1. Overview

EMM084 series of low pressure foaming machine is my factory to track the international high-end technology products, combined with the application of polyurethane industry innovation to develop high-tech products. Main relevant parts imported from abroad, the technical performance and reliability to achieve the advanced level of similar products abroad over the same period.

EMM084-2 three-component low pressure foaming machine, using 2 polyether polyol feed tank (POLY.), An ISO components measurement unit change volumetric gear metering pump output flow separately through frequency conversion deceleration motor speed. This equipment features in it has two polyols system and a polyisocyanates system and these two systems share a mixing head,the control system choose one of two polyols system to mix with polyisocyanates system . Through the change of raw material system or mixing index to change products foaming density and realize two colors, multidimensional or different materials system of foam products production lines. Devoted to the production of polyurethane molding.

2. Equipment and explain the main technical parameters

2.1 Device Model: EMM084-2

2.2 For foam types: soft foam, semi-rigid foam,self-skinning foam,rigid foam

2.3 For the viscosity: (22 ℃)

Polyether polyol: ~ 2000mPas

Polyisocyanate: ~ 1000mPas

2.4 Pouring output: 50-250g/sec (1:1),adjust the mixing ratio range: 5:1 to 1:1

2.5 Injection time: 0.01 ~ 9.99 (accurate to 0.01s)

2.6 The number of injection procedures:

 Manual injection: 99

Automatic injection: 99

2.7 Measurement Unit: For the measurement of components, measurement accuracy of ≤ 0.5%.

Composed by brackets, mechanical stepless speed regulation gear motor, couplings, high-precision volumetric gear metering pump and valve, pressure sensor, rotational speed sensor. Speed gear motor and metering pump are connected through the connecting shaft..

2.8 pressure limit and control system

Polyether polio and isocyanine groups were working pressure control in 0 ~ 4MPa, if the working pressure exceeds set pressure range, equipment and alarm automatically stops the note material.

2.9 Flow measurement and control system

 According to the pump output flow and process requirements mixture components and related parameters; group were traffic speed control motor speed by changing the pump output flow, remove the mixing head, with each injection valve so that A, B flow to each container of raw materials . Flow of each component separately and mixing parameters to detect than the parameters, correction to achieve the component flow regulation and control.

2.10 component filter

Two components with a comb filter, respectively, set the filter were installed in the metering pump and the material between the cans. Filtration accuracy of 350 μ m. through regular cleaning and by opening the valve below the sewage discharge.

2.11 mixing head

Materials to the mixing chamber through the spit valve injection precision, synchronization, no plug.

• Mixing head by the motor driving mechanical mixing;
• ； Between the motor and the stirring shaft through the belt transmission speed can be adjusted by adjusting the motor to facilitate the completion of the push-pull;
• In the test state, the motor and the stirring shaft does not rotate;
• Stir in advance and lag time from the electrical control, optional automatic and manual mixing modes;
• Opening and closing the valve from the cylinder control;
• Mixing head, mixed with a cone of the nozzle chamber, as well as to facilitate removal;
• ； Adjustable needle valve regulating the pressure in each group were balanced;
• Head control box can be foam, stop foaming, cleaning, air blasting, emergency stop, etc. buttons.

2.12 Rack and mixed the first cantilever system

Frame

Materials for the installation of tanks, metering system, mixing the first cantilever.

Mixed first cantilever piping system and installation to support the mixing head and procedures for the button box, from the center of rotation to the end of arm length 2200mm.

• A spring balance device to mix head can move up and down;
• Horizontal rotation range of 160 °;

2.13 mixed head cleaning system

Mixing head cleaning system, including 20L stainless steel barrel, with visual level gauge, safety valve, pressure devices and related instrumentation component.

• Air blast by a solenoid valve control, liquid wash;
• Compressed air used to blow out the residue and the mixture dried first solvent;
• Air blast and liquid washing time by the PLC control, setting through the operation panel;
•  Air blast, wash liquid can also be manually controlled by the process control;
• Way through the manual vent;
• Air blast, liquid wash pipe routing high-pressure pipe solvent composition;
• Set flush pressure 0.15Mpa;
• Stirring shaft rotation when washing the same period;
• Can external signs affixed MC;

2.14 Polyether polyol feed tank: 2

• Effective capacity: 120 liters;
• Sandwich-type, inner SUS304 stainless steel;
• Maximum working pressure: 0.6MPa;
• A heating jacket safety valve set pressure is 0.25MPa;
• A relief valve with pressure gauge, set the pressure of 0.05 ~ 0.45MPa, control feed intake pressure compressed air tank top;
• Output through the three links, two manual valves installed (which bypass valve for sewage);
• Level Gauge: with a visual level, to detect the minimum, maximum, and the appropriate level
• Equipped with a temperature probe: CU50; The bottom of charging bucket filled with the vacuum filling makes of blunt material valve
• Bucket equipped with stirrer, power 0.55KW, speed 51rpm. With mechanical seal, foam tightness sufficient to meet the technological requirements;
• The maximum allowable operating temperature of 100 ℃;
• ；Take-insulation layer;
• Can external signs affixed POLY.

2.15 Polyisocyanates tank material: 1

• Effective capacity:120 liters;
• Sandwich-type, inner SUS304 stainless steel;
• Maximum working pressure: 0.6MPa;
• A heating jacket safety valve set pressure is 0.25MPa;
• A relief valve with pressure gauge, set the pressure of 0.05 ~ 0.45MPa, control feed intake pressure compressed air tank top;
• Output through the three links, two manual valves installed (which bypass valve for sewage);
• Level Gauge: with a visual level, to detect the minimum, maximum, and the appropriate level
• Equipped with a temperature probe: CU50;
• Bucket equipped with stirrer, power 0.55KW, speed 51rpm. With mechanical seal,foam tightness sufficient to meet the technological requirements;
• Take out insulating layer;
• ISO logo affixed external tank.

2.16 Temperature Control Unit:

Heating: 3× 2KW, sandwich-type thermostat body two heating units were the two materials can control the heating.

Through the cooling unit, to control foaming temperature process required raw materials (excluding chiller).

2.17 Electrical Control System

Electrical control system controlled by LG PLC, equipped with controllable silicon solid-state button, OP7 operation panel , convenient operation. Main electric elements equipped with import brand, to ensure the safety and reliability of the control system

Operation panel display each of the following parameters:

• ；Note material station 99;
• Note feeding time 0.01-99.99; through the SPS button to regulate the temperature of the components and the pressure of the components;
• The pressure group were too small or too large, such as metering pump overpressure fault information; set three kinds of different proportion directly through man-machine interface,it can change to A, B material ratio simultaneous tracking, note material time, qi chong, liquid washing, stirring advance delay time etc;
• Choosing A1 / A2 material barrels of raw material system switching in mixing head controller

Control system is highly fault alarm function, with sound and light alarm devices, equipment, auto stop when necessary.

Control cabinet include:

• Programming controller
• Various relays;
• Various contactor;
• Transducer
• ；Various types of switches, buttons;
• sofeware and control procedures

2.18 piping and air handling system

Piping components, including hoses used to transport components of raw materials, feed tube installed in the mixing head, feed tube with the material back to tank connections;

Liquid tube used to deliver compressed air and cleaning fluid, high pressure pipe from the solvent composition;

Equipment for compressed air through the oil-water separator, respectively, lubricator for processing.

2.19 Supply and equipment weight, area:

  Input voltage: 3 × 380V/50HZ (AC)

Control voltage: 220V/24V

Relay Voltage: 24V

（ Input power: 12KWAbout)  

Weight: 1800NG