Composite plate production system and composite plate production method

Abstract

The present application discloses a composite sheet production system and a composite sheet production method. The composite sheet production system includes a material preparation unit, a composite shaping unit, a first cutting unit, a detection unit and a control unit. The material preparation unit is used to form a blank from raw materials, and includes a material preparation table, a continuous sheet unwinding mechanism, a metal plate pick-up and placement mechanism and a non-continuous supplementary sheet pick-up and placement mechanism. The composite shaping unit is used to hot press and shape the blank into a continuous plate. The first cutting unit includes a transverse cutting device, which is used to cut the continuous plate into a composite rough plate between adjacent metal plates of the continuous plate. The detection unit is used to perform double-sided detection on the composite rough plate. According to the composite sheet production system of the present application, the degree of automation is high and the versatility is strong, which reduces manual operation, improves work efficiency and improves product precision.

Description

Technical Field

[0001] The present application relates to the technical field of composite materials, and in particular to a composite board production system and a composite board production method. Background Art

[0002] Solid composite panels with metal plates have many advantages such as high strength, corrosion resistance, light weight and recyclability, and are becoming increasingly popular in the market.

[0003] However, the current production of solid plate composite materials with metal steel plates varies due to different production processes in various factories and the corresponding equipment is also different. However, overall, the proportion of manual operation is very large, which makes it difficult to guarantee production efficiency and product quality, and it is difficult to reduce production costs.

[0004] Therefore, a composite board production system and a composite board production method are needed to at least partially solve the above problems. Summary of the invention

[0005] A series of simplified concepts are introduced in the Summary of the Invention section, which will be further described in detail in the Detailed Description of the Invention section. The Summary of the Invention section of this application does not mean to attempt to define the key features and essential technical features of the claimed technical solution, nor does it mean to attempt to determine the scope of protection of the claimed technical solution.

[0006] In order to at least partially solve the above problems, the first aspect of the present application provides a composite sheet production system, wherein the composite sheet production system is used to continuously produce composite sheets with metal plates embedded therein, and the composite sheet production system comprises:

[0007] A material preparation unit is used to form a blank from raw materials, and the material preparation unit comprises:

[0008] A material preparation platform, which can lay and transport raw materials in the longitudinal direction;

[0009] A continuous sheet unwinding mechanism, used for delivering the continuous sheet to the material preparation table;

[0010] A metal plate picking and placing mechanism is arranged on one side of the material preparation platform along the transverse direction, the transverse direction is orthogonal to the longitudinal direction, and is used to place the metal plates on the material preparation platform along the longitudinal direction at intervals; a discontinuous material sheet picking and placing mechanism is arranged on the other side of the material preparation platform along the transverse direction, and is used to place the discontinuous material sheet into the gaps between the adjacent metal plates on the material preparation platform along the longitudinal direction;

[0011] A composite shaping unit, disposed downstream of the material preparation unit, for hot pressing and shaping the blank into a continuous plate;

[0012] A first cutting unit is arranged downstream of the composite shaping unit, the first cutting unit comprises a transverse cutting device, the transverse cutting device is used to cut the continuous plate into composite rough plates between the adjacent metal plates of the continuous plate;

[0013] an inspection unit, disposed downstream of the first cutting unit, for performing double-sided inspection on the composite rough board, and sending qualified composite rough boards to the next process, and sending unqualified composite rough boards to an unqualified product storage area; and

[0014] A control unit is respectively connected to the material preparation unit, the composite shaping unit, the first cutting unit and the detection unit by signals.

[0015] The composite board production system according to the present application can automatically load materials, accurately position and apply continuous sheets, metal plates and patch sheets; and can perform processes such as composite forming of blanks, rough cutting and inspection and sorting of semi-finished products. It has a high degree of automation and strong versatility, reduces manual operations, improves operating efficiency and increases product precision.

[0016] Optionally, the control unit is configured to control the application speed of the metal plate picking and placing mechanism and the non-continuous patch sheet picking and placing mechanism according to the speed at which the material preparation unit conveys the raw materials along the longitudinal direction, so that adjacent metal plates and non-continuous patch sheets can be connected, and control the metal plate picking and placing mechanism and the non-continuous patch sheet picking and placing mechanism to place the metal plates and the non-continuous patch sheets to the middle of the continuous sheet along the transverse direction.

[0017] Optionally, the metal plate picking and placing mechanism comprises a metal plate storage area and a first mechanical arm, wherein the first mechanical arm is configured to transfer the metal plate from the metal plate storage area to the material preparation table;

[0018] The discontinuous replenishment sheet material taking and placing mechanism comprises a discontinuous replenishment sheet material storage area and a second robot arm, wherein the second robot arm is configured to transfer the discontinuous replenishment sheet material from the discontinuous replenishment sheet material storage area to the material preparation station.

[0019] Optionally, the continuous sheet unwinding mechanism of the material preparation unit includes:

[0020] A backing sheet unwinding mechanism is arranged upstream of the material preparation platform and is used to apply the backing sheet to the material preparation platform, wherein the metal plate taking and placing mechanism is used to apply the metal plate onto the backing sheet;

[0021] a continuous patching sheet unwinding mechanism, disposed upstream or above the material preparation platform, for applying continuous patching sheets to both ends of the backing sheet along the transverse direction, so that the metal plate can be located between two spaced continuous patching sheets; and

[0022] The facing sheet material unwinding mechanism is arranged upstream or above the material preparation platform and is used for applying the facing sheet material onto the metal plate.

[0023] Optionally, the backing sheet unwinding mechanism comprises a continuous fiber reinforced thermoplastic backing unwinding mechanism and a first thermoplastic film unwinding mechanism, wherein the continuous fiber reinforced thermoplastic backing unwinding mechanism is located upstream of the first thermoplastic film unwinding mechanism, so that the first thermoplastic film unwinding mechanism can apply the first thermoplastic film onto the continuous fiber reinforced thermoplastic backing; and / or

[0024] The cladding sheet unwinding mechanism comprises a continuous fiber reinforced thermoplastic cladding unwinding mechanism and a second thermoplastic film unwinding mechanism, wherein the continuous fiber reinforced thermoplastic cladding unwinding mechanism is located downstream of the second thermoplastic film unwinding mechanism, so that the second thermoplastic film unwinding mechanism can apply the second thermoplastic film onto the metal plate and the continuous fiber reinforced thermoplastic cladding unwinding mechanism can apply the continuous fiber reinforced thermoplastic cladding onto the second thermoplastic film.

[0025] Optionally, the composite shaping unit includes a thermal composite device, which includes a preheating zone, a hot mold zone and a cold mold zone arranged in the longitudinal direction, wherein the hot mold zone is located downstream of the preheating zone, the cold mold zone is located downstream of the hot mold zone, and the thermal composite device is constructed to have an upper mold part and a lower mold part, and the minimum distance between the upper mold part and the lower mold part can be adjusted.

[0026] Optionally, the composite shaping unit further comprises a pressing roller and a hot air blower, wherein the pressing roller and the hot air blower are arranged upstream of the thermal composite device to pre-process the blank into a size suitable for entering the thermal composite device.

[0027] Optionally, the first cutting unit further includes:

[0028] a first traction roller, disposed downstream of the composite shaping unit, for pulling the continuous plate to the first cutting unit;

[0029] a longitudinal cutting device, arranged upstream of the transverse cutting device, for cutting the edges of the continuous plate on both sides along the transverse direction; and

[0030] Two waste edge cutting devices are respectively arranged on both sides of the longitudinal cutting device and are used to cut off the waste edges cut off by the longitudinal cutting device.

[0031] Optionally, the longitudinal cutting device comprises a first cutting knife assembly and a second cutting knife assembly arranged vertically in the height direction, the first cutting knife assembly comprises a first cutting knife shaft and two first cutting knife discs, the first cutting knife disc is arranged at the end of the first cutting knife shaft, the second cutting knife assembly comprises a second cutting knife shaft and two second cutting knife discs, the second cutting knife disc is arranged at the end of the second cutting knife shaft, wherein the first cutting knife disc and the second cutting knife disc are rotatable, the projections of the first cutting knife disc and the second cutting knife disc on a vertical plane perpendicular to the horizontal direction at least partially overlap, and the first cutting knife disc and the second cutting knife disc located on the same side are arranged close to each other in the horizontal direction; and / or

[0032] The scrap edge cutting device comprises a rolling cutter mechanism, wherein the rolling cutter mechanism comprises a rolling cutter shaft and a plurality of rolling cutters arranged along the circumference of the rolling cutter shaft, wherein the cutting edges of the rolling cutters extend along the transverse direction.

[0033] Optionally, the first cutting unit further includes:

[0034] The second traction roller is arranged downstream of the longitudinal cutting device and is used to convey the continuous plate to the transverse cutting device at a fixed length.

[0035] A bending roller, disposed between the transverse cutting device and the second pulling roller, wherein at least a portion of the bending roller is configured to be movable up and down;

[0036] The control unit is further configured to control the lifting and lowering frequency of the arching roller according to the cutting frequency of the transverse cutting device so as to arch the continuous plate portion when the transverse cutting device blocks the movement of the continuous plate.

[0037] Optionally, the first cutting unit further includes:

[0038] A discharging platform is arranged downstream of the transverse cutting device, and a third mechanical arm is arranged at the discharging platform, and the third mechanical arm is used to transfer the composite rough plate to the detection unit;

[0039] A discharging transition roller is arranged between the discharging platform and the transverse cutting device, and is used for pulling the composite rough plate to the discharging platform.

[0040] Optionally, the detection unit includes:

[0041] A first inspection station, disposed downstream of the first cutting unit, for inspecting the front side of the composite rough board;

[0042] A turning device, disposed downstream of the first inspection station, for turning over the composite rough plate;

[0043] The second inspection station is arranged downstream of the turning device and is used for inspecting the reverse side of the composite rough plate.

[0044] Optionally, the composite board production system also includes a second cutting unit, which is arranged downstream of the detection unit. The second cutting unit is used to cut the composite rough board that has passed the detection into finished composite boards with a predetermined size. The control unit is also connected to the second cutting unit signal.

[0045] Optionally, the inspection unit further comprises a first abnormal product storage area and a first transition area, wherein the first transition area is arranged downstream of the first inspection station, the first abnormal product storage area is arranged on the side of the first transition area, and the first transition area is provided with a fourth robot arm, and the fourth robot arm is used to transfer the front qualified products to the flipping device or transfer the front unqualified products to the first abnormal product storage area; and / or

[0046] The inspection unit also includes a second abnormal product storage area and a second transition area, wherein the second transition area is arranged downstream of the second inspection station, the second abnormal product storage area is arranged on the side of the second transition area, and the second transition area is provided with a fifth robotic arm, and the fifth robotic arm is used to transfer qualified products on the back side to the second cutting unit or transfer unqualified products on the back side to the first abnormal product storage area.

[0047] Optionally, the turning device comprises:

[0048] A rotating part, wherein the rotating direction of the rotating part is perpendicular to the horizontal direction;

[0049] A plurality of inserts are arranged on the rotating part along the circumference of the rotating part, and a gap between two of the inserts is used to receive the composite rough plate.

[0050] Optionally, the second cutting unit includes:

[0051] a cutting table having a metal sheet detection device; and

[0052] Laser cutting device;

[0053] The control unit is configured to control the laser cutting device to extend the edge of the metal plate detected by the metal plate detection device outward by a predetermined distance and then cut to obtain a finished composite plate.

[0054] Optionally, the composite board production system also includes a packaging unit, which is arranged downstream of the second cutting unit. The packaging unit includes a sixth robotic arm and a packaging table, and the fifth and sixth robotic arms are constructed to transfer the finished composite board to a predetermined position of the packaging table.

[0055] A second aspect of the present application provides a composite sheet production method, the composite sheet production method is used to continuously produce a composite sheet with a metal plate embedded therein, the composite sheet production method comprising:

[0056] Placing a continuous backing sheet on a material preparation table and conveying it longitudinally, and applying a plurality of metal plates longitudinally and at intervals on the backing sheet;

[0057] On the backing sheet, a discontinuous patching sheet is applied between two adjacent metal plates in the longitudinal direction, and a continuous patching sheet is applied at both ends of the metal plate in the transverse direction, so that the discontinuous patching sheet and the continuous patching sheet surround the metal plate;

[0058] Applying a continuous facing sheet to the metal plate so that the metal plate is embedded between the backing sheet and the facing sheet to form a blank;

[0059] hot pressing and shaping the blank into a continuous plate;

[0060] Cutting the continuous plate into composite rough plates;

[0061] Conduct double-sided inspection on the composite rough plate, and send the qualified composite rough plate to the next process, and send the unqualified composite rough plate to the unqualified product storage area;

[0062] Cutting the composite rough board into finished composite boards with predetermined sizes;

[0063] The finished composite board is packaged. BRIEF DESCRIPTION OF THE DRAWINGS

[0064] The following drawings of the present application are used as a part of the present application for understanding the present application. The drawings show the embodiments of the present application and their descriptions, which are used to explain the principle of the present application.

[0065] In the attached figure:

[0066] Figure 1 It is a schematic diagram of a top view module of a composite board production system according to an embodiment of the present application;

[0067] Figure 2 It is a side view schematic diagram of the front half of a composite board production system according to one embodiment of the present application;

[0068] Figure 3 It is a side view schematic diagram of the second half of a composite board production system according to an embodiment of the present application;

[0069] Figure 4 It is a schematic diagram of a longitudinal cutting device in a first cutting unit of a composite board production system according to an embodiment of the present application;

[0070] Figure 5 A schematic diagram of a waste edge cutting device in a first cutting unit of a composite board production system according to an embodiment of the present application;

[0071] Figure 6 It is a schematic diagram of a turning device in a detection unit of a composite board production system according to an embodiment of the present application;

[0072] Figure 7 It is a schematic diagram of the middle cutting positioning method of the second cutting unit of the composite board production system according to one embodiment of the present application. DETAILED DESCRIPTION

[0073] In the following description, a large number of specific details are provided to provide a more thorough understanding of the present application. However, it is obvious to those skilled in the art that the present application can be implemented without one or more of these details. In other examples, in order to avoid confusion with the present application, some technical features well known in the art are not described.

[0074] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should also be understood that when the terms "comprise" and / or "include" are used in this specification, it indicates the presence of the features, wholes, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, wholes, steps, operations, elements, components and / or combinations thereof.

[0075] Ordinal numbers such as "first" and "second" cited in this application are merely identifiers and do not have any other meaning, such as a specific order. Moreover, for example, the term "first component" itself does not imply the existence of a "second component", and the term "second component" itself does not imply the existence of a "first component". It should be noted that the terms "upper", "lower", "front", "back", "left", "right", "inner", "outer" and similar expressions used in this document are for illustrative purposes only and are not limiting.

[0076] Now, refer to Figures 1 to 7 Exemplary embodiments according to the present application are described in more detail.

[0077] The present application provides a composite sheet production system 100 for continuously producing composite sheets with metal sheets embedded therein. Figure 1In an optional embodiment shown, the composite board production system 100 includes a material preparation unit 110 , a composite shaping unit 130 , a first cutting unit 140 , a detection unit 160 , a second cutting unit 170 and a control unit. Optionally, the composite board production system 100 may also have a packaging unit 180 .

[0078] In this embodiment, the composite sheet with the metal plate embedded therein includes a metal plate and at least one sheet material of the upper layer and at least one sheet material of the lower layer. The metal plate is located between the upper cladding sheet and the lower lining sheet, and between the upper cladding sheet and the lower lining sheet, a filler sheet is arranged around the metal plate to avoid the unevenness of the sheet material. More specifically, in some embodiments, the lining sheet may include a first thermoplastic film and a continuous fiber reinforced thermoplastic lining, and the cladding sheet includes a fiber reinforced thermoplastic cladding and a second thermoplastic film.

[0079] Among them, the material preparation unit 110 is used to form the raw materials into blanks. The composite shaping unit 130 is arranged downstream of the material preparation unit 110, and is used to hot press and shape the blank into a continuous plate. The first cutting unit 140 is arranged downstream of the composite shaping unit 130, and is used to cut the continuous plate into a composite rough plate. The detection unit 160 is arranged downstream of the first cutting unit 140, and is used to perform double-sided detection on the composite rough plate, and send the qualified composite rough plate to the next process, and send the unqualified composite rough plate to the unqualified product storage area. The second cutting unit 170 is arranged downstream of the first cutting unit 140, and is used to cut the composite rough plate into a finished composite plate material with a predetermined size. The control unit is connected to the material preparation unit 110, the composite shaping unit 130, the first cutting unit 140, the detection unit 160 and the second cutting unit 170 for overall control of the production process.

[0080] Specifically, refer to Figure 1 and Figure 2 The material preparation unit 110 includes a material preparation platform 111, a continuous sheet unwinding mechanism 112, a metal plate pick-up and placement mechanism 113, and a discontinuous sheet material pick-up and placement mechanism 114. The material preparation platform 111 is provided with a conveying device 121, which can be a belt conveying device to convey the raw materials in the longitudinal direction.

[0081] The continuous sheet material unwinding mechanism 112 is used to discharge the continuous sheet material to the material preparation platform 111. The continuous sheet material unwinding mechanism 112 includes a backing sheet material unwinding mechanism 116, a continuous supplementary sheet material unwinding mechanism 122 and a covering sheet material unwinding mechanism 115.

[0082] The backing sheet unwinding mechanism 116 is disposed upstream of the material preparation platform 111, and is used to apply the backing sheet to the material preparation platform 111. More specifically, the backing sheet unwinding mechanism 116 includes a continuous fiber reinforced thermoplastic backing unwinding mechanism 117 and a first thermoplastic film unwinding mechanism 118, and the continuous fiber reinforced thermoplastic backing unwinding mechanism 117 is located upstream of the first thermoplastic film unwinding mechanism 118, so that the first thermoplastic film unwinding mechanism 118 can apply the first thermoplastic film onto the continuous fiber reinforced thermoplastic backing.

[0083] The metal plate pick-up and placement mechanism 113 and the discontinuous patch sheet pick-up and placement mechanism 114 are respectively arranged on both sides of the material preparation platform 111 in the horizontal direction. The metal plate pick-up and placement mechanism 113 is used to apply metal plates to the material preparation platform 111 along the longitudinal interval, and the discontinuous patch sheet pick-up and placement mechanism 114 is used to apply discontinuous patch sheets to the gaps between adjacent metal plates on the material preparation platform 111. Specifically, the metal plate pick-up and placement mechanism 113 and the discontinuous patch sheet are applied to the backing sheet respectively.

[0084] The metal plate picking and placing mechanism 113 includes a metal plate storage area and a first robot arm, and the first robot arm is configured to transfer the metal plate from the metal plate storage area to the material preparation platform 111. The discontinuous replenishment sheet material picking and placing mechanism 114 includes a discontinuous replenishment sheet material storage area and a second robot arm, and the second robot arm is configured to transfer the discontinuous replenishment sheet material from the discontinuous replenishment sheet material storage area to the material preparation platform 111.

[0085] The continuous filler sheet unwinding mechanism 122 is arranged upstream or above the material preparation platform 111, and is used to apply the continuous filler sheet to both ends of the backing sheet in the transverse direction, so that the metal plate can be located between the two spaced continuous filler sheets. Here, the longitudinal direction can be understood as the running direction of the raw material or plate, and the transverse direction is the direction perpendicular to the longitudinal direction.

[0086] Thus, the two ends of the backing sheet in the width direction or the transverse direction have continuous patching sheets, and the metal plate and the discontinuous patching sheets are arranged between the continuous patching sheets, so that the metal plate, the discontinuous patching sheets and the continuous patching sheets are located in the same layer, and the discontinuous patching sheets and the continuous patching sheets surround the metal plate. Here, the metal plate, the discontinuous patching sheets and the continuous patching sheets can be collectively referred to as a reinforcement layer.

[0087] The facing sheet unwinding mechanism 115 is arranged upstream or above the material preparation table 111, and is used to apply the facing sheet to the metal plate, or to apply the facing sheet on the layer composed of the metal plate, the discontinuous patch sheet and the continuous patch sheet.

[0088] The cladding sheet unwinding mechanism 115 includes a continuous fiber reinforced thermoplastic cladding unwinding mechanism 119 and a second thermoplastic film unwinding mechanism 120. The continuous fiber reinforced thermoplastic cladding unwinding mechanism 119 is located downstream of the second thermoplastic film unwinding mechanism 120, so that the second thermoplastic film unwinding mechanism 120 can apply the second thermoplastic film to the metal plate and the continuous fiber reinforced thermoplastic cladding unwinding mechanism 119 can apply the continuous fiber reinforced thermoplastic cladding to the second thermoplastic film.

[0089] Thus, a continuous fiber reinforced thermoplastic cladding, a second thermoplastic adhesive film, a reinforcing layer, a first thermoplastic adhesive film, and a continuous fiber reinforced thermoplastic backing can be formed from top to bottom.

[0090] The control unit is configured to control the application speed of the metal plate picking and placing mechanism 113 and the discontinuous patch sheet picking and placing mechanism 114 according to the speed at which the material preparation unit 110 conveys the raw materials along the longitudinal direction, so that adjacent metal plates and discontinuous patch sheets can be connected, and control the metal plate picking and placing mechanism 113 and the discontinuous patch sheet picking and placing mechanism 114 to place the metal plates and discontinuous patch sheets to the middle of the continuous sheet along the transverse direction.

[0091] The first robot arm and the second robot arm can be constructed as robot arms with multiple groups of vacuum suction cups capable of vertical suction and horizontal movement, thereby being able to suck and place metal plates or non-continuous patch sheets through the vacuum suction cups.

[0092] Further optionally, the control unit can calculate the running speed of the conveying device 121 of the preparation table 111 and the material thereon based on machine vision (such as a camera, etc.), thereby controlling the above-mentioned first robotic arm and second robotic arm to accurately follow the advancement of the material according to the running speed while placing metal plates or non-continuous filling sheets at the exact position.

[0093] The composite board production system according to the present application can automatically load materials, accurately position and apply continuous sheets, metal plates and patch sheets; and can perform processes such as composite forming of blanks, rough cutting and inspection and sorting of semi-finished products. It has a high degree of automation and strong versatility, reduces manual operations, improves operating efficiency and increases product precision.

[0094] At least one of the above-mentioned continuous fiber reinforced thermoplastic backing unwinding mechanism 117, first thermoplastic film unwinding mechanism 118, continuous fiber reinforced thermoplastic covering unwinding mechanism 119, second thermoplastic film unwinding mechanism 120 or continuous replenishment sheet unwinding mechanism 122 can be constructed as a plurality of unwinding racks arranged in parallel, and the unwinding racks are equipped with magnetic powder brake devices to maintain constant tension output unwinding of each continuous sheet.

[0095] Preferably, one or more of the unwinding racks can be laterally slidably arranged on the base, for example, connected to the base via a screw mechanism, so that the lateral position of the unwinding rack can be adjusted by using the cooperation of the screw and a sprocket (such as a hand-cranked sprocket).

[0096] The composite shaping unit 130 includes a thermal composite device 131, which is longitudinally divided into a preheating zone, a hot mold zone and a cold mold zone, wherein the hot mold zone is located downstream of the preheating zone, and the cold mold zone is located downstream of the hot mold zone.

[0097] Furthermore, the thermal composite device 131 is configured to have an upper mold portion and a lower mold portion, and a minimum distance between the upper mold portion and the lower mold portion can be adjusted, for example, to adjust the spacing of composite belts or composite steel belts.

[0098] As a preferred embodiment, the composite shaping unit 130 further includes a hot air blower and a pressing roller, which are arranged upstream of the thermal composite device 131 to preheat and extrude the laid blank. These two pretreatments are helpful in processing the blank into a size suitable for entering the thermal composite device 131.

[0099] Preferably, a coder 132 may be provided between the composite shaping unit 130 and the first cutting unit 140 to reserve product information on the plate.

[0100] Please refer to the following Figure 1 and Figure 3 The first cutting unit 140 includes a first traction roller 146, a longitudinal cutting device 141, a waste edge cutting device 142, a second traction roller 147, a bending roller 148, a transverse cutting device 145, a discharging platform 150 and a discharging transition roller 149.

[0101] The first traction roller 146 is disposed downstream of the composite shaping unit 130, and is used to pull the continuous plate to the first cutting unit 140, specifically to the longitudinal cutting device 141. The longitudinal cutting device 141 is disposed downstream of the first traction roller 146 and upstream of the transverse cutting device 145, and is used to cut the edges of the continuous plate on both sides along the transverse direction. Figure 4 , the longitudinal cutting device 141 includes a first cutting knife assembly 151 and a second cutting knife assembly 152. The first cutting knife assembly 151 and the second cutting knife assembly 152 are arranged up and down along the height direction. For example, the first cutting knife assembly 151 is arranged on the upper side, and the second cutting knife assembly 152 is arranged on the lower side. The first cutting knife assembly 151 includes a first cutting knife shaft 153 and two first cutting discs 154, and the first cutting disc 154 is arranged at the end of the first cutting knife shaft 153. The second cutting knife assembly 152 includes a second cutting knife shaft 155 and two second cutting discs 156, and the second cutting disc 156 is arranged at the end of the second cutting knife shaft 155. The first cutting disc 154 and the second cutting disc 156 can rotate.

[0102] As an optional embodiment, the first cutter disc 154 is fixedly connected to the first cutter shaft 153, and the second cutter disc 156 is fixedly connected to the second cutter shaft 155, and the rotation of the first cutter shaft 153 and the second cutter shaft 155 respectively drives the first cutter disc 154 and the second cutter disc 156 to rotate. As another optional embodiment, the first cutter disc 154 is rotatably disposed on the first cutter shaft 153, and the second cutter disc 156 is rotatably disposed on the second cutter shaft 155, so that the cutter discs can be directly driven to rotate by the relevant driving mechanism.

[0103] The projections of the first cutter disc 154 and the second cutter disc 156 on a vertical plane perpendicular to the horizontal direction at least partially overlap, and the first cutter disc 154 and the second cutter disc 156 on the same side in the horizontal direction are arranged close to each other in the horizontal direction. Thus, staggered shearing of the upper and lower cutter discs is formed, so that the waste edges can be cut continuously in the longitudinal direction by rotating the cutter discs. Figure 4 In the illustrated embodiment, the two first blade discs 154 are disposed inside the two second blade discs 156. In an embodiment not shown, the two first blade discs 154 may also be disposed outside the two second blade discs 156. Alternatively, the first blade disc 154 on one side along the lateral direction is inside and the second blade disc 156 is outside; the first blade disc 154 on the other side is outside and the second blade disc 156 is inside, or vice versa. Specifically, the ends of the first blade disc 154 and the second blade disc 156 on the opposite side overlap approximately at the middle height position of the plate.

[0104] In order to process the cut continuous waste edges, preferably, a waste edge cutting device 142 is respectively provided on both sides of the longitudinal cutting device 141 in the transverse direction, and the waste edge cutting device 142 is used to cut off the waste edges cut by the longitudinal cutting device 141. Figure 5 The scrap cutting device 142 includes a hob mechanism, which includes a hob shaft 143 and a plurality of hob blades 144 arranged along the circumference of the hob shaft 143, and the blades of the hob blades 144 extend in the transverse direction. When the hob mechanism rotates in a backward direction, or in other words, in a direction opposite to the forward direction of the material, for example, in a counterclockwise direction in the figure, the plurality of hob blades 144 can successively cut the continuous scrap into small segments for easy collection and recycling.

[0105] The second traction roller 147 is arranged downstream of the longitudinal cutting device 141, and is used to convey the continuous plate to the transverse cutting device 145 at a fixed length. The transverse cutting device 145 is arranged downstream of the second traction roller 147, and is used to cut the continuous plate into a composite rough plate between adjacent metal plates of the continuous plate. The transverse cutting device 145 has a punch-type tool, which is configured to be able to move vertically, and the blade of the punch-type tool extends in the transverse direction, so that the continuous plate can be cut in its width direction or in the transverse direction by lifting and lowering the punch-type tool.

[0106] However, since the punch-type tool will block the upstream continuous plate from continuing to move forward after cutting off the continuous plate in the descending state, it is preferred to set an arching roller 148 between the transverse cutting device 145 and the second traction roller 147. The arching roller 148 is at least partially configured to be able to move up and down, so that the control unit can be configured to control the lifting frequency of the arching roller 148 according to the cutting frequency of the punch-type tool to partially arch the continuous plate when the punch-type tool blocks the continuous plate from moving, thereby allowing the upstream continuous plate to continue to move forward, ensuring the normal operation of the assembly line and realizing continuous production of the plate.

[0107] The discharging transition roller 149 is arranged downstream of the transverse cutting device 145, and the discharging platform 150 is arranged downstream of the discharging transition roller 149. The discharging transition roller 149 is used to pull the composite rough board to the discharging platform 150. The discharging platform 150 is provided with a third mechanical arm, and the third mechanical arm is used to transfer the composite rough board to the detection unit 160.

[0108] Continue to refer Figure 1 The detection unit 160 includes a first detection station 161, a first transition area 163, a first abnormal product storage area 162, a turning device 164, a second detection station 167, a second abnormal product storage area 168 and a second transition area 169.

[0109] The first inspection station 161 is arranged downstream of the first cutting unit 140 and is used to inspect the front side of the composite rough plate. The first transition zone 163 is arranged downstream of the first inspection station 161, and the first abnormal product storage area 162 is arranged on the side of the first transition zone 163. The first transition zone 163 is provided with a fourth robot arm, which is used to transfer the front qualified products to the flip device 164 or transfer the front unqualified products to the first abnormal product storage area 162.

[0110] The flipping device 164 is arranged downstream of the first inspection station 161, specifically, downstream of the first transition zone 163, and is used to flip the composite rough plate. The fourth robot arm is also used to transfer the front qualified products to the flipping device 164. The specific structure of the flipping device 164 can be referred to Figure 6 , which includes a rotating part 165 and a plurality of inserts 166. The plurality of inserts 166 are arranged on the rotating part 165 along the circumference of the rotating part 165, and the gap between two inserts 166 is used to receive the composite rough plate. The rotating direction of the rotating part 165 is perpendicular to the horizontal direction, or the rotating part 165 can rotate along the forward direction of the material, so that the composite rough plate can be turned over and transferred to the next station at the same time.

[0111] The second inspection station 167 is arranged downstream of the flipping device 164 and is used to inspect the back side of the composite rough plate. The second transition zone 169 is arranged downstream of the second inspection station 167, and the second abnormal product storage area 168 is arranged on the side of the second transition zone 169. The second transition zone 169 is provided with a fifth robot arm, which is used to transfer the qualified products on the back side to the second cutting unit 170 or transfer the unqualified products on the back side to the second abnormal product storage area 168.

[0112] Among them, the flipping device 164 can directly transfer the composite rough plate to the second inspection station 167, or a seventh robot arm can be set between the second inspection station 167 and the flipping device 164, so as to transfer the composite rough plate to the second inspection station 167 through the seventh robot arm.

[0113] The first inspection station 161 and the second inspection station 167 adopt integrated online inspection, and dynamically scan the surface of the running composite rough plate through a high-precision camera, and compare it with the qualified drawing pre-set and stored in the control unit to determine whether there are surface defects or flaws, and then determine whether the composite rough plate is a qualified product or a defective product. Therefore, the defective products can be output in the first abnormal product storage area 162 or the second abnormal product storage area 168.

[0114] Continue to refer to Figure 1 The second cutting unit 170 includes a cutting table and a laser cutting device. The cutting table has a metal plate detection device. The control unit is configured to control the laser cutting device to extend the edge of the metal plate detected by the metal plate detection device outward by a predetermined distance to cut the finished composite plate. That is, based on the known size of the metal plate, the four sides of the rectangular metal plate are used as reference lines, and a certain distance is extended outward from the four sides of the metal plate to perform precise cutting to cut off the redundant parts. Specifically, refer to Figure 7 The second cutting unit 170 can adopt a three-point edge-finding cutting method, that is, by moving through laser positioning to find a positioning point of the metal plate, and then find the second positioning point on the same side after recording, and then find the third positioning point on the adjacent side after recording, so as to accurately confirm one edge of the metal plate, or directly confirm the exact position of the metal plate on the premise of knowing the precise size of the metal plate.

[0115] Optionally, the packaging unit 180 of the composite board production system 100 is arranged downstream of the second cutting unit 170, and the packaging unit 180 includes a sixth robot arm and a packaging table. The sixth robot arm is configured to transfer the finished composite board to a predetermined position of the packaging table for final packaging.

[0116] The third robot arm, the fourth robot arm, the fifth robot arm, the sixth robot arm and the seventh robot arm can also be constructed in a similar structure to the first robot arm and the second robot arm, that is, a robot arm with multiple sets of vacuum suction cups that can vertically absorb and move horizontally.

[0117] According to the composite board production system of the present application, automated robotic arm handling is added, such as automation in the handling and placement of metal boards, automated handling at the finished product unloading point, etc., which reduces manual work; and the front and back sides of the composite boards are inspected through online detection units to reduce manual flipping, improve work efficiency and labor intensity; in addition, a conveying port for abnormal products is added after detection, so that unqualified products can be output in a timely manner, improving the operating efficiency of the entire production line.

[0118] The second aspect of the present application provides a composite sheet production method, which is used to continuously produce a composite sheet with a metal plate embedded therein. The composite sheet production method comprises the following steps:

[0119] A continuous backing sheet is placed on a preparation table and conveyed longitudinally, and a plurality of metal plates are applied on the backing sheet at intervals longitudinally.

[0120] On the backing sheet, a discontinuous patching sheet is applied between two metal plates adjacent in the longitudinal direction, and a continuous patching sheet is applied at both ends of the metal plate in the transverse direction, so that the discontinuous patching sheet and the continuous patching sheet surround the metal plate.

[0121] A continuous facing sheet is applied to the metal plate so that the metal plate is embedded between the backing sheet and the facing sheet and forms a blank.

[0122] The blank is hot pressed and shaped to form a continuous sheet.

[0123] The continuous plate is cut into composite rough plates.

[0124] The composite rough board is inspected on both sides, and the qualified composite rough board is sent to the next process, and the unqualified composite rough board is sent to the unqualified product storage area.

[0125] The composite rough board is cut into finished composite boards with predetermined sizes.

[0126] Packing of finished composite panels.

[0127] Unless otherwise defined, the technical and scientific terms used herein have the same meaning as those generally understood by those skilled in the art of the present application. The terms used herein are only for describing specific implementation purposes and are not intended to limit the present application. The features described herein in one embodiment may be applied to another embodiment individually or in combination with other features, unless the feature is not applicable or otherwise specified in the other embodiment.

[0128] The present application has been illustrated through the above-mentioned embodiments, but it should be understood that the above-mentioned embodiments are only for the purpose of example and explanation, and the present application is not limited to the above-mentioned embodiments. According to the teachings of the present application, more variations and modifications can be made, and these variations and modifications all fall within the scope of protection claimed by the present application.

Claims

1. A composite board production system, characterized in that: The composite sheet production system is used for continuously producing composite sheets with metal plates embedded therein, and the composite sheet production system comprises: A material preparation unit is used to form a blank from raw materials, and the material preparation unit comprises: A material preparation platform, which can lay and transport raw materials in the longitudinal direction; A continuous sheet unwinding mechanism, used for delivering the continuous sheet to the material preparation table; A metal plate picking and placing mechanism is arranged on one side of the material preparation platform along the transverse direction, wherein the transverse direction is orthogonal to the longitudinal direction, and is used for placing the metal plates onto the material preparation platform along the longitudinal direction at intervals; A discontinuous patch sheet material taking and placing mechanism is arranged on the other side of the material preparation platform along the transverse direction, and is used for placing discontinuous patch sheets into the gaps between the adjacent metal plates along the longitudinal direction of the material preparation platform; A composite shaping unit, disposed downstream of the material preparation unit, for hot pressing and shaping the blank into a continuous plate; A first cutting unit is arranged downstream of the composite shaping unit, the first cutting unit comprises a transverse cutting device, the transverse cutting device is used to cut the continuous plate into composite rough plates between the adjacent metal plates of the continuous plate; an inspection unit, disposed downstream of the first cutting unit, for performing double-sided inspection on the composite rough board, and sending qualified composite rough boards to the next process, and sending unqualified composite rough boards to an unqualified product storage area; and A control unit, wherein the control unit is respectively connected to signals of the material preparation unit, the composite shaping unit, the first cutting unit and the detection unit, and the control unit is configured to control the application speed of the metal plate picking and placing mechanism and the non-continuous patch sheet material picking and placing mechanism according to the speed at which the material preparation unit conveys the raw materials along the longitudinal direction, so that adjacent metal plates and non-continuous patch sheet materials can be connected, and control the metal plate picking and placing mechanism and the non-continuous patch sheet material picking and placing mechanism to place the metal plates and the non-continuous patch sheet materials to the middle of the continuous sheet material along the transverse direction.

2. The composite board production system according to claim 1, characterized in that: The metal plate picking and placing mechanism comprises a metal plate storage area and a first mechanical arm, wherein the first mechanical arm is configured to transfer the metal plate from the metal plate storage area to the material preparation table; The discontinuous replenishment sheet material taking and placing mechanism comprises a discontinuous replenishment sheet material storage area and a second robot arm, wherein the second robot arm is configured to transfer the discontinuous replenishment sheet material from the discontinuous replenishment sheet material storage area to the material preparation station.

3. The composite board production system according to claim 1, characterized in that: The continuous sheet unwinding mechanism of the material preparation unit comprises: A backing sheet unwinding mechanism is arranged upstream of the material preparation platform and is used to apply the backing sheet to the material preparation platform, wherein the metal plate taking and placing mechanism is used to apply the metal plate onto the backing sheet; a continuous patching sheet unwinding mechanism, disposed upstream or above the material preparation platform, for applying continuous patching sheets to both ends of the backing sheet along the transverse direction, so that the metal plate can be located between two spaced continuous patching sheets; and The facing sheet material unwinding mechanism is arranged upstream or above the material preparation platform and is used for applying the facing sheet material onto the metal plate.

4. The composite board production system according to claim 3, characterized in that: The substrate sheet unwinding mechanism includes a continuous fiber reinforced thermoplastic substrate unwinding mechanism and a first thermoplastic film unwinding mechanism, wherein the continuous fiber reinforced thermoplastic substrate unwinding mechanism is located upstream of the first thermoplastic film unwinding mechanism so that the first thermoplastic film unwinding mechanism can apply the first thermoplastic film to the continuous fiber reinforced thermoplastic substrate.

5. The composite board production system according to claim 3, characterized in that: The cladding sheet unwinding mechanism comprises a continuous fiber reinforced thermoplastic cladding unwinding mechanism and a second thermoplastic film unwinding mechanism, wherein the continuous fiber reinforced thermoplastic cladding unwinding mechanism is located downstream of the second thermoplastic film unwinding mechanism, so that the second thermoplastic film unwinding mechanism can apply the second thermoplastic film onto the metal plate and the continuous fiber reinforced thermoplastic cladding unwinding mechanism can apply the continuous fiber reinforced thermoplastic cladding onto the second thermoplastic film.

6. The composite board production system according to claim 1, characterized in that: The composite shaping unit includes a thermal composite device, which includes a preheating zone, a hot mold zone and a cold mold zone arranged in the longitudinal direction, wherein the hot mold zone is located downstream of the preheating zone, the cold mold zone is located downstream of the hot mold zone, and the thermal composite device is constructed to have an upper mold part and a lower mold part, and the minimum distance between the upper mold part and the lower mold part can be adjusted.

7. The composite board production system according to claim 6, characterized in that: The composite shaping unit further comprises a pressing roller and a hot air blower, wherein the pressing roller and the hot air blower are arranged upstream of the thermal composite device to pre-process the blank into a size suitable for entering the thermal composite device.

8. The composite board production system according to any one of claims 1 to 7, characterized in that: The first cutting unit also includes: a first traction roller, disposed downstream of the composite shaping unit, for pulling the continuous plate to the first cutting unit; a longitudinal cutting device, arranged upstream of the transverse cutting device, for cutting the edges of the continuous plate on both sides along the transverse direction; and Two waste edge cutting devices are respectively arranged on both sides of the longitudinal cutting device and are used to cut off the waste edges cut off by the longitudinal cutting device.

9. The composite board production system according to claim 8, characterized in that: The longitudinal cutting device includes a first cutting knife assembly and a second cutting knife assembly which are arranged up and down along the height direction, the first cutting knife assembly includes a first cutting knife shaft and two first cutting discs, the first cutting disc is arranged at the end of the first cutting knife shaft, the second cutting knife assembly includes a second cutting knife shaft and two second cutting discs, the second cutting disc is arranged at the end of the second cutting knife shaft, wherein the first cutting disc and the second cutting disc are rotatable, the projections of the first cutting disc and the second cutting disc on a vertical plane perpendicular to the horizontal direction at least partially overlap, and the first cutting disc and the second cutting disc located on the same side are arranged close to each other along the horizontal direction.

10. The composite board production system according to claim 8, characterized in that: The scrap edge cutting device comprises a rolling cutter mechanism, wherein the rolling cutter mechanism comprises a rolling cutter shaft and a plurality of rolling cutters arranged along the circumference of the rolling cutter shaft, wherein the cutting edges of the rolling cutters extend along the transverse direction.

11. The composite board production system according to claim 8, characterized in that: The first cutting unit also includes: The second traction roller is arranged downstream of the longitudinal cutting device and is used to convey the continuous plate to the transverse cutting device at a fixed length. A bending roller, disposed between the transverse cutting device and the second pulling roller, wherein at least a portion of the bending roller is configured to be movable up and down; The control unit is further configured to control the lifting and lowering frequency of the arching roller according to the cutting frequency of the transverse cutting device so as to arch the continuous plate portion when the transverse cutting device cuts and blocks the movement of the continuous plate.

12. The composite board production system according to claim 6, characterized in that: The first cutting unit also includes: A discharging platform is arranged downstream of the transverse cutting device, and a third mechanical arm is arranged at the discharging platform, and the third mechanical arm is used to transfer the composite rough plate to the detection unit; A discharging transition roller is arranged between the discharging platform and the transverse cutting device, and is used for pulling the composite rough plate to the discharging platform.

13. The composite board production system according to any one of claims 1 to 7, characterized in that: The detection unit comprises: A first inspection station, disposed downstream of the first cutting unit, for inspecting the front side of the composite rough board; A turning device, disposed downstream of the first inspection station, for turning over the composite rough plate; The second inspection station is arranged downstream of the turning device and is used for inspecting the reverse side of the composite rough plate.

14. The composite board production system according to claim 13, characterized in that: The composite board production system also includes a second cutting unit, which is arranged downstream of the detection unit. The second cutting unit is used to cut the composite rough board that has passed the detection into finished composite boards with predetermined sizes. The control unit is also connected to the second cutting unit signal.

15. The composite board production system according to claim 14, characterized in that: The inspection unit also includes a first abnormal product storage area and a first transition area, wherein the first transition area is arranged downstream of the first inspection station, the first abnormal product storage area is arranged on the side of the first transition area, and the first transition area is provided with a fourth robotic arm, and the fourth robotic arm is used to transfer the front qualified products to the flipping device or transfer the front unqualified products to the first abnormal product storage area.

16. The composite board production system according to claim 14, characterized in that: The inspection unit also includes a second abnormal product storage area and a second transition area, wherein the second transition area is arranged downstream of the second inspection station, the second abnormal product storage area is arranged on the side of the second transition area, and the second transition area is provided with a fifth robotic arm, and the fifth robotic arm is used to transfer qualified products on the back side to the second cutting unit or transfer unqualified products on the back side to the second abnormal product storage area.

17. The composite board production system according to claim 13, characterized in that: The turning device comprises: A rotating part, wherein the rotating direction of the rotating part is perpendicular to the horizontal direction; A plurality of inserts are arranged on the rotating part along the circumference of the rotating part, and a gap between two of the inserts is used to receive the composite rough plate.

18. The composite board production system according to claim 14, characterized in that: The second cutting unit comprises: a cutting table having a metal sheet detection device; and Laser cutting device; The control unit is configured to control the laser cutting device to extend the edge of the metal plate detected by the metal plate detection device outward by a predetermined distance and then cut to obtain a finished composite plate.

19. The composite board production system according to claim 14, characterized in that: The composite board production system also includes a packaging unit, which is arranged downstream of the second cutting unit. The packaging unit includes a sixth robotic arm and a packaging table. The sixth robotic arm is configured to transfer the finished composite board to a predetermined position of the packaging table.

20. A method for producing a composite board, characterized in that: The composite sheet production method is used to continuously produce composite sheets with metal plates embedded therein on a composite sheet production system according to any one of claims 1 to 19, and the composite sheet production method comprises: Placing a continuous backing sheet on a material preparation table and conveying it longitudinally, and applying a plurality of metal plates longitudinally and at intervals on the backing sheet; On the backing sheet, a discontinuous patching sheet is applied between two adjacent metal plates in the longitudinal direction, and a continuous patching sheet is applied at both ends of the metal plate in the transverse direction, so that the discontinuous patching sheet and the continuous patching sheet surround the metal plate; Applying a continuous facing sheet to the metal plate so that the metal plate is embedded between the backing sheet and the facing sheet to form a blank; hot pressing and shaping the blank into a continuous plate; Cutting the continuous plate into composite rough plates; Conduct double-sided inspection on the composite rough plate, and send the qualified composite rough plate to the next process, and send the unqualified composite rough plate to the unqualified product storage area; Cutting the composite rough board into finished composite boards with predetermined sizes; The finished composite board is packaged.

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