Foam forming machine and foam forming control system

Abstract

The invention relates to the technical field of foam forming machines, in particular to a foam forming machine and a foam forming control system. The conveying assembly is arranged below the forming assembly, and the conveying assembly is used for conveying the formed foam products; the conveying assembly comprises a conveying belt, the conveying belt is arranged under the forming assembly, and multiple sets of through holes are formed in the surface of the conveying belt. The conveying belt is supported through an inner supporting box body, a negative pressure machine used for generating negative pressure is arranged in the inner supporting box body, and the negative pressure is generated through the negative pressure machine to adsorb and transport formed foam. After the foam board falls every time, the protection net is made of an elastic material and can prevent the foam board from being damaged, the bottom opening of the protection net is slightly larger than the foam board in size, the foam board is buffered through the protection net in the falling process, the falling speed of the foam board is slowed down, and formation of the foam board in the falling process is reduced; and the foam board is protected, and the phenomenon that foam is damaged is avoided.

Description

Technical Field

[0001] The invention relates to the technical field of foam molding machines, in particular to a foam molding machine and a foam molding control system. Background Art

[0002] Foam molding machines are mechanical equipment used to process raw materials such as expandable polystyrene (EPS) into foam products. They are widely used in industries such as packaging, construction, furniture, electronics, automotive, and cold chain logistics. They operate by using high-temperature melting, foaming, and molding processes to produce lightweight, high-strength foam products with cushioning and thermal insulation properties.

[0003] During the transportation of home appliances, foam boards are usually padded in the box to provide support and prevent the appliances from being damaged by bumps. When the foam boards are produced and formed, foam particles are sucked into the mold in the foam molding machine for molding. The formed foam boards will be ejected from the bottom of the foam molding machine. During the production process, the foam boards are 90cm-100cm away from the ground. During the falling process, the foam boards may come into contact with the bottom edge and surrounding hard objects, causing damage to the edges and corners, affecting the yield and the integrity of the foam boards. Summary of the Invention

[0004] In view of the problems in the prior art, the present invention provides a foam molding machine and a foam molding control system.

[0005] The technical solution adopted by the present invention to solve its technical problem is: a foam molding machine, including a molding component;

[0006] The conveying assembly is placed below the molding assembly and is used to convey the molded foam product;

[0007] Conveyor belt, the conveying assembly includes a conveyor belt, the conveyor belt is placed directly below the forming assembly, and a plurality of through holes are opened on the surface of the conveyor belt;

[0008] Inner support box; the conveyor belt is supported by the inner support box, and a negative pressure machine for generating negative pressure is provided in the inner support box, and the negative pressure generated by the negative pressure machine is used to adsorb and transport the formed foam.

[0009] Preferably, a layer of silicone sheet is provided on the surface of the conveyor belt, and through holes adapted to the conveyor belt are provided on the surface of the silicone sheet, and the thickness of the silicone sheet is 4mm-6mm.

[0010] Preferably, a through hole is opened on one side of the inner support box body, the exhaust port of the negative pressure machine is adapted to the through hole, and an air pipe is provided at the air intake of the negative pressure machine.

[0011] Preferably, sealing strips are fixedly connected to both ends of the upper surface of the negative pressure machine, and the sealing strips, the negative pressure machine, the inner support box and the conveyor belt form a closed space.

[0012] Preferably, the inner support box body is sealed at its connection with the negative pressure machine and the conveyor belt.

[0013] Preferably, two groups of side support protrusions are fixedly connected to the outer side of the conveyor belt, and a pushing grid is fixedly connected to the middle part of each group of side support protrusions.

[0014] Preferably, the pushing grid is made of rubber, and the projection of the side wall of the pushing grid is trapezoidal.

[0015] Preferably, a protective net is fixedly connected to the bottom of the molding component, the protective net is made of elastic material, a wire cover is provided at the bottom of the protective net, and a drawstring is connected inside the wire cover;

[0016] Pulling the drawstring changes the size of the bottom opening of the protective net.

[0017] Preferably, a support frame is provided at the bottom of the forming assembly for support, and a guide groove is provided on the side wall of the support frame; a partition is fixedly connected in the guide groove.

[0018] Preferably, a servo motor is fixedly connected to the lower surface of the partition, a threaded rod is fixedly connected to the output end of the servo motor, a movable plate frame is sleeved on the outer wall of the threaded rod, and the movable plate frame is fixedly connected to the outer wall of the inner support box.

[0019] The present invention also provides a foam forming control system, comprising a central controller, a multimodal sensor array, an actuator and a human-computer interaction interface;

[0020] The central controller integrates a PLC or microprocessor, communicates with the cloud data platform, and supports real-time parameter adjustment and historical data tracing;

[0021] The multimodal sensor array includes an infrared image sensor, a pressure sensor, and a temperature sensor;

[0022] The actuator includes a variable frequency foaming pump, a hydraulic ejection device and a pneumatic valve group, which respectively control the raw material injection rate, mold opening and closing and demoulding actions;

[0023] The human-computer interaction interface supports foam parameter preset and real-time status visualization.

[0024] Preferably, the actuator includes a demoulding member including a flexible push plate, a negative pressure adsorption module and a liftable buffer platform;

[0025] The flexible push plate fits the inner wall of the mold and is driven by a servo motor with a programmable push speed (0.1-5cm / s);

[0026] Negative pressure adsorption module, the adsorption force is dynamically adjusted according to the weight of the foam to prevent local tearing during demoulding;

[0027] The height of the buffer platform can be automatically adjusted according to the position of the mold. After receiving the demoulding foam, it is output smoothly through the conveyor belt, and the falling height is ≤10cm.

[0028] Beneficial effects of the present invention:

[0029] (1) The foam forming machine and foam forming control system described in the present invention are different from the prior art. After each foam board is lowered, the protective net is made of elastic material to avoid damage to the foam board. The bottom opening of the protective net is slightly larger than the size of the foam board. During the descent of the foam board, the protective net is first used to buffer the board, slowing down the descent speed of the foam board. The conveyor belt is controlled to be about 10 cm away from the foam board outlet at the bottom of the forming component, reducing the stroke of the foam board during the descent process, protecting the foam board, and avoiding damage to the foam.

[0030] (2) The foam forming machine and foam forming control system described in the present invention adjust the conveyor belt to a position with the same thickness as the foam board when conveying the foam board for the second time, and convey the second foam board so that the second foam board is just stacked on top of the first foam board, thereby achieving the effect of automatic stacking.

[0031] (3) In the foam forming machine and foam forming control system described in the present invention, the silicone sheet can play a buffering role to prevent the foam board from being damaged. When the silicone sheet contacts and squeezes the foam board, the silicone sheet will be deformed by the squeezing, thereby achieving sealing at the contact position. During the operation of the negative pressure machine, air leakage at the adsorption position is avoided, which is beneficial to the smooth transportation of the foam board. When one end of the foam board leaks out of the conveyor belt, it can prevent the foam board from tilting and warping, which plays a key role in the smooth transportation of the foam board. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] The present invention will be further described below with reference to the accompanying drawings and examples.

[0033] Figure 1 It is a schematic diagram of the overall structure of the present invention;

[0034] Figure 2 A three-dimensional diagram of a single foam forming machine of the present invention;

[0035] Figure 3 For the present invention Figure 2 Schematic diagram of the structure at A in the middle;

[0036] Figure 4 This is a diagram of the position of the push grid of the present invention;

[0037] Figure 5This is a diagram showing the positions of the conveyor belt and the silicone sheet of the present invention;

[0038] Figure 6 This is a schematic diagram of the three-dimensional structure of the protection net of the present invention;

[0039] Figure 7 This is a diagram showing the interior of the inner support box of the present invention.

[0040] In the figure: 100, forming assembly; 101, support frame; 102, threaded rod; 103, partition; 104, servo motor; 105, movable plate frame;

[0041] 200, conveyor assembly; 201, conveyor belt; 202, silicone sheet; 203, inner support box; 206, edge; 210, push grid; 211, side support protrusion; 220, negative pressure machine; 221, air pipe; 222, sealing strip;

[0042] 300. Protective net; 301. Wire cover; 302. Pull rope. DETAILED DESCRIPTION

[0043] In order to make the technical means, creative features, objectives and effects achieved by the present invention easier to understand, the present invention is further described below in conjunction with specific implementation methods.

[0044] like Figure 1-Figure 7 As shown, a foam forming machine of the present invention includes a forming assembly 100;

[0045] The conveying assembly 200 is placed below the molding assembly 100 and is used to convey the molded foam product;

[0046] Conveyor belt 201, the conveyor assembly 200 includes a conveyor belt 201, the conveyor belt 201 is placed directly below the molding assembly 100, and a plurality of through holes are opened on the surface of the conveyor belt 201;

[0047] Inner support box 203; the conveyor belt 201 is supported by the inner support box 203, and a negative pressure machine 220 for generating negative pressure is provided in the inner support box 203. The negative pressure generated by the negative pressure machine 220 is used to adsorb and transport the formed foam.

[0048] Through the setting of the molding component 100, the foam raw material can be processed into a preset shape. After the molding is completed, it is pushed out through the bottom of the molding component 100. After being pushed out, the foam board falls to the upper surface of the conveyor belt 201. The foam board is slowly pushed out and placed by the rotation of the conveyor belt 201. The position of the conveyor belt 201 can be moved up and down. After each foam board completes the fall, the conveyor belt 201 is controlled at a position about 10 cm away from the foam board outlet at the bottom of the molding component 100, reducing the stroke of the foam board during the falling process, protecting the foam board, and avoiding damage to the foam.

[0049] During the pushing process, the negative pressure machine 220 can continuously keep the foam board and the upper surface of the conveyor belt 201 in an adsorption state, so that the foam board can be continuously in a horizontal state during the pushing process. After adjusting the conveyor belt 201 to an appropriate height, the foam boards can also be stacked when they are pushed out.

[0050] As a technical optimization solution of the present invention, a layer of silicone sheet 202 is provided on the surface of the conveyor belt 201. The surface of the silicone sheet 202 is provided with through holes adapted to the conveyor belt 201. The thickness of the silicone sheet 202 is 4mm-6mm.

[0051] Silicone sheet 202 has excellent flexibility, can be bent and folded without breaking, and can quickly return to its original shape. Silicone sheet 202 has a thickness of 4mm-6mm. When the foam board falls, silicone sheet 202 can act as a cushion to prevent damage to the foam board. When silicone sheet 202 contacts and squeezes the foam board, it will deform due to the squeeze, achieving a seal at the contact point. During the operation of negative pressure machine 220, it prevents air leakage at the adsorption point, which facilitates the smooth transportation of the foam board. When one end of the foam board leaks out of conveyor belt 201, it can prevent the foam board from tilting and warping, playing a key role in the smooth transportation of the foam board.

[0052] As a technical optimization solution of the present invention, a through hole is opened on one side of the inner support box 203, the exhaust port of the negative pressure machine 220 is adapted to the through hole, and an air pipe 221 is provided at the air intake of the negative pressure machine 220.

[0053] The initial stop position of the conveyor belt 201 makes the air inlet of the negative pressure machine 220 coincide with the through hole of the conveyor belt 201. At this time, the adsorption force is optimal, and the foam board can be adsorbed and fixed at the fastest speed.

[0054] Sealing strips 222 are fixedly connected to both ends of the upper surface of the negative pressure machine 220 , and a space is formed by the sealing strip 222 , the negative pressure machine 220 , the inner support box 203 and the conveyor belt 201 .

[0055] During the entire process of pushing the foam board, the negative pressure machine 220 continues to work, and there is a pressure difference between the inside and outside of the space formed by the sealing strip 222, the negative pressure machine 220, the inner support box 203 and the conveyor belt 201. The bottom of the foam board is continuously adsorbed through the pressure difference until all the through holes on the surface of the conveyor belt 201 are moved out from between the two sealing strips 222.

[0056] As a technical optimization solution of the present invention, the connections between the inner support box 203 and the negative pressure machine 220 and the conveyor belt 201 are all sealed.

[0057] The connection position is sealed with sealant to avoid air leakage. When the foam board is transported, the stability of the foam board is maintained during the transportation process. When more than half of the overall length of the foam board is placed outside the conveyor belt 201, the foam board is still in a horizontal state, which can stably ensure the stability of the stacking of the foam board during transportation.

[0058] Protruding edges 206 are provided on both sides of the conveyor belt 201 to limit the foam board.

[0059] As a technical optimization solution of the present invention, two sets of side support protrusions 211 are fixedly connected to the outside of the conveyor belt 201, and the middle part of each set of side support protrusions 211 is fixedly connected to a push grid 210. The push grid 210 is made of rubber, and the side wall projection of the push grid 210 is trapezoidal.

[0060] The pushing grid 210 is made of rubber and can be stretched when following the conveyor belt 201 to move to the bending position. The pushing grid 210 can limit the foam board so that the foam board falls above the through hole of the conveyor belt 201. The pushing grid 210 can also prevent the foam board and the conveyor belt 201 from slipping, causing the foam board to stay on the conveyor belt 201 for a long time.

[0061] As a technical optimization solution of the present invention, a protective net 300 is fixedly connected to the bottom of the molding assembly 100. The protective net 300 is made of elastic material. A wire cover 301 is provided at the bottom of the protective net 300. A pull rope 302 is connected to the wire cover 301.

[0062] Pulling the pull rope 302 changes the size of the bottom opening of the protection net 300 .

[0063] By pulling the pull rope 302, the size of the protective net 300 can be changed. The protective net 300 is made of elastic material to avoid damage to the foam board. The bottom opening of the protective net 300 is slightly larger than the size of the foam board. During the descent of the foam board, it is first buffered by the protective net 300 to slow down the descent speed of the foam board, and then the foam board falls to the upper surface of the conveyor belt 201, further slowing down the falling speed of the foam board. The protective net 300 can also play a guiding role, and can make the foam board fall to the through hole of the conveyor belt 201 during the descent.

[0064] As a technical optimization solution of the present invention, a support frame 101 is provided at the bottom of the molding assembly 100 for supporting, and a guide groove is provided on the side wall of the support frame 101; a partition 103 is fixedly connected in the guide groove;

[0065] A servo motor 104 is fixedly connected to the lower surface of the partition 103 , and a threaded rod 102 is fixedly connected to the output end of the servo motor 104 . A movable plate frame 105 is sleeved on the outer wall of the threaded rod 102 , and the movable plate frame 105 is fixedly connected to the outer wall of the inner support box 203 .

[0066] During the foam board conveying process, the output shafts of multiple servo motors 104 are controlled to rotate at the same time. The output end of the servo motor 104 drives the threaded rod 102 to rotate during the rotation. The threaded rod 102 can make the movable plate frame 105 slide along the guide groove during the rotation. The movable plate frame 105 can drive the inner support box 203 to move during the sliding process. The conveyor belt 201 is adjusted to a position about 10 cm away from the foam board outlet at the bottom of the forming assembly 100 through the inner support box 203. After the foam board falls, the conveyor belt 201 is controlled to move downward. At this time, the foam board slides out of the protective net 300, and then the conveyor belt 201 is controlled to move to the lowest point to convey the foam board out.

[0067] When the foam board is conveyed for the second time, the conveyor belt 201 is adjusted to a position with the same thickness as the foam board, and the second foam board is conveyed so that the second foam board is just stacked on top of the first foam board, achieving the effect of automatic stacking.

[0068] A foam forming control system comprises the following steps: a central controller, a multimodal sensor array, an actuator and a human-machine interface;

[0069] The central controller integrates a PLC or microprocessor, communicates with the cloud data platform, and supports real-time parameter adjustment and historical data tracing;

[0070] The multimodal sensor array includes an infrared image sensor (for monitoring foam density and surface integrity), a pressure sensor (for detecting pressure inside the mold), and a temperature sensor (for monitoring temperature gradient during the foaming process);

[0071] The actuator includes a variable frequency foaming pump, a hydraulic ejection device and a pneumatic valve group, which respectively control the raw material injection rate, mold opening and closing and demoulding actions;

[0072] The human-computer interaction interface supports foam parameter preset (such as density, thickness, and molding cycle) and real-time status visualization.

[0073] Achieve closed-loop control of the entire foam molding process, reducing the scrap rate to below 5%;

[0074] Through multi-sensor collaboration and intelligent algorithms, the problem that traditional systems cannot take into account multi-dimensional parameters such as density, temperature, and pressure is solved.

[0075] As a technical optimization solution of the present invention, the actuator includes a demoulding member including a flexible push plate, a negative pressure adsorption module and a liftable buffer platform;

[0076] The flexible push plate fits the inner wall of the mold and is driven by a servo motor with a programmable push speed (0.1-5cm / s);

[0077] Negative pressure adsorption module, the adsorption force is dynamically adjusted according to the weight of the foam to prevent local tearing during demoulding;

[0078] The height of the buffer platform can be automatically adjusted according to the position of the mold. After receiving the demoulding foam, it is output smoothly through the conveyor belt, and the falling height is ≤10cm.

[0079] The demoulding damage rate is reduced to below 1%, which is especially suitable for foam parts with complex structures (such as curved PMI foam);

[0080] Through flexible contact and dynamic buffering, the mold life is extended by more than 30%.

[0081] The basic principles, main features, and advantages of the present invention are shown and described above. Those skilled in the art should understand that the present invention is not limited to the above-described embodiments. The above-described embodiments and descriptions are merely illustrative of the principles of the present invention. Various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention. Such changes and modifications are intended to fall within the scope of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A foam forming machine, characterized in that: including a molding assembly (100); A conveying assembly (200), the conveying assembly (200) being placed below the molding assembly (100), and the conveying assembly (200) being used to convey the molded foam product; A conveyor belt (201), wherein the conveyor assembly (200) comprises a conveyor belt (201), the conveyor belt (201) is placed directly below the forming assembly (100), and a plurality of through holes are provided on the surface of the conveyor belt (201); An inner support box (203); the conveyor belt (201) is supported by the inner support box (203); a negative pressure machine (220) for generating negative pressure is provided in the inner support box (203); the negative pressure generated by the negative pressure machine (220) is used to absorb and transport the formed foam; Sealing strips (222) are fixedly connected at both ends of the upper surface of the negative pressure machine (220), and the sealing strips (222), the negative pressure machine (220), the inner support box (203) and the conveyor belt (201) form a closed space; The connections between the inner support box (203), the negative pressure machine (220), and the conveyor belt (201) are all sealed.

2. A foam forming machine according to claim 1, characterized in that: A layer of silicone sheet (202) is provided on the surface of the conveyor belt (201), and a through hole adapted to the conveyor belt (201) is opened on the surface of the silicone sheet (202), and the thickness of the silicone sheet (202) is 4 mm to 6 mm.

3. A foam forming machine according to claim 1, characterized in that: A through hole is provided on one side of the inner support box (203), the exhaust port of the negative pressure machine (220) is adapted to the through hole, and an air pipe (221) is provided at the air intake port of the negative pressure machine (220).

4. A foam forming machine according to claim 1, characterized in that: Two groups of side support protrusions (211) are fixedly connected to the outside of the conveyor belt (201), and a pushing grid (210) is fixedly connected to the middle of each group of side support protrusions (211).

5. A foam forming machine according to claim 4, characterized in that: The pushing grid (210) is made of rubber, and the projection of the side wall of the pushing grid (210) is in a trapezoidal shape.

6. A foam forming machine according to claim 5, characterized in that: A protective net (300) is fixedly connected to the bottom of the molding assembly (100), the protective net (300) is made of elastic material, a wire cover (301) is provided at the bottom of the protective net (300), and a drawstring (302) is connected inside the wire cover (301); Pulling the pull rope (302) changes the size of the bottom opening of the protection net (300).

7. A foam forming machine according to claim 3, characterized in that: A support frame (101) for supporting is provided at the bottom of the molding assembly (100), and a guide groove is provided on the side wall of the support frame (101); a partition (103) is fixedly connected in the guide groove.

8. A foam forming machine according to claim 7, characterized in that: A servo motor (104) is fixedly connected to the lower surface of the partition (103), an output end of the servo motor (104) is fixedly connected to a threaded rod (102), an outer wall of the threaded rod (102) is provided with a movable plate frame (105), and the movable plate frame (105) is fixedly connected to the outer wall of the inner support box (203).

9. A foam molding control system, applied to a foam molding machine according to any one of claims 1 to 8, characterized in that: The following steps are involved: It includes a central controller, a multimodal sensor array, an actuator and a human-computer interface; The central controller integrates a PLC or microprocessor, communicates with the cloud data platform, and supports real-time parameter adjustment and historical data tracing; The multimodal sensor array includes an infrared image sensor, a pressure sensor, and a temperature sensor; The actuator includes a variable frequency foaming pump, a hydraulic ejection device and a pneumatic valve group, which respectively control the raw material injection rate, mold opening and closing and demoulding actions; The human-computer interaction interface supports foam parameter preset and real-time status visualization.

10. A foam forming control system according to claim 9, characterized in that: The actuator includes a demoulding part including a flexible push plate, a negative pressure adsorption module and a liftable buffer platform; The flexible push plate fits the inner wall of the mold and is driven by a servo motor with a programmable push speed (0.1-5 cm / s); Negative pressure adsorption module, the adsorption force is dynamically adjusted according to the weight of the foam to prevent local tearing during demoulding; The height of the buffer platform can be automatically adjusted according to the position of the mold. After receiving the demoulding foam, it is smoothly output through the conveyor belt, and the falling height is ≤10 cm.

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