Pu Sandwich Panel Roll Forming Machine

नवम्बर 22, 2023

Pu sandwich panel roll forming machines are equipment used to produce polyurethane (PU) sandwich panels in a continuous process. This comprehensive guide covers everything related to pu sandwich panel roll forming from working principles, types, parts, parameters, to operation, maintenance, and more.

Overview

PU sandwich panel refers to a composite panel structure made of a PU foam core sandwiched between and bonded to two metal facer sheets, typically steel or aluminum. The metal sheets provide strength and rigidity, while the PU foam core gives thermal insulation.

Pu sandwich panels are used extensively in industrial and cold storage buildings, warehouses, factories, commercial complexes etc. They offer superior insulation compared to other building materials along with structural strength. Their growing popularity is driving demand for efficient pu sandwich panel production lines.

Roll forming allows high speed, continuous production of sandwich panels in varying dimensions customized as per application requirements. Automated pu sandwich panel roll forming machines offer advantages like high output, consistency, and flexibility compared to manual production.

This guide provides a deep dive into all key aspects of pu sandwich panel roll forming machine technology.

H806f4582721345f4b3f8e8105abda5361 — Pu Sandwich Panel Roll Forming Machine 8

Pu Sandwich Panel Roll Forming Machine Types

Pu sandwich panel production lines are available in different configurations designed to handle widths from 1000mm to 1500mm and more. Main types of pu sandwich panel roll forming machines include:

Machine Type	Description
PU Sandwich Panel Roll Forming Line	Complete automated line for forming and filling PU foam in metal sheets
PU Sandwich Panel Roll Former	Only the roll forming section for bending sheets
Double Layer Roll Forming Machine	Forms the two facer sheets separately
PU Sandwich Panel Laminating Machine	Bonds facer sheets post production

The machine type impacts production process, output rate, customization flexibility, cost and other factors. PU sandwich panel roll forming lines allow end-to-end automated production in one line.

Working Principle

The working principle of pu sandwich panel roll forming machine involves:

Uncoiling & Feeding: Two strip metals (steel/aluminum coils) are loaded and passed through a de-coiler to uncoil and feed into the line.
रोल बनाना: The sheets go through a series of rolling stands arranged in tandem. Guided by rollers and gears, the sheets are pressed and bent progressively into designed profiles.
PU Foam Injection: Liquid PU chemicals are mixed, reacted and foamed to the desired density before continuously injecting between the formed profile sheets.
Cooling & Curing: The injected PU foam expands and cures into solid form as it moves down the line, bonded to the inner sheets.
Cutting: After cooling, the formed sandwich panel is cut to length by an automatic cutting machine.
Product Output: Continuous pu sandwich panels of fixed lengths exit the line automatically for collection.

Inline processes like punching, embossing, spraying, inkjet printing can be integrated as per application needs. The pu sandwich panel machine working process enables high speed, uniform production without need for molds. Automated lines ensure stability, precision and consistency difficult in manual operations.

Main Parts of Machine

Key parts in pu sandwich panel roll forming machine:

Part	Function
De-coiler and Sheet Guiding Mechanism	Smooth uncoiling and straight feeding of metal coil sheets into the production line preventing skewing
Roll Forming Stands	Rolling metal sheets progressively through series of stands into designed section profiles
PU Foam Machine	Blending, foaming and injecting PU chemicals to fill space between formed sheets
Curing Oven	Heating for foam expansion and curing bonded with facer sheets
Cutting Machine	Trimming formed sandwich panels at fixed lengths
Supporting Rollers	Guides movement of sheets during production without damage
नियंत्रण प्रणाली	Automates production parameters, detects issues, ensures smooth running

Technical Specifications

Pu sandwich panel roll forming machine specifications vary across models and customization requirements. Below table summarizes typical specification ranges:

Parameter	Range
Production Speed	20-40m/min
प्रभावी चौड़ाई	1000-1500mm or more
मोटाई	50-300mm
Length	Customized as needed
Temperature	Up to 230oC in oven
Voltages	230V/380V/415V as standard
शक्ति	15-100kw depending on model

Working Process Details

Roll formed pu sandwich panel production involves sequential working processes:

1. Material Feeding

Facer sheet coils of thickness 0.3-1.0mm fed into de-coiler
De-coiler ensures controlled uncoiling without sudden jerks
Sheet guiding mechanism straightens any warp or skew
Friction grip drive rollers engage and feed sheet through production line
Optional accumulating conveyor inserted for process flexibility

2. Sheet Forming

Sheet enters forming section with initial sheet guiding stands
Progresses through series of rolling stands (10-16 typically)
Each rolling stand bends sheet incrementally by few degrees
Final stand gives complete designed profile shape – trapezoidal, corrugated etc.
Eccentric shafts allow variation in profiling
Top and bottom sheets formed similarly before merging

3. PU Foam Filling

Liquid PU raw materials (polyol/isocyanate) stored in tanks
Precise high pressure pumps control flow rates
Chemicals mixed in impingement chamber before reaction
Reacted chemicals fed to foaming chamber
Foaming agent creates bubbles for required density
Foamed PU chemicals injected between formed sheets
Automated process ensures correct density and uniform filling

4. Curing and Cooling

Sandwich panel with injected foam enters temperature controlled oven
Heating causes foam expansion filling gap between sheets
As panel moves down cooling section, foam cures bonding with sheets
Controlled cooling cycle ensures proper curing without blisters
Optimized oven length reduces process time
Chilled water circulation used for fast cooling

5. Cutting and Output

Cured pu sandwich panel profiles cut by automated cutting machine
Length cutting tolerance within +/- 1mm
Continuous panels of fixed length exit system
Output sandwich panels stacked manually or using handling equipment
Inline process stations like punching, spraying possible

6. Control System

Centralized control system monitors and coordinates entire line
Touch screen allows input of production parameters
Temperature, speed, pressure, level sensors connected
Monitoring for faults, bottlenecks, safety issues
Optimized programming maximizes yield and system reliability

Customization Flexibility

Pu sandwich panel roll forming allows significant customization as per user needs:

Element	Customization Capability
Dimensions	– Width from 1000mm to 1500mm or more – Thickness up to 300mm – Length as needed
Surface Profile	– Various profiles like trapezoidal, corrugated etc. – Changeable rollers for new profiles – Embossed surfaces possible
Facer Sheets	– Steel, aluminum, galvanized steel – Thickness 0.3-1.0mm or more – Coatings, pre-painted sheets
Foam Density	– Density from 30-100 kg/m3 – Higher density = better insulation
Accessories Integration	– Embossing rollers – Punching equipment – Shearing, drilling, notching – Decoilers, recoilers – Conveyors, panel handling system
Automation Level	– Manual to fully automated options – Dependent on budgets, skill levels

Choosing Pu Sandwich Panel Roll Forming Machine Suppliers

With so many pu sandwich panel roll forming machine manufacturers to choose from in China and internationally, proper supplier selection is critical for getting good quality equipment. Below are key criteria for shortlisting suppliers:

Parameter	Checks
Machine Specifications	– Technical capacity – speed, width, thickness etc – Production output meets current and future demand – Check technical datasheet
Build Quality	– Robust fabrication of parts – Precision engineered – Finishing and coatings prevent rusting
Customization Offered	– Flexibility for sheet types, foam density, accessories etc – Integration capability with other equipment – Additions, modifications possible in future
Control Systems	– Level of automation and ease of operation – Monitoring and safety features – Diagnostics capability
Additional Services	– Technical advice during purchase – Shipping/transport coordination – Installation/commissioning support – Operator training services – Maintenance contracts
Cost	– Equipment cost fitting budgets – Total cost of ownership favorable – Cost advantage versus competitors
Company Credentials	– Experience and installations record – Client reviews and ratings – Local after-sales network – Financial stability

Approximate Price Range:

Basic PU sandwich panel roll forming machine: $18,000 – $38,000
Higher capacity PU sandwich panel production line with accessories: $65,000 – $120,000

Pricing varies based on specifications, production output targets, width of panels produced, level of automation, accessories integrated etc. Larger capacity fully automated lines are higher priced while lower budget options with manual features are also available.

Installation & Commissioning

Proper installation and testing of the pu sandwich panel roll forming machine is key before full scale production. Below are key guidelines:

Civil structure construction as needed – rails, trenches, floor flatness
Unloading machine from truck using forklifts/cranes safely
Assembling various sections according to drawing if required
Levelling stands, securing to ground as per manual
Electrical connections to control panel & drives per voltage specs
Pneumatic/hydraulic systems connections if present
Trial run checking for any loose parts, odd sounds
Inch by inch jogging initially, then slow and high speed test runs
Monitoring current consumption during startup
Checking emergency stops, safety mechanisms activation
Integrating other upstream/downstream equipment
Testing against sample production orders and inspection
Fine tuning until optimal performance achieved
Operator training during installation & commissioning
Initial supervised production before handover

Operation & Working

Pu sandwich panel roll forming machines can be operated in manual mode for low volume requirements. Automated lines offer minimal user intervention for high quantity production.

Typical operating steps:

Turn on main power to control panel
Set production speed, oven temperature through HMI
Feed coil sheets into de-coiler
Jog buttons to inch sheets into forming section
Select recipe on interface for desired panel specifications
Start button to activate production
Monitor line operation, inspect product quality
Stop equipment for coil changeovers
Schedule breaks as needed
Record production data
Clean equipment at end of shift

Do’s and Don’ts:

Do’s	Don’ts
– Follow manufacturer instructions	– Exceed machine capacity
– Use certified accessories only	– Modify safety mechanisms
– Maintain cleanliness	– Ignore warning signs
– Employ skilled workforce	– Compromise on maintenance