case study
Forming Line
The scope of delivery is a semiautomatic production line with the following characteristics: cutting of substrate blanks from roll including a semi-automated roll change system, blanket moulding and control system.
Overall description
- Preparing and cutting of substrate blanks from roll including a semi-automated roll change system
- Transferring of substrate blanks through the line
- Preheating of substrate blanks in the contact heating press
- Activating of glue layer on the decor blank in the infrared heating zone
- Transferring of decor and substrate blank into the moulding press
- Moulding of blanks in a moulding press (water-cooled tools with tensioning frames are necessary)
- Manually (due ejectors in the mould assisted) product unloading
- Easy mould change including quick coupling
- Electronic line control system
- EU conform work place safety and environment protection
60-90 s
- SPS Simatic S7with MP
- Simatic touch screen
- Win CC (flex) visualizing
Blanks to be processed:
- Width : 1300 – 1800mm
- Length: 1800 – 3000mm
- Automatic Forming Line – Current Configuration
- Blank Size: 2800 x 1600 mm max
- Decor + Substrate Only
- Automatic Forming Line – Alternative Configuration
- Blank Size: 2800 x 1800 mm max
- Decor + Substrate + Heavy Layer
General Layout
1. Roll-off device
2. Positioning table
3. Heating press
4. Molding press
5. Mould change and Part unloading
6. Side feed decor
From Left to Right: 1. Roll-off device – 2. Positioning table – 3. Heating press – 4. Molding press – 5. Mould change and Part unloading – 6. Side feed decor
Process Flow
insert winding shafts stubs from each side, with pneumatic tension
edge control (working tolerance -+10mm) and material capacity control
pneumatic clamps on the puller bar, servo with drive
circle knife with pneumatic linear drive
material fixed by pneumatic brakes
- Main line – substrate
linear shuttle between all line stations, linked and working in the same cycle stroke
after heating the shuttle is equipped with pneumatic tension system to prevent shrinkage
- Side feed – decor
linear shuttle with servo drive, blank transport via pneumatic clamps on the puller bar
hydraulic lower & upper stroke opening 800 mm max
closing force 30t
HMI controlled closing speed, 2 speed levels
5 zones of IR heaters controlled by pyrometers
after the heating (face down) the decor blank is automatically transferred in to the molding press, turned face up and placed on the preheated substrate
hydraulic 4 column press & upper stroke 1950mm max
closing force 100t
- HMI controlled closing speed (3 speed levels)
the moulded product is ejected from the lower tool in the ergonomic height
Final Design
