An electric heating wire cutting production process of foamed PET block

Abstract

The present application belongs to the field of foam materials, and particularly relates to a production process for cutting electric heating wires of foamed PET blocks, which comprises the following steps: step one, installing a fixed-thickness copper bar with fixed-thickness grooves on the outer wall on the copper bar fixing mechanism of a hot cutting machine to limit the installation of the fixed-thickness copper bar; step two, sleeving the electric heating wire with springs on both ends into the fixed-thickness grooves of the fixed-thickness copper bar, and fixing the springs on both ends of the electric heating wire in cooperation with the spacing adjustment mechanism on the hot cutting machine, adjusting the cutting spacing of the electric heating wire through the spacing adjustment mechanism, and moving the installed electric heating wire to the initial cutting station of the hot cutting machine; and step three, feeding the foamed PET blocks through the front conveying roller, and placing the foamed PET blocks in order to keep the left and right spacing of the foamed PET blocks consistent with the hot cutting machine. The fixed-thickness electric heating wire cutting mode has the characteristics of no dust, loss below 0.5 mm, full-automatic continuous cutting, and heating and melting of the material at the same time to seal the cells, which solves the traditional cutting problem and improves the forming quality of the plate.

Description

Technical Field

[0001] This invention relates to the field of foam materials, and more specifically to a hot wire cutting process for foamed PET blocks. Background Technology

[0002] Foamed PET blocks are used as the core material for the inner lining structure. In the production process of wind turbine blades, they are used to adhere to the inner wall of the blade cavity. The blades directly affect the wind energy conversion efficiency in the wind turbine. Based on the consideration of application and performance requirements, the production process of PET foam currently generally adopts the following method: first, it is extruded into foam boards with a width of about 1m and a thickness of several centimeters, and then the boards are heat-welded into larger block shapes (known in the industry as Blocks). Subsequent processing steps include sheet cutting, irregular cutting, grooving and drilling.

[0003] The sheet cutting process for PET foam blocks is currently mostly carried out by single-sheet sawing. However, sawing has several obvious drawbacks: first, it generates a lot of dust; second, it results in significant process losses; third, it is inefficient; fourth, it causes open cells, requiring subsequent surface sealing; and fifth, it results in high labor intensity for operators. Summary of the Invention

[0004] (a) Purpose of the invention

[0005] To address the technical problems existing in the background art, this invention proposes a hot wire cutting production process for foamed PET blocks, which features dust-free operation, low loss, fully automatic continuous cutting, and simultaneous heating and melting of the material during cutting to seal the foam cells.

[0006] (II) Technical Solution

[0007] To solve the above-mentioned technical problems, the present invention provides a hot wire cutting process for foamed PET blocks, comprising the following steps:

[0008] Step 1: Install the copper rod with a fixed thickness groove on the outer wall onto the copper rod fixing mechanism of the hot cutting machine to limit the installation of the copper rod.

[0009] Step 2: Insert the heating wire with springs at both ends into the thickness groove of the thickness-fixed copper rod. The springs at both ends of the heating wire are fixed in conjunction with the spacing adjustment mechanism on the hot cutting machine. Adjust the cutting spacing of the heating wire through the spacing adjustment mechanism, and move the installed heating wire to the initial cutting position of the hot cutting machine.

[0010] Step 3: Feed the foamed PET blocks through the front conveyor rollers. The foamed PET blocks are arranged neatly, and the left and right distance between the foamed PET blocks and the hot cutting machine is consistent.

[0011] Step 4: Operate the industrial control device of the hot cutting machine, click the automatic button to enter the automatic screen, input the process requirements (position, speed and voltage settings), click automatic run, and the equipment will enter the self-circulation mode;

[0012] Step 5: After the foamed PET block enters the lifting platform of the hot cutting machine from the front conveyor roller, it stops automatically (at this time, another foamed PET block can be placed into the front conveyor roller). The platform lifts the foamed PET block upward to the initial cutting position. The heating wire heats up and moves to start cutting the foamed PET block. After cutting, the platform automatically descends, and the divided PET sheet is conveyed to the rear conveyor roller. The heating wire automatically returns to the initial cutting position of the hot cutting machine.

[0013] Step 6: Remove the slit PET sheets from the rear conveyor rollers.

[0014] Preferably, the heating wire is a nickel-chromium wire with a diameter of 0.3mm-0.8mm and an operating voltage of 0-220V.

[0015] Preferably, the hot cutting machine is equipped with a gantry mechanism that can move back and forth along the cutting direction; the gantry mechanism includes a rail installed on the side of the hot cutting machine's worktable, and a gantry is slidably mounted on the rail.

[0016] Preferably, the copper rod fixing mechanism includes a fixing seat and a top seat installed on the opposing inner side wall of the gantry frame, the fixed-thickness copper rod is snapped between the fixing seat and the top seat, and the fixed-thickness copper rod is connected to an external power supply device.

[0017] Preferably, the spacing adjustment mechanism includes several upright plates set on the inner sidewalls of the gantry frame, with grooves spaced apart on the upright plates, insulating wooden pads embedded in the grooves, pads installed on the insulating bakelite, and bolts that cooperate with the heating wire springs installed on the pads.

[0018] Preferably, the gantry frame is provided with a tensioning mechanism, which includes a slide rail installed on the gantry frame to cooperate with the front and rear displacement of the upright plate. A slide table seat connected to the upright plate is slidably installed on the outer wall of the slide rail, and a limiting structure for auxiliary braking is provided between the slide table seat and the slide rail.

[0019] Preferably, the front conveyor roller and the rear conveyor roller share the same set of loading and unloading drive mechanisms. The loading and unloading drive mechanisms drive the front conveyor roller and the rear conveyor roller to move synchronously through plate chains and gear sets. Loading platforms and unloading platforms with plate chain through slots are installed above the front conveyor roller and the rear conveyor roller.

[0020] Preferably, a lifting mechanism is provided under the table of the hot cutting machine. The lifting mechanism includes a lifting drive motor and a tension wheel at its output end. A chain is sleeved on the outer wall of the tension wheel. Four gears are also connected to the corner of the chain. A screw is threaded in the middle of the gear. A support frame is provided above the screw and is connected to the table.

[0021] Preferably, the loading platform, unloading platform, and table surface are on the same plane when not cut, and the table surface has the same plate chain through groove as the loading platform and unloading platform.

[0022] The above-described technical solution of the present invention has the following beneficial technical effects:

[0023] 1. The fixed-thickness electric heating wire cutting method is characterized by no dust, a loss of less than 0.5mm, and fully automatic continuous cutting. While cutting, the material is heated and melted to seal the bubbles, which solves the problems of traditional cutting and improves the quality of the formed board.

[0024] 2. The cutting thickness of the heating wire can be quickly adjusted by the position of the wire hanging. After adjustment, the tension of the heating wire is easy to adjust, which can meet the process requirements of different cutting thicknesses. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the hot wire cutting process for the foamed PET block of the present invention.

[0026] Figure 2 This is a schematic diagram of the hot cutting machine structure of the present invention;

[0027] Figure 3 This is a schematic diagram of the gantry structure of the present invention;

[0028] Figure 4 This is a schematic diagram of the loading and unloading drive mechanism of the present invention;

[0029] Figure 5 This is a schematic diagram of the lifting mechanism structure of the present invention;

[0030] Figure 6 This is a schematic diagram of the sheet metal structure of the hot cutting machine of the present invention. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments and the accompanying drawings. It should be understood that these descriptions are merely exemplary and not intended to limit the scope of the invention. Furthermore, descriptions of well-known structures and techniques are omitted in the following description to avoid unnecessarily obscuring the concept of the invention.

[0032] like Figure 1-6 As shown, the present invention proposes a hot wire cutting process for foamed PET blocks, which includes the following steps:

[0033] Step 1: Install the copper rod with a fixed thickness groove on the outer wall onto the copper rod fixing mechanism of the hot cutting machine to limit the installation of the copper rod.

[0034] Step 2: Insert the heating wire with springs at both ends into the thickness groove of the thickness-fixed copper rod. The springs at both ends of the heating wire are fixed in conjunction with the spacing adjustment mechanism on the hot cutting machine. Adjust the cutting spacing of the heating wire through the spacing adjustment mechanism, and move the installed heating wire to the initial cutting position of the hot cutting machine.

[0035] Step 3: Feed the foamed PET blocks through the front conveyor rollers. The foamed PET blocks are arranged neatly, and the left and right distance between the foamed PET blocks and the hot cutting machine is consistent.

[0036] Step 4: Operate the industrial control device of the hot cutting machine, click the automatic button to enter the automatic screen, input the process requirements (position, speed and voltage settings), click automatic run, and the equipment will enter the self-circulation mode;

[0037] Step 5: After the foamed PET block enters the lifting platform of the hot cutting machine from the front conveyor roller, it stops automatically (at this time, another foamed PET block can be placed into the front conveyor roller). The platform lifts the foamed PET block upward to the initial cutting position. The heating wire heats up and moves to start cutting the foamed PET block. After cutting, the platform automatically descends, and the divided PET sheet is conveyed to the rear conveyor roller. The heating wire automatically returns to the initial cutting position of the hot cutting machine.

[0038] Step 6: Remove the slit PET sheets from the rear conveyor rollers.

[0039] It should be noted that the heating wire is a nickel-chromium wire. The main chemical components of nickel-chromium wire are nickel and chromium. It is filamentous, hence the name nickel-chromium wire. It has the characteristics of high strength at high temperatures, no brittleness after long-term use and cooling, higher emissivity of fully oxidized nickel-chromium alloy than iron-chromium-aluminum alloy, non-magnetic and corrosion resistant. The diameter of the nickel-chromium wire is 0.3mm-0.8mm (0.5mm in this application), and the voltage is 0-220V.

[0040] In this embodiment, the foamed PET blocks (hereinafter referred to as blocks) are cut by heating wire. During the slicing process, the contact surface with the heating wire is heated and melted to seal the foam cells, thus solving the problem of open foam cells on the cut surface. The cutting process is dust-free. Due to its low diameter, the cutting loss is less than 0.5mm, and the material is fully utilized. Furthermore, the moving design of the heating wire, combined with the continuous loading and unloading of the blocks, enables fully automatic continuous cutting, improving cutting efficiency.

[0041] like Figure 2-3 As shown, the hot cutting machine is equipped with a gantry mechanism that can move back and forth along the cutting direction; the gantry mechanism includes a rail installed on the side of the hot cutting machine's worktable, and a gantry is slidably mounted on the rail.

[0042] The gantry frame moves back and forth on the track via an electric sliding table at the bottom, and the heating wire moves synchronously during the movement to cut the block.

[0043] As an example of the installation of a fixed-thickness copper rod: the copper rod fixing mechanism includes a fixing seat and a top seat installed on the opposing inner side wall of the gantry frame, and the fixed-thickness copper rod is snapped between the fixing seat and the top seat.

[0044] It should be noted that the fixed-thickness copper rod is connected to an external power supply device, and the externally wound heating wire is pressurized and heated by the conductivity of the copper material.

[0045] like Figure 2-3 As shown, the spacing adjustment mechanism includes several upright plates set on the inner sidewalls of the gantry frame. Grooves are opened at intervals on the upright plates, and insulating pads are embedded in the grooves. Pads are installed on the insulating bakelite, and bolts that cooperate with the heating wire spring are installed on the pads.

[0046] As an example of adjusting the thickness of the heating wire: Since there are multiple sets of bolts, the thickness spacing between adjacent heating wires can be changed by switching the springs at both ends of the heating wire to hang on different bolts, thereby adapting to the cutting of blocks with different thickness requirements.

[0047] It should be added that a tensioning mechanism is installed on the gantry frame. After the spacing between adjacent heating wires is adjusted, the tensioning mechanism can help tighten the heating wires on the copper rod of fixed thickness. The tensioning mechanism includes a slide rail installed on the gantry frame to cooperate with the forward and backward movement of the vertical plate. A slide table seat connected to the vertical plate is slidably installed on the outer wall of the slide rail. The vertical plate moves backward with the slide table seat, pulling the spring and heating wire outward, so that they are taut on the copper rod of fixed thickness, preventing the slack heating wire from causing the flatness of the cut surface to be substandard.

[0048] Among them, a limit structure for auxiliary braking is provided between the slide base and the slide rail;

[0049] In an optional embodiment, the limiting structure is a pluggable workpiece, and the limiting is adjusted by sliding. This method has a lower investment cost.

[0050] Alternatively, the limiting structure can be designed as a cylinder structure for the extended slide block. The cylinder stops the slide block on the slide rail by limiting the extension stroke of the piston rod at the output end. The electronic control method offers higher adjustment precision.

[0051] like Figure 2 and Figure 4 As shown, the front conveyor roller and the rear conveyor roller share the same set of loading and unloading drive mechanisms. The loading and unloading drive mechanisms drive the front conveyor roller and the rear conveyor roller to move synchronously through plate chains and gear sets.

[0052] As an example of material feeding: the plate chain and gear set are driven by the drive device, which in turn drives the front conveyor roller and the rear conveyor roller to move synchronously. During the rotation, the plate chain is in a rotating state. After the block is neatly placed on the feeding platform, it is transported to the table above the cutting station by the plate chain, waiting to be cut.

[0053] As an example of material unloading: After cutting, the PET sheets are stacked and moved from the table of the cutting station to the unloading table by the conveyor belt, and the staff manually removes the sheets.

[0054] like Figure 2 and Figure 5 As shown, a lifting mechanism is installed under the table of the hot cutting machine. The lifting mechanism includes a lifting drive motor and a tension wheel at its output end. A chain is sleeved on the outer wall of the tension wheel. Four gears are also connected to the corner of the chain. A screw is threaded in the middle of the gear. A support frame is installed above the screw and is connected to the table.

[0055] In one embodiment, before the heating wire performs block cutting, the cutting station table is extended to make it flush with the heating wire. The blocks and PET sheets at the loading and unloading tables are not affected. The drive motor drives the tension wheel at the output end to rotate. At the same time, the tension wheel and four gears are driven by a chain. During the rotation of the gears, the central screw thread drives the lifting frame upward, thereby causing the table connected to the lifting frame to rise, so that the cutting station moves closer to the cutting path of the heating wire group.

[0056] like Figure 6 As shown, the loading platform, unloading platform, and table surface are on the same plane when not being cut. The loading platform and unloading platform with plate chain through grooves are installed above the front conveyor roller and the rear conveyor roller. The table surface has the same plate chain through grooves as the loading platform and the unloading platform.

[0057] It should be noted that when the loading platform, unloading platform, and table are in the cutting state, the middle table is higher than the loading platform and unloading platform. Because the table has the same plate chain through groove as the loading platform and unloading platform, the loading and unloading movement on the loading platform and unloading platform is not affected when the middle table is raised.

[0058] It should be understood that the specific embodiments described above are merely illustrative or explanatory of the principles of the invention and do not constitute a limitation thereof. Therefore, any modifications, equivalent substitutions, improvements, etc., made without departing from the spirit and scope of the invention should be included within the protection scope of the invention. Furthermore, the appended claims are intended to cover all variations and modifications falling within the scope and boundaries of the appended claims, or equivalent forms of such scope and boundaries.

Claims

1. A hot wire cutting process for producing foamed PET blocks, characterized in that, Includes the following steps: Step 1: Install the copper rod with spacing grooves on its outer wall onto the copper rod fixing mechanism of the hot cutting machine to limit the installation of the copper rod. Step 2: Insert the heating wire with springs at both ends into the thickness grooves of the copper rod. The springs at both ends of the heating wire are fixed in place by the spacing adjustment mechanism on the hot cutting machine. Adjust the cutting spacing of the heating wire using the spacing adjustment mechanism, and move the installed heating wire to the initial cutting position of the hot cutting machine. Step 3: Feed the foamed PET blocks through the front conveyor roller. The foamed PET blocks are neatly arranged, maintaining a consistent left-right spacing between them and the hot cutting machine. Step four: Operate the industrial control device of the hot cutting machine. Click the automatic button to enter the automatic screen, input the process requirements: position, speed, and voltage settings, and click automatic run. The equipment will enter self-circulation mode. Step five: After the foamed PET block enters the lifting platform of the hot cutting machine from the front conveyor roller, it automatically stops. At this time, another foamed PET block can be placed on the front conveyor roller. The platform lifts the foamed PET block upwards to the initial cutting position. The heating wire heats up and moves to begin cutting the foamed PET block. After cutting, the platform automatically lowers, and the segmented PET sheet is conveyed to the rear conveyor roller. The heating wire automatically returns to the initial cutting position of the hot cutting machine. Step six: Remove the segmented PET sheet in pieces on the rear conveyor roller. Hot cutting machine. The machine is equipped with a gantry mechanism that can move back and forth along the cutting direction. The gantry mechanism includes a rail installed on the side of the hot cutting machine's worktable, on which the gantry is slidably mounted. The copper rod fixing mechanism includes a fixed seat and a top seat installed on the inner side wall opposite to the gantry. The copper rod with a fixed thickness is clamped between the fixed seat and the top seat and is connected to an external power supply device. The spacing adjustment mechanism includes several vertical plates set on the inner side wall opposite to the gantry. Grooves are opened at intervals on the vertical plates. Insulating wooden pads are embedded in the grooves. Pads are installed on the insulating wooden pads. Bolts that cooperate with the heating wire spring are installed on the pads. The gantry is equipped with a tensioning mechanism, which includes a slide rail installed on the gantry to cooperate with the back and forth movement of the vertical plates. A slide table seat connected to the vertical plates is slidably mounted on the outer wall of the slide rail. An auxiliary braking limit structure is set between the slide table seat and the slide rail.

2. The hot wire cutting process for foamed PET blocks according to claim 1, characterized in that, The heating wire is made of nickel-chromium wire with a diameter of 0.3mm-0.8mm and an operating voltage of 0-220V.

3. The hot wire cutting process for foamed PET blocks according to claim 1, characterized in that, The front conveyor roller and the rear conveyor roller share the same set of loading and unloading drive mechanism. The loading and unloading drive mechanism drives the front conveyor roller and the rear conveyor roller to move synchronously through the plate chain and gear set. The loading platform and the unloading platform with plate chain through slots are installed above the front conveyor roller and the rear conveyor roller.

4. The hot wire cutting process for foamed PET blocks according to claim 3, characterized in that, The hot cutting machine has a lifting mechanism under its table. The lifting mechanism includes a lifting drive motor and a tension wheel at its output end. A chain is fitted on the outer wall of the tension wheel. Four gears are also connected to the corner of the chain. A screw is threaded in the middle of the gear. A support frame is set above the screw and is connected to the table.

5. The hot wire cutting process for producing foamed PET blocks according to claim 4, characterized in that, The loading platform, unloading platform, and table surface are on the same plane when not cut, and the table surface has the same plate chain through groove as the loading platform and unloading platform.

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