Laminated Glass Production Line
I. Laminated Glass processing Line’s constitution
1. Washing and drying machine
2. Lamination positioning and transmission machine
3. Movable scissor cup suction hanger
4. PVB film unwinding machine
5. Transition conveying machine
6. Pre-press section (Normal quartz heater Pre-pressing Structure with Duplex Chain)
7. Autoclave.
II. Laminated Glass processing Line’s technical feature.
1. The whole line is centralized in Control Cabinet located in Laminating Room, adopting PLC System, Touch Screen Model, and controlling of running speed of all sections.
2. Washing and drying machine is the core equipment of the whole line.The upper Rubber rollers, brush rollers and air-knives etc. can be adjusted on the panel and digital displayed according to the thickness of glass to be processed. The upper section of the machines can be elevated by 400mm for convenience of cleaning and repairing. The Brush Rollers are driven by motors with upper and lower separately. Allocation of one soft brush and two hard brushes (can be lifted when needed) in the upper washing sector is designed for washing hard LOW-E glass, coated glass without damaging the coating. Two Stainless steel air-knives, the blower equipped with muffle cotton and air feeding filter screen pack ensures plenty of air, less noise and the good drying effect.
3. In the laminating room the laminating table, brace of the up-down device, positioning cylinder, PVB film unwinding machine, movable scissor cup suction hunger, convenient for processing of large and big glass. Every single processing glass can be conveyed in a higher speed to enter into the Pre-laminating and press section and regulated automatically the speed to running at the same speed with the Pre-laminating and press section which can make room for the next pieces of glass which improves the running efficiency of the Line.
III. Technical Parameter of the whole line
1. Normal size of processing glass: 2500×3500
2. Max size of processing glass: 2440×6000mm
3. Min length of processing glass: 400mm
4. Min width of processing glass: 400mm
5. Thickness range of processing: 6~80mm
6. Total length: appro.50000mm
7. Current supply: pressure 0.5-0.8Mpa，flux 13.6L/min
8. Total power: appro.275Kw
IV. PARAMETER OF CONSTITUENT MACHINES
1. Washing and drying machine
(1) Max width of processing glass: 2500mm
(2) Min size of processing glass: 300×300mm(diagonal feeding)
(3) Thickness range of processing glass: 3~25mm（digital display）
(4) Speed limits:
·δ≤6mm, Vmax.=8m/min
·δ= 8mm~12mm, V≤5m/min
.δ= 15mm~19mm, V≤4m/min
·δ= 20mm~25mm, V≤3m/min
(5) Speed regulation: frequency variation.
(6) Dimension: appro.6300×3510×2600mm(LxWxH).
(7) Height of roller platform: 860±20 mm
(8) Total power: appro.28.62Kw.
(9) Water supplement: recycle and complemented by running water or soft water（Please note that customer prepares the soft water.
(10) Current supply: 380V, 50Hz, 3phs.
(11) Weight: appro.4000Kgs.
Features
l Brush roller: total three pairs (The top frame equipped two hard brush can be elevated by cylinder when needed and one soft brush)
l The washing section, all water touched sections and side safety covers adopt stainless steel material. Other metal works are cold plate with spray-paint.
l Washing and drying sector can be elevated by 400mm simultaneously.
2. Lamination positioning and transmission machine
(1) Transfer rate: 0.5~5m/min
(2) Speed regulation: frequency variation
(3) PLC control system.
(4) Dimensions: appro.3600×1850×900±20mm (2 sections)
(5) Total power: appro.1.5x2=3Kw
(6) Current supply:
(7) Air supply: pressure 0.5~0.8Mps, flow rate2.63L/min
(8) Weight: appro.2300Kg
3. Transition conveying machine
(1) Transfer rate: 0.5~5m/min
(2) Speed regulation: frequency variation
(3) Control method: centralized PLC controlled
(4) Motor power for conveyor: appro.1.5KW
(5) Dimensions: appro.2400×3000×900mm±20mm
(6) Weight: appro.1200Kg
4. Movable scissor cup suction hanger
(1) Speed: 8m/min
(2) Max suck height: 900Kg
(3) Altitude of rail bellow horizon: 2460mm
(4) Motor power for conveyor: appro.0.75W
(5) Air source: pressure -0.05 ~ -0.08Mpa, flow rate 6.3L/min
(6) Current supply:
(7) Max Vacuum pressure of sucker: -0.08Mpa
(8) Wight: appro.800Kg
(9) Customer supplies walking trail of sucker.
5. PVB film unwinding machine
(1) Loading barrel capacity: 3
(2) Barrel reposition: manual
(3) Dimensions: approx.2000×3920×2400mm
(4) Height of roller platform: 900±20mm
(5) Weight: approx.680Kg
6. Pre-pressing machine (Normal quartz heater and Pre-pressing Structure with Duplex Chain)
(1) Max width of processing glass: 2500mm
(2) Min width of processing glass: 400mm
(3) Max length of processing glass: 4000mm
(4) Min length of processing glass: 400mm
(5) Thickness range of processing glass: 6~40mm
(6) Height of roller platform: 900mm±20mm
(7) Transfer rate: 0.5~2.5m/min
(8) Dimensions: appro.9580×3400×1700mm
(9) Total power: appro.104.4KW
(10) Current supply:
(11) Air supply: pressure 0.5~0.8Mpa flow rate 4.67L/min
(12) Speed regulation: frequency variation
(13) Weight: appro.4500Kg
CHARACTERS
l Gear driven.
l Height of rubber roller is driven by duplex chain: adjusted on the panel and digit-displayed.
l Conveyor structure: Conveyor in heating section and other section is covered with 12x4 rope
l Heating elements: normal glass heating tube
7. Autoclave (Chinese Standard )
(1) : Equipment Describe Using the PLC independent control and touch screen display.
Technical parameters
Glass Autoclave Technical Parameters | ||||
No. | Title | Unit | Technical Parameters | Remark |
1) | Inner diameter | mm | 2850 | |
2) | Length available | mm | 6000 | |
3) | Max glass size | mm | 2440×6000 | |
4) | Designed pressure | Mpa | 1.5 | |
5) | Design temperature | ℃ | 150 | |
6) | Working pressure | Mpa | 1.3 | |
7) | Working temperature | ℃ | 130 | |
8) | Safe valve opening pressure | Mpa | 1.4 | |
9) | Medium inside | Compressed air | ||
10) | Distance between trails inside | mm | 900 | |
11) | heating way | Nickel-chromium alloy heating element | radiation | |
12) | opening way | Electrical type | ||
13) | control way | PLC+Touch screen | Auto control | |
14) | Temperature, pressure | TPC | Special software | |
15) | heating rate | KW | 120 | |
16) | Blower power | Kw | 18.5 | |
17) | Power supply | 220/380VAC, 3P+N+PE, 50/60Hz | ||
(2) Structure feature
l Body of autoclave: Using 16MnR material, completely according to GB150-2011“steel pressure vessel”standard to design and manufacture.
l Head: Tooth shape flange plate and ellipsoidal head all using solid forgine, thickness is greater than the autoclave body thickness
l Quick open autoclave door, Using pneumatic single frame, open on the （ side）facing the autoclave door, realize quick auto open and lock
l Heating element: electro-thermal conversion rate and service life if nickel-chromium alloy electric tube heating element, are distributed evenly over the autoclave body on both side and the tail, to ensure the inside autoclave in the process of heating uniformity of temperature, at the same to shorten the heating time, achieve the purpose of energy saving
l Thermal insulation material: high density rock wool insulation, In addition, the outer layer of insulation is fixed and sealed with brushed stainless steel to further improve the utilization rate of infrared radiation in the autoclave to achieve energy saving.
l Cooling system: Both sides of autoclave(inside the duct) all have snake shape cooler, as an auxiliary cooling, integral galvanized seamless boiler tube + aluminum fins, In the inside of the autoclave, the cold fins heat exchanger are used as the main cooler, which has large heat dissipation area and high heat exchange efficiency.
l Vacuum tube road system: A vacuum tube is arranged on both sides of the autoclave.
l Hot wind cycle system: Cooling sealed direct motor and impeller with water jacket.
l Control system: The PLC system is equipped with a color touch screen, and the whole process can be operated automatically. During the working process, the pressure and temperature curve are displayed at any time, and there is no paper recording function to complete the recording of process curve and process parameters. The advanced TPC control software ensures that temperature and pressure control processes are implemented in the process of rising pressure, so as to ensure that the temperature and pressure are synchronized with the set process curve. In the process of constant temperature constant pressure, automatic filling temperature, filling control PID adjustment process are realized. Other functions such as data exchange , data output and over-temperature、over-pressure alarm can be realized.
(3) Configuration of Autoclave
l PLC: Siemens
l Low voltage electrical element：Schneider
l pressure vessel : 16MnR(GB: Q345R)
l heating element: Medium wave infrared heating tube
l insulating layer: Brushed stainless steel
l Two sides windshield：Brushed stainless steel
l Rail foot pedal using antiskid patterm plate