Automatic processing system and processing method for foamed plastic

Abstract

The invention discloses an automatic processing system and method for foamed plastic products with poor ductility, the automatic processing system comprises a machine body (1), a feeding frame (2), a cutting device (3), an oven (4), a discharging device (5), a shaping device (6), a conveying belt (8), a power device (9) and a control device (10), the cutting device is arranged between the feeding frame (2) and the oven (4) and used for cutting coiled materials into sheets with proper sizes, and the shaping device (6) is arranged on the conveying belt (8). The conveying belt (8) sequentially penetrates through the feeding frame (2), the cutting device (3), the oven (4) and the discharging device (5), and the shaping device (6) is arranged on the periphery of the discharging device (5). By the adoption of the system, the five working procedures of feeding, cutting, heating, modeling and blanking are controlled by the control device and completed in a unified mode, the consistency of products is greatly improved, the yield of the products is greatly improved, and the labor cost is greatly saved.

Description

Technical Field

[0001] This invention relates to the field of product shaping and processing, specifically to a processing machine and method for automatically processing foamed plastics with insufficient extensibility. Background Technology

[0002] EPE, EVA, and sponge are foamed plastic materials that can be shaped but lack sufficient ductility. Currently, the process for producing foamed products using these materials involves: pre-foamed, shapeable sheets of foamed plastic are automatically cut to a predetermined shape and automatically fed into a mold for shaping, resulting in a foamed product with relatively uniform thickness. Most existing processing machines for foamed plastics with insufficient ductility consist of an external heating oven and a shaping machine. The sheet with insufficient ductility is pre-cut into a predetermined shape, heated in the oven to the set temperature, and then manually placed into the mold of the shaping machine. Pressure is applied to the shapeable foamed plastic sheet (EPE, EVA, or sponge) within the mold, causing it to slide and fold along the mold's shape without being fully stretched. After reaching its final position within the mold, it is held under pressure for a period of time to solidify. Once solidified, it is manually removed to obtain a semi-finished product. This semi-finished product is then taken to a punch press where excess burrs are cut off to obtain the finished product. Using existing processing equipment requires three workflows, which wastes manpower, time, and costs. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of the prior art and provide a mechanical device that can effectively reduce the labor and time costs of molding and processing foamed products.

[0004] This invention discloses an automatic processing system for foamed plastics. The automatic processing system for foamed plastics includes a machine body, a feeding rack, an oven, a shaping device, a power device, and a control device. It also includes a cutting device, a feeding device, and a conveyor belt. The feeding rack, cutting device, oven, and feeding device are arranged sequentially on the machine body. The cutting device is used to cut the roll material into sheets of appropriate size. The conveyor belt passes sequentially through the feeding rack, cutting device, oven, and feeding device. The shaping device is arranged around the feeding device and performs punching, shaping, and edge separation of the semi-finished products.

[0005] Furthermore, the shaping device includes a frame and a first worktable, a second worktable, and a third worktable arranged in parallel from top to bottom, wherein the second worktable is fixed, the first worktable and the third worktable are movable, a shaping mold is installed between the first worktable and the second worktable, and a punching die is installed between the second worktable and the third worktable.

[0006] Furthermore, the shaping device includes a frame and a first workbench, a second workbench, and a third workbench arranged in parallel from top to bottom. The first workbench is fixed, while the second and third workbench can be linked. A blanking die is installed between the first and second workbench, and a shaping die is installed between the second and third workbench. The shaping process and the blanking process are carried out in conjunction.

[0007] Furthermore, it also includes a robotic arm, used to place the heated sheet material placed on the feeding device into the shaping mold of the shaping device for shaping processing, and to move the shaped semi-finished product to the punching die of the shaping device for punching.

[0008] Furthermore, the robotic arm is mounted on the feeding device or on the shaping device.

[0009] Furthermore, it also includes a storage device, which is located near the feeding device and the shaping device, within the range of motion of the robot arm. The storage device is mounted on the machine body, or a trolley independent of the machine body is used as the storage device.

[0010] Furthermore, the machine body is a horizontal metal frame; the conveyor belt is a chain; the control device is an independent control cabinet, or is installed on the machine body, to control the operation of the entire system.

[0011] The present invention also discloses a method for processing using the above-mentioned automatic processing system, comprising the following steps: 1) Place the foamed material roll into the feeding rack, and it will be conveyed to the cutting device by the conveyor belt; 2) The cutting device cuts the roll material into sheets of suitable size; 3) Place the sheet in the oven and heat it to a certain temperature; 4) Send the heated sheet onto the feeding device; 5) The robotic arm places the sheet into the forming mold of the forming device; 6) Control the mold closing to press the sheet material into shape; 7) The robotic arm delivers the pressed semi-finished product into the punching die; 8) Control the movement of the blanking die to blank the semi-finished product; 9) The robotic arm places the punched product into the storage device.

[0012] The control system can control steps 6) and 7) to be performed at the same time.

[0013] Compared with the prior art, the processing system of the present invention has the following advantages: The system is equipped with a feeding rack and a cutting device, and integrates the oven, shaping position, and edge trimming device into a unified control unit. This allows for the pre-cutting of foam product sheets with insufficient extensibility into predetermined shapes before heating and feeding them into the mold. The sheets are then allowed to fold more freely and stretch less during the shaping process, resulting in foam products with more uniform thickness. This offers significant advantages for foam products requiring deeper shaping. Furthermore, the unified control system streamlines the five processes of feeding, cutting, heating, shaping, and die-cutting, greatly improving product consistency, increasing yield, and significantly reducing material and labor costs. Attached Figure Description

[0014] Figure 1 : A top view of the first embodiment of the automatic processing system of the present invention; Figure 2 : A front view schematic diagram of the first embodiment of the automatic processing system of the present invention; Figure 3 : Schematic diagram of the shaping device in the first embodiment; Figure 4 : Schematic diagram of the shaping device in the second embodiment;

[0015] Explanation of reference numerals in the attached figures: 1-Machine body; 2-Feeding rack; 3-Cutting device; 4-Oven; 5- Feeding device; 6- Shaping device; 61-Frame; 62-Upper worktable; 63 - Middle worktable; 64 - Lower worktable; 65-Robotic arm; 7-Storage device; 8-Conveyor belt; 9-Power unit; 10-Control device. Implementation

[0016] The present invention will now be described in detail with reference to the accompanying drawings. First Embodiment

[0017] like Figure 1 , 2 As shown, the processing system of the present invention includes: a machine body 1, a feeding rack 2, a cutting device 3, an oven 4, a feeding device 5, a shaping device 6, a storage device 7, a conveyor belt 8, a power device 9, and a control device 10.

[0018] The machine body 1 is a horizontal metal frame, in which the loading rack 2, cutting device 3, oven 4, and unloading device 5 are sequentially installed adjacent to each other, with the center lines of these devices on a horizontal line. A conveyor belt 8 passes through the loading rack 2, cutting device 3, oven 4, and unloading device 5, used to transport the processed parts between these devices. The conveyor belt can be a chain or other conveying structure. A shaping device 6 and a receiving device 7 are located on the machine body 1, arranged around the unloading device 5.

[0019] The feeding rack 2 is installed at the front end of the machine body 1. The foamed sheet roll is conveyed to the cutting device 3 through the feeding rack 2. The cutting device 3 is used to cut the roll into sheets of appropriate size, which are then conveyed to the oven 4 for heating by the conveyor belt 8. The heated sheets are then conveyed to the unloading device 5 by the conveyor belt 8. The unloading device 5 is equipped with a robotic arm, which can transfer materials between the unloading device 5, the shaping device 6, and the storage device 7.

[0020] Shaping device 6, such as Figure 3 As shown, the machine includes a frame 61, an upper worktable 62, a middle worktable 63, and a lower worktable 64. The frame 61 can be a separate, upright metal frame or part of the machine body 1, used to support the three worktables. A shaping mold is installed between the upper worktable 62 and the middle worktable 63; the shaping mold is a mold adapted to the shape of the finished product. A blanking die is installed between the middle worktable 63 and the lower worktable 64; the blanking die is used to blank the semi-finished product, separating the finished product from the burrs. The installation positions of the shaping mold and the blanking die can be interchanged.

[0021] The main functions of the robotic arm on the feeding device 5 are: 1) to place the heated sheet material placed on the feeding device 5 into the shaping mold of the shaping device 6; 2) to move the shaped semi-finished product into the punching die for punching; 3) to move the punched finished product into the storage device 7.

[0022] The storage device 7 is located adjacent to the feeding device 5 and the shaping device 6, within the range of motion of the robotic arm. The robotic arm moves the finished products to the storage device for storage. The storage device can also be a trolley independent of the machine body, which facilitates the transport of multiple finished products stacked together.

[0023] The power unit 9 is mounted on the frame 1 and is controlled by the control unit 10. It provides power to multiple devices and drives each device to perform molding processing. The control unit 10 can be mounted on the frame 1, installed in a separate control cabinet, or partially mounted on the frame and partially installed in the control cabinet to control the operation of the entire system.

[0024] The main body 1 connects multiple devices into a single mechanical device.

[0025] The processing procedure of the first embodiment of the present invention will now be described with reference to the accompanying drawings.

[0026] 1) Place the foamed material roll into the feeding rack 2, and it is conveyed to the cutting device 3 by the conveyor belt 8.

[0027] 2) The cutting device 3 cuts the roll material into sheets of suitable size.

[0028] 3) Place the sheet into oven 4 and heat it to a certain temperature.

[0029] 4) Send the heated sheet to the feeding device 5.

[0030] 5) The robotic arm of the feeding device 5 places the sheet into the shaping mold of the shaping device 6.

[0031] 6) Control the mold closing to press the sheet into shape.

[0032] 7) The robotic arm delivers the pressed semi-finished product to the die-cutting mold for cutting.

[0033] 8) The robotic arm places the punched product into the storage device 7. Second Embodiment

[0034] Compared to Embodiment 1, the feeding device 5 in this embodiment does not have a robotic arm, but instead uses... Figure 4 The shaping device shown has a robot arm. The heated sheet material is conveyed by the feeding device 5 to the shaping mold of the shaping device 6, and the semi-finished product after shaping is conveyed to the punching die. Both are performed by the robot arm 65 installed on the shaping device.

[0035] The shaping device in this embodiment can be the shaping processing machine in the invention patent 2018103958025 that the inventor has applied for. All contents of invention patent 2018103958025 are cited in this invention.

[0036] The above description is merely a preferred embodiment of the present invention and should not be construed as limiting the scope of the present invention. All equivalent changes and modifications made in accordance with the scope of the present invention application and the contents of the specification should still fall within the scope of the present invention patent.

Claims

1. An automatic processing system for foamed plastics, comprising a machine body (1), a feeding rack (2), an oven (4), a shaping device (6), a power unit (9), and a control device (10), characterized in that: It also includes a cutting device (3), a feeding device (5) and a conveyor belt (8). The feeding rack (2), the cutting device (3), the oven (4) and the feeding device (5) are arranged sequentially on the machine body (1). The cutting device (3) is used to cut the roll into sheets of appropriate size. The conveyor belt (8) passes sequentially through the feeding rack (2), the cutting device (3), the oven (4) and the feeding device (5). The shaping device (6) is set around the feeding device (5). The shaping device (6) performs punching, shaping and burr separation of semi-finished products.

2. The automatic processing system according to claim 1, characterized in that: The shaping device includes a frame (61) and a first workbench (62), a second workbench (63) and a third workbench (64) arranged in parallel from top to bottom. The second workbench (63) is fixed, while the first workbench and the third workbench (64) are movable. A shaping mold is installed between the first workbench (62) and the second workbench (63), and a punching die is installed between the second workbench (63) and the third workbench (64).

3. The automatic processing system according to claim 1, characterized in that: The shaping device includes a frame (61) and a first workbench (62), a second workbench (63) and a third workbench (64) arranged in parallel from top to bottom. The first workbench (62) is fixed, while the second workbench (63) and the third workbench (64) can be linked. A blanking die is installed between the first workbench (62) and the second workbench (63), and a shaping die is installed between the second workbench (63) and the third workbench (64). The shaping process and the blanking process are carried out in conjunction.

4. The automated processing system according to claim 2 or 3, characterized in that: It also includes a robotic arm, which is used to place the heated sheet material placed on the feeding device (5) into the shaping mold of the shaping device (6) for shaping processing, and to move the shaped semi-finished product to the punching die of the shaping device (6) for punching.

5. The automatic processing system according to claim 4, characterized in that: The robotic arm is mounted on the feeding device (5) or on the shaping device (6).

6. The automated processing system according to claim 4, characterized in that: It also includes a storage device (7), which is located near the feeding device (5) and the shaping device (6), within the range of motion of the robot arm. The storage device is installed on the body (1), or a trolley independent of the body (1) is used as the storage device (7).

7. The automatic processing system according to any one of claims 1-5, characterized in that: The machine body (1) is a horizontal metal frame; the conveyor belt is a chain; the control device (9) is an independent control cabinet, or is installed on the machine body (1) to control the operation of the entire system.

8. A method for processing using the automatic processing system according to any one of claims 1-6, characterized in that... Includes the following steps: 1) Place the foamed material roll into the feeding rack (2) and convey it to the cutting device (3) by the conveyor belt (8); 2) Cutting device (3) cuts the roll material into sheets of suitable size; 3) Place the sheet into the oven (4) and heat it to a certain temperature; 4) The heated sheet is fed onto the feeding device (5); 5) The sheet is placed into the shaping mold of the shaping device (6) by a robotic arm; 6) Control the mold closing to press the sheet material into shape; 7) The robotic arm delivers the pressed semi-finished product into the punching die; 8) Control the movement of the blanking die to blank the semi-finished product; 9) The robotic arm places the punched product into the storage device (7).

9. The method according to claim 8, wherein the control system performs steps 6) and 7) at the same time.

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