Machine Specification Machine Type: 1220A
Table of Contents 1220A Sandwich panel Machine Specification ----------------------------------- 3 Electrical Specification ----------------------------------------------------------------- 6
1220A SANDWICH PANEL MACHINE SPECIFICATION Automatic Adhesive Application System type 1220A for two-component polyurethane adhesive. The machine is designed as a spreader beam with a reciprocating spreader applying adhesive across a lay-up table. As the spreader is reciprocating over the lay-up table in the Y direction, the whole set-up is moving in the X-direction and thus creating a diamond pattern. Picture of diamond pattern. The application width can be adjusted step less from 500mm to 1400mm. The traverse Y-axis speed can be selected from the operator panel. The maximum traverse speed is 1,5m/sec. The bonding speed is adjusted in accordance with the Y-axis speed in order to obtain exact coverage of the adhesive layer. The bonding speed is depending on the actual oscillating time for the individual panel width; however the maximum X-axis speed is 10m/min. The control system is based on PLC-servo technology and the control of the machine is performed through an operator panel with graphic display. Configuration of essential machine parameters can be done from the HMI. The coat weight is controlled by a flow-controller measuring the adhesive flow with flow meters. By calculating the amount of adhesive per second and comparing with the set point value, the output to the adhesive pump is controlled and adjusted in order to achieve the desired coat weight. The datum line for the adhesive applicator is fixed. The skins are placed on the table and aligned in accordance herewith. The optimal application speed is determined from the spreader width, the desired speed and the acceptable waste at panel ends. The Y-axis speed can be increased within the limitation of the pump capacity and the maximum conveyor speed. The recommended spreader width is 500mm and the corresponding X-axis speed is 10m/min. Max adhesive capacity is approx. 5.0 kg/min. giving a maximum coat weight of up to 300g/m 2 with an X-axis speed of 10m/min. It is recommended to using an adhesive spreader of 200mm application width, but other spreaders can also be used.
The System consists of the following: A. Drive unit. Chassis in mild steel and powder coated. To allow variations in panel thickness there is automatic step less vertical adjustment of the spreader up to 200mm. Cable reels for electrical cables and air supply hose in X & Y direction. B. Adhesive system The base is supplied from fluid bags. The fluid bags are placed on a stand; where pneumatic driven transport pumps are mounted. It pumps base to the accumulator tank. The curing agent is supplied in drums. The drum is placed next to the fluid bag stand; the pneumatic driven pump is placed into the drum. It pumps curing agent to the curing agent accumulator tank. The buffer tanks are equipped with level sensors. During filling of the tanks, the level sensors automatically switch of filling pumps when maximum level is reached. The level sensors register and send an alarm, if the level is at minimum or lower. The main pumps are rotor pumps. The mixing ratio and flow are controlled by flow meters. Base and curing agent is pumped separately to the static mixer and spreader, in the right ratio and quantity. The spreader is equipped with an adhesive mixing unit with a static mixer. The static mixer mixes the two components to a homogeneous mass. The spreader ensures a uniform application of the adhesive. C. Cleaning / flushing system The cleaning system is automatic. It consists of a purge tray and a wash tray. When cleaning of the mixer and spreader are required, the spreader moves to the purge tray. There compressed air presses the main part of the mixed adhesive into the purge tray. After that the spreader moves to the wash tray and cleaner is circulated through the mixer and spreader. After a pre-set time the cleaner circulation stops and compressed air is blowing the rest of the cleaner out of the system. The spreader moves back over the purge tray and is ready for bonding. D. Pneumatic system. For transport pump drives, air motor, adhesive valves and fluid bag stretcher. Technical Data: Pump capacity : 5.0 Kg/min. Application speed : At a machine speed of 10 m/min (X-axis) and a application speed of 1,5m/sec (Y-axis) using a 200mm spreader, the application time of a panel with the dimensions of 1.215 x 6,524m is less than 60 sec. Application time calculation. 6,524m / 0,200m = 32,62 x 2 = 65,24 + 2,76 = 68cycle 68c x 1.215m = 82,62m / 1,5m/s = 55,08sec
Coat weight adjustable Coat weight tolerance : : From 100 to 300 g/m 2 ± 1% Average Air pressure required : Peak 800 litre/min. at 6 bar Mixing ratio : 100:25 Vol. Adjustable Spreader width : 200mm
ELECTRICAL SPECIFICATION Local control system based on a PLC system, with an operator panel to display the selected application layer, panel size and coat weight. Further a Recipe system and templates for machine configuration settings are available. The control system can handle panels with up to 10 layers, with following data (example) Panel size (mm) Layer X: 6524 Order no: 123456 No of layers: 2 Y: 1215 Recipe name: ABCDEFG Actual layer: 1 Coat weight Frame X1 Frame X2 Frame Y1 Frame Y2 (g/m²) (mm) (mm) (mm) (mm) 1 150 10 10 10 10 1 2 180 15 20 20 20 20 3 0 0 0 0 0 0 4 0 0 0 0 0 0 Thickness (mm) The coat weight is controlled by measuring the volumetric displacement of the base pump with a rotary pulse counter. By calculating the amount of base and comparing with the set point value, the rotation speed of the pumps is controlled and adjusted by a frequency converter in order to achieve the desired coat weight. The frame dimension (X1, X2, Y1 and Y2) is the distance from the panel outer edge to the adhesive application area in order to avoid adhesive to be pressed out of the panel when under pressure. The Recipe system is integrated in the operator panel, and gives possibility to store essential production data such as panel size, coat weight and number of layers as a unique recipe number. The recipe feature facilitates repetitive production of panels with the same physical properties. The recipes can be created from the operator panel. The Data logger is integrated in the operator panel and operates as a batch orientated data logger system that store information such as production date/time, Start time, Open time, panel size, coat weight (Set point/actual) and Batch number on a removable flash-ram (CF Card). The data will be stored in CSV format (Comma Separated Values). The flash-ram can be read from a normal pc with a standard flash card reader, and the data accessed through a spreadsheet or database programme such as MS Excel or MS Access. Manual panel targeting system and jog function are available by means of a joy-stick for the manual movement of the machine and another joy stick for the up and down movement of the spreader. The complete system is in conformity with the Machine Directive 89/392, EN 60204-1and EN 50 081-1. The Vetacs adhesive application machine type 1220AG has a control panel which contains PLC, Motor control unit and Operator interface for local operation (Preparation of mechanical calibration etc.). The machine needs a dedicated electrical group and supply connection, only this machine will use. The group should not have a conventional earth-leakage circuit breakers (e.l.c.bs) installed, since the machine is installed with EMC-filters and AC/DC-conversion on servo and inverter drives. These drives filters/drives leak current to ground and can therefore cancel the protective function of the relay OR trigger the relay. A Universal-current sensitive e.l.c.bs. (>=300mA) can be used. The electrical group should be fused with 16A fuse or similar.
Supply specification: - Power supply min.: 3x400V ±5%, 50 Hz + PE - Consumption max.: ~12 A - Recommended fuses: 16 A - Ikmax: 10 ka Hardware documentation: Will be supplied in paper version only (2 off) and CD-Rom, with the following documents: - Instrumentation diagram language: English - Operator instruction language: Local - Circuit diagram language: English - Parts lists/spare parts list language: English (Electrical and mechanical) - Lay-out/Location drawing language: English Vetacs supplies all internal cabling between our units, and all systems are tested prior to shipment.