Composite sleeper continuous production line

Ordinary sleepers have the following shortcomings: 1) the strength and durability of traditional sleepers are not uniform enough, so that the service life of sleepers is short; 2) reinforced concrete sleepers have high hardness, poor elasticity, and poor noise reduction and shock absorption effect. After using for a period of time, cracks are prone to occur, which affects the safe operation of the railway; 3) The steel sleepers are large in size and inconvenient to lay, maintain and transport. The manufacturing cost of steel sleepers is very high. In order to make up for the shortcomings of the above-mentioned traditional sleepers, WEIHUA has developed a new composite sleeper production line through continuous development and innovation. Glass fiber reinforced polyurethane composite sleepers have good elasticity, greatly improving the overall elasticity of the track structure, reducing the impact of vibration on the roadbed and noise pollution to the environment during train operation; good insulation performance, it has no impact on the track circuit, ensuring the safe operation of the train; at the same time, it also has excellent hydrolysis resistance, grease resistance, and unique weathering resistance.

Automatic door panel production line

The automatic door panel production line is a complete production line designed and manufactured by our company independently according to the requirements of Australian customers. Including double-head 180 rotatable uncoiler, wood grain pressing machine, finishing machine, servo clamping and leveling machine, stamping mechanism, hydraulic punching mechanism, front shearing mechanism, conveying mechanism, tendon pressing mechanism, edge wire crusher, waste conveying mechanism, roll forming machine, online marking machine, full-automatic palletizing machine and baler. The production line can meet the production needs of door panels of different widths and lengths, that is, door panels of different specifications can be produced continuously in a single sheet. The design of the side shredder part is a major innovation of our company and one of the shining points of this production line. The design of this part fundamentally solves the technical core problem of whether the production line can continuously produce door panels of different specifications.

Corrugated plate forming machine

Feeding rack, forming host, hydraulic forming shears, computer control cabinet, hydraulic oil tank, discharging table

Four-component foaming machine

1. Introduction: The foaming machine is the core component of the continuous sandwich panel production line, which directly affects the quality of the finished panel. Due to the difficulty of foaming technology and the invisible foaming process, it is covered with a mysterious veil. WEIHUA has been committed to the research of foaming machine for many years. This technology involves 1) fluid mechanics, 2) fluid heat exchange, 3) gas-liquid emulsification 4) chemical raw materials 5) electrical automation control, 6) internal combustion engine common rail injector technology (needle tip injection technology),7) precision mechanical design and manufacturing heat treatment, (VIII) pentane explosion-proof safety and other sub-areas of the core technology. 2. Technology: With the promotion and application of high flame retardant PIRB1 grade polyurethane, pentane is put into use as a foaming agent, and the new foaming machine will become the core configuration of the production line. After nearly two decades of continuous development and optimization of the foaming machine, Weihua has now fully mastered all the core technologies and has been successfully applied to many production lines at home and abroad. These technologies include: flow control technology: temperature control technology: self-cleaning gun head technology: high-speed shear mixing and emulsification technology: 3. technical parameters: 1) unit pouring volume: 120-500 g/s;2) Spray pressure range of pouring head: 12-18Mpa, rated 15Mpa;3) pouring head pressure adjustment: pneumatic, on-line adjustment during production; 4) Flow system control of each component: automatic closed-loop control of flow (manual operation);5) Working nature of the unit: continuous operation under high pressure; 6) working material tank volume: polyol 300L; Isocyanate 300L;7) material temperature control error: 2 ℃;8) temperature control system heating: 2 × 6Kw, cooling: 20000Kcal/h (refrigerating capacity);4. Foaming performance: the foaming performance of the finished board is quite good. The following figure is a cold storage sandwich panel with a thickness of 250mm and a fire rating of B2. The enclosed area percentage is high and the thermal conductivity is low. 9) The input power is about 45Kw pentane system. According to the Montreal Protocol on Substances that Deplete the Ozone Layer published in 1989, the use of chlorofluorocarbons has been discontinued in Europe and the Americas. Since 1993, cyclopentane has been considered in Europe as an alternative to chlorofluorocarbons. Currently, China, India, the United Arab Emirates and other developing countries are phasing out CFCs/HCFCs. For the foaming system with pentane as foaming agent, the following factors need to be considered: 4. Pentane storage system Pentane storage and conveying system is mainly used to store cyclopentane unloaded from the tanker and automatically feed the foaming machine. Because pentane vapor is flammable and explosive, the system must be strictly in accordance with the relevant standards. The pentane storage system includes: tank body, pentane delivery system, tank body breathing system, liquid level system, unloading system and pentane detection system. 5. Pentane foaming system All pentane-related parts and pipelines on the foaming machine are installed in a small room with probes and dual exhaust systems to ensure safety. The detection head is installed on the storage tank. The safety system is controlled by an independent electrical cabinet, independent of the operating cabinet. 6. Pentane safety system Pentane detection devices will be installed in pentane leakage areas and possible leakage areas, including crawler and cloth areas and storage tanks. Help customers run production lines safely and reliably. MAIN ACHIEVEMENTS WEIHUA is the only Chinese company that has won the bid for the United Nations pentane continuous foaming machine project (refer to the winning documents). We have mastered pentane storage, transportation, mixing, safety and other technologies, and put into actual production in 2014. We not only provide equipment, but also provide customers with a series of services such as establishing employee training mechanism, operating procedures, post leakage early warning mechanism, etc., to achieve 100 percent safety from machine to personnel. WEIHUA's latest product: four-component foaming machine for polyurethane sandwich panel production line, delivered to Duowei Group, a leading domestic sandwich panel manufacturer. The flow accuracy of MDI is 1 ‰, the mixture is 1 ‰, the catalyst is 1 ‰, and the foaming agent is 5 ‰.

Two-component foaming machine

1. Introduction: WH-PU-2-40 two-component continuous high-pressure foaming machine adopts two-component foaming system, 1 polyether (polyester) and 2 isocyanate. Each component is measured separately, and the flow rate is controlled in closed loop. Inverter, high-precision volume flowmeter and magnetic coupling are adopted, and the system can automatically change the output flow rate and mixing ratio instantaneously. The working mode of the system is continuous on-line mixing. The polyether is fed to the dynamic mixer through respective metering units for high-speed mixing. In order to improve the foaming effect and make the mixed polyether fully blend into the foaming nucleation gas, we adopt a group of gas metering devices and stir at high speed to make the mixed polyether fully nucleate and emulsify. The output mixed polyether is sprayed into mist form through the damping hole of the mixing head through the high-precision high-pressure metering unit, then it is micromixed with high-pressure mist of isocyanate. The whole machine adopts man-machine interface control, animation display work flow, various process parameters, including component flow rate, mixing ratio and mixing mode, can be set and modified in the panel, the electronic control system and the production line part are provided with signal communication interface, when the production line changes speed, the various material flow rate of the foaming machine is also changed in the same proportion, so as to ensure the quality stability of the composite board and realize the online automatic production of the whole line. 2. Technology: With the promotion and application of high flame retardant PIRB1 grade polyurethane, pentane is put into use as a foaming agent, and the new foaming machine will become the core configuration of the production line. After nearly two decades of continuous development and optimization of the foaming machine, Weihua has now fully mastered all the core technologies and has been successfully applied to many production lines at home and abroad. These technologies include: flow proportional control technology: temperature control technology: self-cleaning gun head technology: high-speed shear mixing and emulsification technology: 3. technical parameters 1) unit pouring volume: 120-500 g/s;2) the spray pressure range of the pouring head: 12-18Mpa, rated 15Mpa;3) pouring head pressure adjustment: pneumatic, on-line adjustment during production; 4) flow system control of each component: automatic closed-loop control of flow (manual operation);5) Working nature of the unit: continuous operation under high pressure; 6) working tank volume: l polyol 300L;l isocyanate 300L;7) two-component flow rate (adjustable mixing ratio):l polyol 50~300 g/s;PLOY50 ~ 300g/sl isocyanate 50~300g/s;MDI50 ~ 300g/s8) material temperature control error: 2 ℃;9) Temperature control system heating: 2 × 6Kw, cooling: 20000Kcal/h (refrigerating capacity);10) Input power is about 40Kw4. Foaming performance The foaming performance of the finished board is quite good. The following figure is a cold storage sandwich panel with a thickness of 250mm and a fire rating of B2. The enclosed area percentage is high and the thermal conductivity is low.

Five-component foaming machine

Overview WH-PU-5-80 type continuous sheet foaming machine mainly solves PUR/PIR foaming. The main parts of the equipment are all imported, the material ratio is adjustable online, the performance is stable, the operation is simple, and the production efficiency is high. The raw materials used in this machine are mainly dry white material, MDI polyester, catalyst 1, catalyst 2, foaming agent 1 and gas nucleating agent. The dry white material and each component are premixed in advance through high-speed shearing and emulsification, then the combined polyether is output through a high-pressure metering system, and the black material from another group of high-pressure metering systems collides in the gun head to realize continuous foaming. Design of gun head: gun head adopts self-cleaning gun head flow ratio control technology with loop: temperature control technology: self-cleaning gun head technology: high-speed shear mixing emulsification technology: technical parameters: 4) spray pressure range of pouring head: 8-18Mpa, rated 15Mpa;5) Pouring head pressure adjustment: pneumatic, online adjustment during production; 6) Flow rate of each component (adjustable mixing ratio): B) Polyol (polyol):50~320 g/s f) isocyanate: 60~600 g/s; G) catalyst 1:1.5-15 g/s; H) catalyst 2:1.5-15 g/s; I) n-pentane blowing agent: 5-35 g/s

Slitting unit

1. Processing plate: suitable for carbon steel plate with δb≤ 380Mpa 2. Processing plate thickness: δ0.5-3mm 3. Processing plate width: 1500mm 4. Shear accuracy: width allowed: ± 0.15mm 5. Slitting burr: ≤ 0.05 plate thickness δ 6. Width range of side wire: ≥ plate thickness δ 7. Longitudinal shear speed: 0.5-2mm high speed gear 120 m/min, 2-3mm bottom gear 70 m/min 8. Minimum slitting width: ≥ 50mm 9. Number of slitters: δ0.3-2 ㎜ 12 and δ3 ㎜ 7 10. Uncoiler bearing: 15T 11. Inner diameter of coil plate: Φ508mm, Φ610mm, Φ762mm 12. Outer diameter of coil plate: ≤ Φ1800mm 13. Longitudinal scissors shaft diameter: Φ225mm, material 42CrMo 14. Slitting blade: Φ225 × Φ350 × 50mm 15. Shear blade material: Cr12MoV 16. Shear blade hardness: HRC580-HRC600 17. Inner diameter of winding: Φ508mm 18. Equipment floor area: 26m × 8m

Leveling and shearing unit

1. Processing plate thickness: δ0.3-3mm 2. Processing plate: 0.5-3.0mm hot rolled plate, cold rolled plate, galvanized plate, color coated plate 3. Processing plate width: 800-1500mm 4. Uncoiler bearing: 16T 5. Inner diameter of coil plate: Φ508mm-Φ610mm 6. Outer diameter of coil plate: ≤ Φ1600mm 7. Length shear accuracy: ± 0.75mm (based on plate thickness of 1.5mm and length of 2000mm) 8. Diagonal error: ± 1.0mm (2000mm in length) 9. Length range: 0-9999.99mm 10. Shear speed: 16 sheets/min (2m length) 11 leveling speed: 0- 60 m/min 12. Number of fine straightening rollers: 19 rollers 13. Diameter of fine straightening roller: ￠ 60mm 14. Material of fine straightening roller: 90CrSi 15. Heat treatment hardness of fine straightening roller: HRC50 °-52 ° 16. Number of intermediate rollers: 21 rollers 17. Intermediate roller material 9CrSi 18. Intermediate roller heat treatment hardness: HRC50 °- 52 ° 19. Number of support rollers: 115 (five rows) 20. Load bearing of stacking material lifting platform: 5000kgs 21. Length range of blanking and stacking: 500-4000mm (side discharge, 2 sets in total) 22. Maximum stacking height range: 400mm Device Configuration Hydraulic feeding trolley, hydraulic single-head uncoiler (16T), hydraulic pressure shovel head and straight head mechanism, initial straightening clamping mechanism and front transverse shear, five-weight 19-roller fine straightening (controlled by grating ruler), hydraulic bridge storage device, guide mechanism, servo sizing mechanism, high-speed plate shearing machine, fast conveying table, automatic stacking, unloading trolley, hydraulic system, electrical system, etc.

Building board forming machine

1. Manual uncoiler, no power (8T) 2. Feed guide 3. Forming host 4. Hydraulic cutting 5. Computer control cabinet 6. Hydraulic station 7. The discharge station