Including bracket with vibration pads, variable frequency motor, magnetic couplings, axial piston pumps and valves, electronic pressure switches and so on.

2.8 Pressure limitation & system

Working pressure range is 6~22MPa，if beyond this range, machine stop injection automatically, alarm and indicate error “unnormal working pressure”

Component metering pump’s limit setting for safe pressure is 25MPa, double-protection, make sure safety of metering pump and system

Electrical protection: When the pressure reaches 25MPa, the device automatically shut down, alarm and displays the "pump over pressure" of the fault information

Mechanical protection: When the pressure reaches 25MPa, the valve overflow;

Metering pump lowest pre-pressure to protect POLY. 0.25MPa, ISO 0.15MPa。When the pre-pressure below the set value, the device automatically stop and alarm and display the "pre-pressure is too low," the fault information

2.9 Component Flow Control and Test Unit

   According to requirement of pump output flow and mixture ratio components, in the casting process to set relevant parameters of four groups.；Components flow through the frequency converter to adjust the motor speed to change the pump output flow, testing parameters of four components’ flow & mix ratio by using metering pumps with hand wheel adjustment and the respective flow meters, correct，in order to achieve automatic adjustment of components and control flow.

2.10 Component filter

Ensure that foreign bodies cannot enter the circulatory system

2.11 Hydraulic unit

Pump Flow（L/min）：23

Motor power（kw）：7.5

Motor speed（rpm）：1450

l    One oil tank capacity 80L，Mounting plate above the support；

l    Mounting plate to install drive motor, oil pump, buffer coupling, hydraulic manifold block, which is installed with the booster valve, safety valve, pressure gauge, pressure switch and manual load-release valve

l    One 10L High-pressure accumulator, to ensure rapid mixing head quick-change and absorbed oscillation；

l    One scavenge filter and one high pressure precision filter with sender

l    Ensure the hydraulic system will not work in a continuous temperature rise is too high

l    One set liquid level display shows the oil level inside the tank；

l    Three NG10 solenoid valve control L-shape mixing head, two mix rooms and main piston’s open and close

2.12 High pressure mixing head

Mixing head        1piece

Use high-pressure self-clean L-shaped from DUT Korea Technology and needle adjustable nozzle. For excellent mixing, materials mix collision from two different directions nozzles. Assembly of imported components, and more than 50 million times use has been proved by our customers

2.13 Mixing head flyarm

To support piping system and install mix head and procedures button box, 2000mm from rotatory center to end.

1.        A spring balance device to make mix head freely up and down；

2.        Horizontal rotation range 160°

2.14 High and low pressure cycle switch unit   2sets

    Control high and low pressure cycle switch separately, save power

2.15 POLY. Tank：                     2units

l        Effective capacity：250L；

l        Layered type: inner SU304 S/S；

l        Max. working pressure：0.6MPa；

l        One jacket water safe valve, set working pressure 0.30MPa；

l        One safe valve, set pressure 0.60MPa；

l        One relief valve with pressure gauge, set pressure 0.35 ~ 0.40MPa control max. pressure input compressed-air of tank

l        Automatic feed exit installed check valve

l        Manual shut-off valves (including bypass valve for sewage)

l        Liquid gauge：fully computer control with visible liquid level

l        Heat exchanger: calandna；

l        Thermo-sensor：PT100

l        Mechanical seal mixer, power 0.75KW, speed 46rpm; airtight enough to meet the foaming process requirements;

l        With insulation layer outside

2.16 ISO Tank                   1set

l        Effective capacity：250L；

l        Layered type: inner SU304 S/S；

l        Max. working pressure：0.06MPa

l        One jacket water safe valve, set working pressure 0.30MPa；

l        One safe valve, set pressure 0.60MPa；

l        One relief valve with pressure gauge, set pressure 0.35 ~ 0.40MPa control max. pressure input compressed-air of tank；

l        Automatic feed exit installed check valve；

l        Manual shut-off valves (including bypass valve for sewage)；

l        Liquid gauge：fully computer control with visible liquid level

l        Inside Heat exchanger: calandna；

l        Thermo-sensor：PT100

l        Mechanical seal mixer, power 0.75KW, speed 46rpm; airtight enough to meet the foaming process requirements；

l        With insulation layer outside

2.17 Temperature control unit

     Heating：3×3KW

     Cooling unit〖Cooling Capacity（Kcal/h）〗；18000；

 Three heating units can separately control the heating of three tanks，Cooling unit is equipped with 7.5HP compressor, pressure 0.25MPa, to control material temperature to reach excellent foaming effect (water cooler by the user)

2.18 Automatic lubrication of metering pumps

    Supply Automatic lubrication & clean for ISO metering pump adjusted hand wheel axis’ seal , Lubricating medium is DOP

2.19 Auto-feeding unit

POLY. Feeding pump（SET）           2

ISO Feeding pump（SET）           1

Flow：40L/min，add with liquid level control, can reach manual/auto feeding

2.20 Electric control system

Adopt PLC, input and output modular, 7.5 inch color touch-screen OP operator, have powerful function, easy-operation. Main electric parts are imported to ensure reliability

Equipment manual, automatic features, dry / wet injection selection function, auto circulation, equipment function and hand function and dry injection is mainly used for device debugging. Normal working conditions opt for wet injection automatic function. Automatic circulation device is mainly used to maintain normal production conditions after long time no use. Mixing ratio witching function used to change different mixing ratio in the same material system. Intermittent mode is mainly used when non-continuous production to reduce energy consumption and prolong the life of machinery. Level display control feature allows users to check material level through the screen and can be easily set the up &　down limited level and feeding level．Various functions Parameters operate in the Actions menu. Control system has strong fault-alarm function, display every test points’ failure information on operation screen, with sound and light alarm devices, automatically shut down when necessary Control cabinet includes；

l        Siemens PLC controller；

l        Siemens Inverter controller；

l        Omron Relay；

l        Schneider contactor；

l        Various switches, buttons；

l        External Communication Interface；

l        system software and control program

2.21 Pipe system

    Including Various components pipe and hydraulic pipe for transport components and hydraulic oil.

2.22 Machines with electric mobile system, guide by the user provide and install.

2.23 Power supply and equipment weight, area

Voltage： 3×380V/50HZ

Input power： ～47KW 

Weight：  ～3200KG

Cover area： 2800mmX2100mm(L×W)

3．Configuration and fitting parts