Brand-new production process for producing plastic tray

Abstract

The invention discloses a brand new production process for producing a plastic tray, which comprises the following steps of: pretreating raw materials, sequentially crushing, cleaning and drying waste plastics, wood wastes or waste textile raw materials through a crusher, special cleaning equipment and a dryer, controlling the discharging granularity of the raw materials to be 1-10mm, reducing the water content to be 8-12%, and adopting a two-station design, an electric hydraulic pump drives ten 200-ton and 150-mm-stroke jacks to apply pressure to a mold, the mold is of a 90-degree flip type mold opening structure, and after a left tray mold trolley and a right tray mold trolley are in place, a patent accumulation type mold head extrudes molten materials into the mold according to the extrusion amount set by a PLC. Therefore, according to the process, through alternate operation of two stations and multi-procedure integration, waiting and manual intervention are reduced, the forming precision is guaranteed through synchronous control and independent supporting, equipment is simplified through low-pressure driving, faults are reduced, modular design is suitable for unconventional tray production, and the problems that in the background technology, the production efficiency is low, and unconventional trays are difficult to prepare are effectively solved.

Description

Technical Field

[0001] This invention relates to the field of waterjet cutting technology, and in particular to a novel manufacturing process for producing plastic pallets. Background Technology

[0002] Currently, the production of molded recycled plastic pallets mostly adopts high temperature and high pressure one-time molding technology. The core process includes pretreatment steps such as raw material crushing, cleaning and drying. After the recycled material is mixed with additives, it is plasticized by internal mixer and melt extruder. Then, pressure is applied to the mold by a large hydraulic press to achieve molding. Finally, the production is completed by demolding, trimming and quality inspection. The industry generally adopts a single mold and upper and lower mold opening design, which relies on high pressure drive equipment and some processes require manual assistance for material distribution.

[0003] The core drawback of existing technology is its low production efficiency. Its single mold and single workstation configuration, combined with the operation mode of large hydraulic presses, results in cumbersome process connections. Furthermore, the manual intervention in material distribution and other aspects further slows down the production pace, resulting in limited output per unit hour. This makes it difficult to meet the needs of large-scale production, and it is also unable to efficiently produce unconventional pallets with special aspect ratios. Summary of the Invention

[0004] The present invention aims to at least partially solve one of the technical problems in the related art.

[0005] Therefore, the purpose of this invention is to propose a novel production process for plastic pallets, providing a four-step production flow: raw material pretreatment, mixing and melting, compression molding (including one pallet with two sets of molds + two-station design, ten evenly distributed jacks for driving, and multi-channel die nozzles and station table swing coordination), and post-processing by a frame-type robotic arm, coupled with 220V low-voltage drive and independent support structure; the core solution is to address the problem of low production efficiency in existing technologies, significantly increasing the hourly output by alternating operation of two stations; at the same time, it eliminates the need for manual intervention in material distribution and can efficiently produce unconventional pallets, further compensating for the shortcomings of existing technologies.

[0006] To achieve the above objectives, this invention proposes a novel manufacturing process for plastic pallets, comprising the following steps:

[0007] S1: Raw material pretreatment involves crushing, washing, and drying waste plastics, wood waste, or waste textiles sequentially using a crusher, specialized cleaning equipment, and a dryer to control the output particle size to 1-10mm and reduce the moisture content to 8%-12%.

[0008] S2: Mixing and melting. The pretreated recycled material and additives are mixed evenly and then passed through an internal mixer (temperature 160-285℃) and a melt extruder (temperature 150-250℃) for melting and plasticizing. The molten material is then transported to a patented accumulator die for storage.

[0009] S3: Compression molding, using a two-station design. Ten 200-ton, 150mm stroke jacks are driven by an electric hydraulic pump to apply pressure to the mold. The mold adopts a 90-degree flip-top mold opening structure. After the left and right pallet mold trolleys are in place, the patented accumulation die head extrudes the molten material into the mold according to the extrusion amount set by the PLC. After the material flows level, it is held under pressure to form the mold, and then cooled and solidified. The jacks are evenly distributed around the mold, and the applied pressure can be adjusted between 100-1800 tons.

[0010] S4: Post-processing and quality inspection, using robotic arms to demold, trim, load-bearing and dimensionally inspect the molded products, and finally stack and put them into storage;

[0011] The production process uses a one-to-two mold configuration, and the equipment is powered by a 220V low-voltage electric drive.

[0012] This invention presents a novel manufacturing process for plastic pallets. Raw materials undergo crushing, cleaning, and drying in a sealed, interconnected pretreatment system. After mixing with additives, the mixture is plasticized in a mixer and melt extruder before being stored in a accumulator die. A 220V low-voltage drive system, coupled with a single-bearer-two-set die, enables alternating operation at two workstations. A PLC controls the die trolley's positioning, and an electric hydraulic pump, through a mechanical synchronization mechanism and a synchronization valve, drives jacks to apply pressure evenly. Multi-channel die nozzles and the workstation oscillate to automatically distribute the material. Independent support seats provide stable force transmission. A frame-type robotic arm integrates demolding, trimming, inspection, and stacking processes. Modular molds are adaptable to non-standard pallet sizes. This process reduces waiting time and manual intervention through alternating operation at two workstations and multi-process integration. Synchronous control and independent support ensure molding accuracy. Low-voltage drive simplifies equipment and reduces malfunctions. The modular design adapts to the production of non-standard pallets, effectively solving the problems of low production efficiency and difficulty in producing non-standard pallets in the prior art.

[0013] In addition, the novel plastic pallet manufacturing process proposed above according to the present invention may also have the following additional technical features:

[0014] Specifically, the electric hydraulic pump described in S3 drives ten jacks with a stroke of 150mm to achieve absolutely synchronized forward and backward movement. The synchronization control method is the coordinated action of a mechanical synchronization mechanism and a synchronization valve.

[0015] Specifically, the S3 patented accumulator die head uses a multi-channel diffusion structure for its injection nozzle, and the die station can swing left and right. Through the synergistic effect of the multi-channel diffusion injection nozzle's material distribution and the station's swing, the molten material is automatically and evenly distributed in the die before mold closing, without the need for manual intervention.

[0016] Specifically, the mold station platform base of S3 is equipped with an independent support seat. The independent support seat and the movable base are connected by a pin positioning and bolt fastening method. When pressure is applied when the mold is closed, the force is directly transmitted to the ground through the independent support seat.

[0017] Specifically, the robotic arm described in S4 is a frame-type robotic arm that can move along the XYZ coordinates and can stop at a preset height. After simultaneously completing product trimming, load-bearing, and dimensional inspection operations, it performs palletizing operations.

[0018] Specifically, the configuration of one support for two sets of molds improves the production efficiency per unit hour through the alternating operation mode of two workstations.

[0019] Specifically, the 220V low-voltage electric drive system can drive the jack to generate a force of over a thousand tons, meeting the pressure requirements of compression molding.

[0020] Specifically, the production process can be used to prepare unconventional plastic pallets, which have an aspect ratio of 3-4.

[0021] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0022] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the following description of the embodiments taken in conjunction with the accompanying drawings, wherein:

[0023] Figure 1 This is a schematic diagram of the production process for the novel plastic pallet manufacturing of this invention. Detailed Implementation

[0024] Embodiments of the present invention are described in detail below. Examples of these embodiments are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the invention, and should not be construed as limiting the invention. Rather, embodiments of the invention include all variations, modifications, and equivalents falling within the spirit and scope of the appended claims.

[0025] The following describes the novel manufacturing process for producing plastic pallets according to an embodiment of the present invention, with reference to the accompanying drawings.

[0026] like Figure 1 As shown, this invention presents a novel manufacturing process for producing plastic pallets.

[0027] S1: Raw material pretreatment, waste plastics, wood waste or waste textile raw materials are crushed, cleaned and dried in sequence through crusher, special cleaning equipment and dryer, so that the output particle size of raw materials is controlled to 1-10mm and the moisture content is reduced to 8%-12%.

[0028] It should be noted that the crusher, special cleaning equipment, and dryer described in this embodiment are rigidly connected in sequence through a sealed conveying channel. The crusher's feed inlet is equipped with an inclined anti-blocking material guiding structure. The special cleaning equipment is equipped with symmetrically arranged rotating brush rollers and high-pressure spray components. The dryer is equipped with multi-layer staggered guide plates. The operation of the three components is synchronized by a linkage control switch to ensure that there is no leakage or secondary pollution of the raw materials during the transfer process, and to ensure the continuity of the pretreatment process.

[0029] S2: Mixing and melting. The pretreated recycled material and additives are mixed evenly and then passed through a mixer (temperature 160-285℃) and a melt extruder (temperature 150-250℃) for melting and plasticizing. The molten material is then transported to an accumulator die for storage.

[0030] It should be noted that the internal mixer, melt extruder, and accumulator described in this embodiment are connected in sequence via flange-type sealing joints. The rotor of the internal mixer adopts an anti-meshing structure and has a wear-resistant coating on its surface. The inner wall of the barrel of the melt extruder is equipped with a removable bushing. The accumulator has an annular uniform flow channel and a heat-insulating chamber. The feed end of the accumulator is equipped with a one-way shut-off valve to prevent the molten material from flowing back and to ensure the stability of the material after plasticization.

[0031] S3: Compression molding, using a two-station design. Ten 200-ton, 150mm stroke jacks are driven by an electric hydraulic pump to apply pressure to the mold. The mold adopts a 90-degree flip-top mold opening structure. After the left and right pallet mold trolleys are in place, the accumulator mold head squeezes the molten material into the mold according to the extrusion amount set by the PLC. After the material flows level, it is held under pressure to form the mold, and then cooled and solidified. The jacks are evenly distributed around the mold, and the applied pressure can be adjusted between 100-1800 tons.

[0032] It should be noted that the electric hydraulic pump, jacks, mold, mold trolley, PLC controller, and independent support base described in this embodiment cooperate with each other. The electric hydraulic pump is connected to each of the ten jacks through a branch pipeline. The piston rod end of the jack is equipped with a pressure-sensing contact plate. The flip-top side of the mold is connected to the frame through a rotating hinge and is equipped with a locking buckle. The bottom of the mold trolley is equipped with a guide rail and a positioning pin assembly. The PLC controller is electrically connected to the electric hydraulic pump, the mold trolley, and the discharge valve of the accumulator mold head through signal lines. The independent support base and the frame base are fitted together through positioning grooves to form a stable force transmission path, ensuring that the mold is subjected to uniform force and no deviation when the mold is closed and pressure is applied.

[0033] S4: Post-processing and quality inspection. The molded products are demolded, trimmed, subjected to load-bearing and dimensional inspection by robotic arms, and finally stacked and put into storage.

[0034] It should be noted that the frame-type robot, trimming tool, load-bearing detection component, size detection sensor, and palletizing platform described in this embodiment work together. The execution end of the frame-type robot is equipped with a detachable demolding fixture. The trimming tool is mounted on the arm of the frame-type robot through an elastic connector. The load-bearing detection component and size detection sensor are integrated into the fixed-point stopping area of ​​the frame-type robot. The frame-type robot moves along the XYZ coordinate guide rail and aligns with the positioning reference line of the palletizing platform to achieve a smooth connection between demolding, trimming, detection, and palletizing actions.

[0035] The production process uses a one-to-two mold configuration, and the equipment is powered by a 220V low-voltage electric drive.

[0036] It should be noted that the one-to-two auxiliary molds, the 220V low-voltage electric drive system, and the reversing valve group described in this embodiment are mutually compatible. The one-to-two auxiliary molds correspond to the molding areas of the two workstations respectively. The 220V low-voltage electric drive system is equipped with an overload protection device and a voltage stabilization module. The reversing valve group is installed in the hydraulic control circuit of the one-to-two auxiliary molds. The 220V low-voltage electric drive system realizes the switching of pressure output between the two workstations through the reversing valve group, ensuring the smooth alternation of the two workstations.

[0037] Specifically, waste plastics, wood waste, or waste textile materials are first fed into a crusher, a dedicated cleaning device, and a dryer, which are rigidly connected and linked by a sealed conveying channel. The crusher's inclined anti-blocking feeding structure assists in feeding, the dedicated cleaning device uses rotating brush rollers and high-pressure spray components for cleaning, and the dryer uses multi-layered staggered guide plates for guiding, completing the pre-treatment of crushing, cleaning, and drying. The pre-treated recycled material is then mixed with additives and sequentially passed through a flange-sealed internal mixer and a melt extruder. The internal mixer's counter-rotating rotors plasticize the material, and the melt extruder's removable bushing protects the barrel. Finally, the molten material is conveyed to a storage die head with an annular uniform flow channel, a heat-insulated chamber, and a one-way shut-off valve. It then enters a two-station compression molding stage, where a 220V low-voltage electric drive system switches the pressure input via a reversing valve group. The process begins with a two-part mold assembly. Under the signal control of the PLC controller, the mold trolley moves along the guide rail and is positioned by the positioning pin assembly. The electric hydraulic pump drives ten jacks evenly distributed around the mold via a diversion pipeline. Pressure is applied evenly by the pressure-sensing plates at the piston rod ends of the jacks. Simultaneously, the independent support base and the positioning groove of the frame base fit together to form a stable force transmission path. The accumulating die head discharges material according to the set extrusion amount. The mold opens by a 90-degree flip-top through a rotating hinge and locking buckle. After the material flows level, it is held under pressure, cooled, and shaped. Finally, the frame-type robot moves along the XYZ coordinate guide rail and demolds the material using the detachable demolding fixture at the execution end. Trimming is performed using the elastic connecting trimming cutter on the arm. Quality inspection is completed at the fixed stopping area by the integrated load detection component and size detection sensor. Then, the material is aligned with the positioning baseline of the palletizing platform and palletized for storage. This process utilizes a design that combines two sets of molds on one stand with alternating operation at two workstations, along with a PLC controller to coordinate the actions of all equipment, reducing waiting time between processes. The frame-type robotic arm integrates multiple processes such as demolding, trimming, inspection, and palletizing, eliminating the need for manual intervention. Furthermore, the sealed connection between the internal mixer, melt extruder, and accumulator die head, as well as the synchronous pressure application design of the jacks, ensures continuous production. The 220V low-voltage electric drive system, combined with the reversing valve group, enables smooth switching, and the independent support base and optimized mold structure ensure molding stability. This effectively solves the problem of low production efficiency in the background technology and is also suitable for the production needs of non-standard pallets.

[0038] In one embodiment of the present invention, such as Figure 1 As shown in the figure, the electric hydraulic pump described in S3 drives ten jacks with a stroke of 150mm to achieve absolutely synchronous forward and backward movement. The synchronization control method is the coordinated action of a mechanical synchronization mechanism and a synchronization valve.

[0039] It should be noted that the mechanical synchronization mechanism described in this embodiment adopts a rigid linkage structure. The two ends of the linkage are hinged to the cylinder end of the jack through universal joints. The synchronization valve is connected in series between the diversion pipeline of the electric hydraulic pump and the oil inlet of the jack. Furthermore, the synchronization valve and the linkage of the mechanical synchronization mechanism are equipped with displacement sensors to form a closed-loop feedback cooperation, ensuring the consistency of the jack's forward and backward movements.

[0040] Specifically, the hydraulic oil output by the electric hydraulic pump is evenly distributed to ten jacks through a synchronization valve. The synchronization valve precisely controls the inlet and outlet oil flow of each jack. At the same time, the rigid connecting rod of the mechanical synchronization mechanism constrains the movement trajectory of all jacks, preventing displacement deviation of individual jacks. The displacement sensor monitors the position of the connecting rod in real time and feeds it back to the control system to correct the flow distribution of the synchronization valve in a timely manner. This design solves the problems of jamming and insufficient synchronization accuracy that are common with single synchronization methods in the background technology. It ensures that the mold is subjected to uniform force during the molding process, avoids product molding defects caused by asynchronous jack movements, reduces rework time, and indirectly improves production efficiency.

[0041] In one embodiment of the present invention, such as Figure 1 As shown, the injection nozzle of the accumulator head in S3 adopts a multi-channel diffusion structure, and the mold station can swing left and right. Through the synergistic effect of the material distribution of the multi-channel diffusion injection nozzle and the swing of the station, the molten material is automatically and evenly distributed in the mold before mold closing, without the need for manual intervention.

[0042] It should be noted that the channels of the multi-channel diffusion injection nozzle described in this embodiment are evenly distributed around the nozzle outlet. Each channel outlet is provided with an inclined guide surface. The swing of the mold station is achieved by a servo motor driving a gear and rack mechanism. The bottom of the station is provided with a guide slider that cooperates with the frame guide rail. The swing stroke can be precisely controlled by a limit switch.

[0043] Specifically, the molten material from the accumulator die head is diffused out through the inclined guide surface of the multi-channel injection nozzle, covering most of the mold cavity. At the same time, the servo motor drives the station table to swing smoothly left and right along the guide rail, causing the material in the mold to spread evenly to the edge of the cavity. The limit switch ensures that the swing amplitude of the station table is adapted to the mold size. There is no need for manual material pushing, which solves the problems of slow production rhythm and uneven distribution caused by manual material distribution in the background technology, shortens the preparation cycle of a single product, and improves production efficiency and product qualification rate.

[0044] In one embodiment of the present invention, such as Figure 1 As shown, the mold station platform base in S3 is equipped with an independent support seat. The independent support seat and the movable base are connected by a pin positioning and bolt fastening method. When pressure is applied during mold closing, the force is directly transmitted to the ground through the independent support seat.

[0045] It should be noted that the independent support base described in this embodiment adopts an integrated cast iron structure. The top is provided with a positioning groove that is compatible with the movable base. The pins are embedded in the positioning groove and the pin holes of the movable base. The bolts are evenly distributed around the positioning groove. The bottom of the independent support base is provided with an anti-slip and wear-resistant pad and is fixedly connected to the ground by expansion bolts.

[0046] Specifically, before mold closing and pressure application, the movable base is precisely positioned in the positioning groove of the independent support base by pins, and the two are fastened together by circumferentially distributed bolts. The pressure generated by mold closing is transmitted sequentially through the mold and the movable base to the independent support base, and then directly to the ground through the bottom structure fixed by the anti-slip wear-resistant pad and expansion bolts. This avoids pressure dispersion that could cause frame deformation, solves the problem of insufficient frame rigidity affecting mold accuracy in the background technology, ensures mold position stability during molding, reduces product size deviation, eliminates the need for frequent machine stops to adjust the frame, ensures production continuity, and improves production efficiency.

[0047] In one embodiment of the present invention, such as Figure 1 As shown, the robotic arm described in S4 is a frame-type robotic arm that can move along the XYZ coordinates and can stop at a preset height. After simultaneously completing product trimming, load-bearing, and dimensional inspection operations, it performs palletizing operations.

[0048] It should be noted that the XYZ coordinate movement of the frame-type robot described in this embodiment is achieved by three sets of servo motors driving ball screws respectively. A photoelectric positioning sensor is provided at the fixed height position. The trimming tool is installed on the robot's crossbeam through an elastic clamping seat. The load detection component and the size detection sensor are integrated into the side arm of the robot, and the detection data is transmitted to the control system in real time.

[0049] Specifically, a servo motor drives a ball screw to move a frame-type robotic arm precisely along the XYZ coordinates. A photoelectric positioning sensor ensures that the robotic arm stays stably at a preset height. While staying, the trimming cutter fixed by the elastic gripper trims the product. The detection components integrated into the side arm simultaneously complete the load-bearing capacity and size detection. After passing the detection, the robotic arm continues to move to the palletizing area to perform palletizing. All processes are integrated into the same robotic arm, eliminating the need to change equipment or transfer products. This solves the problem of cumbersome and inefficient production processes caused by multiple devices operating in separate steps in the background technology, shortens the product post-processing cycle, and improves overall production efficiency.

[0050] In one embodiment of the present invention, such as Figure 1 As shown, the configuration of one support for two sets of molds improves the production efficiency per unit hour through the alternating operation mode of two workstations.

[0051] It should be noted that the two workstations described in this embodiment correspond to two sets of molds respectively. A linkage conveyor rail is provided between the workstations. The PLC controller is electrically connected to the molding mechanism and the accumulator mold head discharge valve of the two workstations to form an alternating operation trigger logic. When one set of molds is holding pressure and cooling, the other set of molds simultaneously performs feeding and material distribution operations.

[0052] Specifically, after the PLC controller controls the mold trolley at the first station to reach its position, the accumulator mold head feeds and molds the material, while the mold at the second station completes demolding and cleaning. After the first station finishes holding pressure and cooling, the linkage conveyor rail drives the mold trolley to switch stations. The second station immediately feeds and molds the material, while the first station simultaneously demolds and cleans. The two stations cycle alternately without waiting gaps, solving the problem in the background technology where a single mold and single station must wait for demolding and cleaning before the next round of production can begin. This significantly increases the product output per hour and improves production efficiency.

[0053] In one embodiment of the present invention, such as Figure 1 As shown, the 220V low-voltage electric drive system can drive the jack to generate a force of over a thousand tons, meeting the pressure requirements of compression molding.

[0054] It should be noted that the 220V low-voltage electric drive system described in this embodiment includes a low-voltage motor, a gearbox, and a hydraulic pump unit. The low-voltage motor and the gearbox are connected by a coupling. The output end of the gearbox drives the hydraulic pump unit. The oil outlet of the hydraulic pump unit is connected to the oil inlet of the jack through a high-pressure oil pipe. The system is also equipped with a pressure relay as an overload protection device.

[0055] Specifically, after the 220V low-voltage motor starts, the torque is amplified by the gearbox to drive the hydraulic pump unit. The hydraulic pump unit converts low-voltage electrical energy into hydraulic energy, and delivers high-pressure hydraulic oil to the jack through the high-pressure oil pipe. This pushes the piston rod of the jack to extend and generate a huge force. The pressure relay monitors the system pressure in real time to avoid overload damage to the equipment. It does not rely on high-pressure drive equipment, which solves the problems of complex structure, high maintenance cost and low operation safety of high-pressure drive equipment in the background technology. It ensures a stable output of the thousand-ton pressure required for molding, while simplifying the equipment structure, reducing the failure rate and ensuring continuous and efficient production.

[0056] In one embodiment of the present invention, such as Figure 1 As shown, the production process can be used to prepare unconventional plastic pallets, which have an aspect ratio of 3-4.

[0057] It should be noted that the mold for adapting to non-standard plastic pallets described in this embodiment adopts a modular structure with adjustable cavity length. The length and width of the mold station can be adapted and adjusted according to the pallet size. The number of channels and the swing stroke of the multi-channel diffusion injection nozzle can be set by the control system.

[0058] Specifically, based on the non-standard pallet size with an aspect ratio of 3-4 times, the cavity length and station size of the modular mold are adjusted. The control system sets the channel output of the multi-channel injection nozzle and the swing amplitude of the station, so that the molten material is evenly distributed in the long-size cavity. Ten evenly distributed jacks ensure that the long-size mold is subjected to uniform force. The 90-degree flip-top mold opening structure facilitates the removal of long-size products. The XYZ coordinate movement range of the frame-type robot is adapted to the size of the non-standard pallet, which solves the problem that traditional equipment is difficult to adapt to the production of long-size non-standard pallets in the background technology, expands the production range, and at the same time adopts the efficient two-station alternation and integrated post-processing mode to ensure that the production efficiency of non-standard pallets is consistent with that of conventional pallets, thereby improving the overall production capacity.

[0059] In summary, the novel plastic pallet production process of this invention involves the raw materials being crushed, cleaned, and dried in a sealed, interconnected pretreatment system. After being mixed with additives, the raw materials are plasticized in a mixer and melt extruder before being stored in a accumulator die. A 220V low-voltage drive system, in conjunction with a single-bearer-two-set die, enables alternating operation at two workstations. A PLC controls the positioning of the die trolley, and an electric hydraulic pump drives jacks to apply pressure evenly via a mechanical synchronization mechanism and a synchronization valve. A multi-channel die nozzle and the workstation swing to automatically distribute the material. Independent support seats provide stable force transmission, and a frame-type robotic arm integrates demolding, trimming, inspection, and stacking processes. Modular molds are adaptable to non-standard pallet sizes. This process reduces waiting time and manual intervention through alternating operation at two workstations and integration of multiple processes. Synchronous control and independent support ensure molding accuracy. The low-voltage drive simplifies equipment and reduces malfunctions. The modular design adapts to the production of non-standard pallets, effectively solving the problems of low production efficiency and difficulty in producing non-standard pallets in the prior art.

[0060] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A novel manufacturing process for producing plastic pallets, characterized in that, Includes the following steps: S1: Raw material pretreatment involves crushing, washing, and drying waste plastics, wood waste, or waste textiles sequentially using a crusher, specialized cleaning equipment, and a dryer to control the output particle size to 1-10mm and reduce the moisture content to 8%-12%. S2: Mixing and melting. The pretreated recycled material and additives are mixed evenly and then passed through an internal mixer (temperature 160-285℃) and a melt extruder (temperature 150-250℃) for melting and plasticizing. The molten material is then transported to a patented accumulator die for storage. S3: Compression molding, using a two-station design. Ten 200-ton, 150mm stroke jacks are driven by an electric hydraulic pump to apply pressure to the mold. The mold adopts a 90-degree flip-top mold opening structure. After the left and right pallet mold trolleys are in place, the patented accumulation die head extrudes the molten material into the mold according to the extrusion amount set by the PLC. After the material flows level, it is held under pressure to form the mold, and then cooled and solidified. The jacks are evenly distributed around the mold, and the applied pressure can be adjusted between 100-1800 tons. S4: Post-processing and quality inspection, using robotic arms to demold, trim, load-bearing and dimensionally inspect the molded products, and finally stack and put them into storage; The production process uses a one-to-two mold configuration, and the equipment is powered by a 220V low-voltage electric drive.

2. The production process according to claim 1, characterized in that, The electric hydraulic pump described in S3 drives ten jacks with a stroke of 150mm to achieve absolutely synchronized forward and backward movement. The synchronization control method is the coordinated action of a mechanical synchronization mechanism and a synchronization valve.

3. The production process according to claim 1, characterized in that, The S3's patented accumulator nozzle features a multi-channel diffusion structure, and the mold station can swing left and right. Through the synergistic effect of the multi-channel diffusion nozzle's material distribution and the station's swing, the molten material is automatically and evenly distributed within the mold before mold closing, without the need for manual intervention.

4. The production process according to claim 1, characterized in that, The S3 mold station table frame base is equipped with an independent support seat. The independent support seat and the movable base are connected by a pin positioning and bolt fastening method. When the mold is closed and pressure is applied, the force is directly transmitted to the ground through the independent support seat.

5. The production process according to claim 1, characterized in that, The robotic arm described in S4 is a frame-type robotic arm that can move along the XYZ coordinates and stop at a preset height. After simultaneously completing product trimming, load-bearing, and dimensional inspection operations, it performs palletizing operations.

6. The production process according to claim 1, characterized in that, The configuration of one support for two sets of molds improves the production efficiency per unit hour through the alternating operation mode of two workstations.

7. The production process according to claim 1, characterized in that, The 220V low-voltage electric drive system can drive the jack to generate a force of over a thousand tons, meeting the pressure requirements of compression molding.

8. The production process according to any one of claims 1-7, characterized in that, The manufacturing process can be used to produce unconventional plastic pallets with an aspect ratio of 3-4.

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