A debris collection device for a polyurethane foam production line

Abstract

This utility model relates to the field of polyurethane foam production technology, specifically to a debris collection device for a polyurethane foam production line, comprising: a triggering unit, an air blowing unit, a collection unit, and a dust collection and discharge unit. The triggering unit detects the production line's operating status and generates a trigger signal. The air blowing unit generates airflow to blow debris off the production line and includes a main air pipe and a solenoid valve. The solenoid valve receives the trigger signal to control the opening and closing of the main air pipe. The collection unit includes an air duct for receiving the blown debris and a suction hood with a negative pressure generating element. The air duct is connected to the suction hood to transport the debris downstream. The dust collection and discharge unit is connected to the air duct. The triggering unit is signal-connected to the solenoid valve. The air blowing direction of the main air pipe corresponds to the receiving area of ​​the air duct. The suction hood uses negative pressure to send the debris inside the suction hood into the dust collection and discharge unit. All units of this device form an organic whole through signal connections and structural cooperation.

Description

Technical Field

[0001] This utility model relates to the field of polyurethane foam production technology, specifically to a debris collection device for a polyurethane foam production line. Background Technology

[0002] In the industrial production of polyurethane foam products, the production line inevitably generates a large amount of sponge burrs (i.e., polyurethane foam scraps) during processes such as cutting and molding. The handling of these burrs has always been a key issue restricting production efficiency and environmental management. Although the technology for handling these burrs has gone through several stages of development, significant bottlenecks still exist.

[0003] In the early stages, the industry generally used manual cleaning methods to handle such debris. Operators had to enter the production line during production breaks to manually sweep up the scattered debris using tools such as brooms and scrapers. This method was not only labor-intensive and inefficient, but also limited by the complexity of the production line structure, making it difficult to thoroughly clean debris from hidden areas such as equipment gaps and the bottom of mold trolleys. Long-term accumulation of debris not only polluted the production environment but also easily fostered bacteria, potentially affecting product quality.

[0004] With the increasing automation of production, the industry is gradually adopting air gun cleaning to replace manual cleaning. Using compressed air to blow debris off the equipment surface reduces the intensity of manual labor to some extent. However, this method has a fundamental drawback: during the cleaning process, debris is dispersed by the airflow, causing secondary accumulation in other areas of the production line. It is particularly prone to getting caught in the casters and transmission components of the mold trolley, increasing equipment operating resistance and causing malfunctions such as jamming and wear, significantly increasing equipment maintenance costs and downtime risks.

[0005] Currently, existing technologies lack a systematic solution for debris handling, primarily exhibiting the following problems: First, incomplete cleaning leads to debris accumulation in corners, worsening the production environment; second, high equipment failure rates result in debris being caught in moving parts, causing frequent repairs; third, high maintenance costs require weekly downtime for manual deep cleaning, severely impacting production continuity; and fourth, low automation levels and reliance on manual operation lead to inconsistent cleaning results. These issues directly restrict the operational efficiency of polyurethane foam production lines, increase production costs, and pose potential threats to worker health and product quality. Therefore, developing a systematic device capable of efficient debris collection and automated processing has become a pressing technical challenge for the industry. Utility Model Content

[0006] To address the aforementioned issues, a debris collection device for a polyurethane foam production line is provided. Through the coordinated operation of multiple units, each unit achieves effective collection of debris generated during the polyurethane foam production line via signal connections and structural cooperation, thus solving the problem that a systematic debris handling solution has not yet been formed in existing production lines.

[0007] To address the problems of existing technologies, this utility model provides a debris collection device for a polyurethane foaming production line, comprising: a triggering unit, an air blowing unit, a collection unit, and a dust collection and discharge unit; the triggering unit is used to detect the operating status of the production line and generate a trigger signal; the air blowing unit is used to generate airflow to blow debris off the production line, including a main air pipe and a solenoid valve, the solenoid valve receiving the trigger signal to control the opening and closing of the main air pipe; the collection unit includes an air duct for receiving the blown debris and a suction hood with a negative pressure generating element, the air duct being connected to the suction hood to transport the debris downstream; the dust collection and discharge unit is connected to the air duct; the triggering unit is signal-connected to the solenoid valve; the air blowing direction of the main air pipe corresponds to the receiving area of ​​the air duct; the suction hood uses negative pressure to send the debris inside the suction hood into the dust collection and discharge unit.

[0008] Preferably, the triggering unit includes a trigger block and a detection switch. The trigger block is installed on the trolley of the polyurethane foaming production line, and the detection switch is located outside the polyurethane foaming production line and corresponds to the movement trajectory of the trigger block. The detection switch is used to send a signal to the control system when it is touched by the trigger block, and the control system controls the opening and closing of the solenoid valve.

[0009] Preferably, the main air pipe is laid at the bottom front end of the polyurethane foaming production line, and the solenoid valve is electrically connected to the control system. The control system is used to control the opening and closing of the solenoid valve to achieve intermittent air blowing in the main air pipe.

[0010] Preferably, the air duct is laid at the bottom of the polyurethane foam production line and is located on the corresponding side of the main air duct. The air duct and the main air duct have opposite air blowing directions. The suction hood is used to receive debris blown by the airflow generating component.

[0011] Preferably, the dust collection and discharge unit includes an automatic unloading dust collector and a debris collection bin, wherein the automatic unloading dust collector is connected to the suction hood, and the debris collection bin is connected to the unit including the automatic unloading dust collector.

[0012] Preferably, the automatic unloading dust collector includes a sealing movable cover and an unloading valve. The sealing movable cover is located at the top of the automatic unloading dust collector and is used to seal the inside of the automatic unloading dust collector. The unloading valve is located at the bottom of the automatic unloading dust collector and is connected to the debris collection bucket.

[0013] Preferably, the suction hood is connected to the automatic unloading dust collector via a pipe, and the automatic unloading dust collector has an air volume of 9000 m³ / h. 3 / h, wind pressure is 3700Pa, and inlet diameter is 35cm.

[0014] Preferably, the control system is a PLC control system, and the PLC control system is configured with air blowing parameters.

[0015] The advantages of this utility model compared to the prior art are:

[0016] 1. The triggering unit, as the "sensing center" of the device, generates trigger signals by detecting the operating status of the production line, providing start commands for the automated operation of the entire device; the blowing unit is the "power source" for debris cleaning, and its main air pipe is responsible for delivering airflow, while the solenoid valve acts as a "switch," controlling the opening and closing of the main air pipe by receiving signals from the triggering unit, thereby precisely controlling the timing of airflow injection and achieving directional blowing of debris on the production line; the collection unit acts as a "conveying channel," with the air duct used to receive the blown debris and prevent it from spreading, while the suction hood uses the suction force generated by the negative pressure generating element to efficiently transport the debris in the air duct to the downstream; the dust collection and discharge unit, as a "terminal processing station," receives and centrally discharges debris after connecting to the air duct, completing the closed loop of the entire collection process. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the application of a debris collection device for a polyurethane foaming production line according to this utility model on a polyurethane foaming production line.

[0018] Figure 2 This utility model relates to the side of a debris collection device for a polyurethane foam production line. Figure 1 .

[0019] Figure 3 This utility model relates to the side of a debris collection device for a polyurethane foam production line. Figure 2 .

[0020] Figure 4 This utility model discloses an automatic unloading dust collector for a polyurethane foam production line. Figure 1 .

[0021] Figure 5 This utility model discloses an automatic unloading dust collector for a polyurethane foam production line. Figure 2 .

[0022] Figure 6 This is a schematic diagram of the main air duct and the auxiliary air duct of a debris collection device for a polyurethane foam production line according to this utility model.

[0023] The diagram is labeled as follows: 1. Polyurethane foam production line; 2. Air blowing unit; 20. Main air pipe; 200. Auxiliary air pipe; 3. Collection unit; 30. Air duct; 300. Auxiliary air duct; 301. Pneumatic valve; 4. Dust collection and discharge unit; 40. Automatic unloading dust collector; 40. Fan; 400. Inlet; 401. Filter; 402. Blowpipe; 403. Pneumatic gate valve; 404. Discharge port; 405. Debris collection bin; 41. Detailed Implementation

[0024] To further understand the features, technical means, and specific objectives and functions achieved by this utility model, the following detailed description of this utility model is provided in conjunction with the accompanying drawings and specific embodiments.

[0025] like Figures 1-6 As shown, this utility model provides a debris collection device for a polyurethane foam production line 1, including: a triggering unit, an air blowing unit 2, a collection unit 3, and a dust collection and discharge unit 4; the triggering unit is used to detect the operating status of the production line and generate a trigger signal; the air blowing unit 2 is used to generate airflow to blow up debris on the production line, including a main air pipe 20 and a solenoid valve; the solenoid valve receives the trigger signal to control the opening and closing of the main air pipe 20; the collection unit 3 includes an air duct 30 for receiving the blown debris and a suction hood with a negative pressure generating element; the air duct 30 is connected to the suction hood to transport the debris downstream; and the dust collection and discharge unit 4 is connected to the air duct 30.

[0026] The trigger unit is connected to the solenoid valve signal. The blowing direction of the main air pipe 20 corresponds to the receiving area of ​​the air pipe 30. The suction hood sends the debris in the suction hood into the dust collection and discharge unit 4 through negative pressure.

[0027] The triggering unit, acting as the "sensing center" of the device, generates trigger signals by detecting the operating status of the production line, providing start commands for the automated operation of the entire device. The blowing unit 2 is the "power source" for debris cleaning. Its main air pipe 20 is responsible for delivering airflow, while the solenoid valve acts as a "switch," controlling the opening and closing of the main air pipe 20 by receiving signals from the triggering unit, thereby precisely controlling the timing of airflow injection and achieving directional blowing of debris on the production line. The collection unit 3 serves as a "conveying channel." The air duct 30 is used to receive the blown debris, preventing debris from spreading. The suction hood, using the suction force generated by the negative pressure generating element, efficiently transports the debris in the air duct 30 to the downstream. The dust collection and discharge unit 4, acting as a "terminal processing station," is connected to the air duct 30 to receive and centrally discharge debris, completing the closed loop of the entire collection process.

[0028] In terms of collaborative working logic, each unit forms an organic whole through signal connection and structural cooperation: the signal connection between the trigger unit and the solenoid valve ensures precise synchronization between the blowing action and the production line operation status; the corresponding design of the blowing direction of the main air pipe 20 and the receiving area of ​​the air pipe 30 minimizes the loss and diffusion of debris during the transmission process; the negative pressure conveying method of the suction hood provides continuous power for the entire process of debris from collection to discharge, ensuring collection efficiency.

[0029] The triggering unit includes a trigger block and a detection switch. The trigger block is installed on the trolley of the polyurethane foaming production line 1. The detection switch is located outside the polyurethane foaming production line 1 and corresponds to the movement trajectory of the trigger block. The detection switch is used to send a signal to the control system when the trigger block touches it. The control system controls the opening and closing of the solenoid valve.

[0030] The trigger block moves synchronously with the production line trolley. Once the detection switch is triggered, it immediately sends an electrical signal to the control system. Upon receiving the signal, the control system drives the solenoid valve, opening the air-blowing unit 2 and initiating the blowing of debris. This design achieves precise linkage of "collection starts as soon as the trolley is in position," ensuring complete synchronization between debris collection and the production line's operating rhythm. This design, through mechanical linkage, realizes closed-loop control of "motion-detection-action," providing precise and reliable startup logic for the entire debris collection device and is a core component ensuring the system's automated operation.

[0031] The main air pipe 20 is laid at the bottom front end of the polyurethane foaming production line 1. A solenoid valve is electrically connected to the control system, which controls the opening and closing of the solenoid valve to achieve intermittent air blowing from the main air pipe 20. Figure 1 As shown, the main air pipe 20 is laid at the "bottom front end of the production line," its position designed to conform to the distribution pattern of debris on the table. The air blowing direction can directly act on the debris accumulation area. The control system achieves "intermittent air blowing" through a solenoid valve, avoiding ineffective airflow consumption, reducing compressed air energy consumption, and minimizing interference from continuous airflow to other components of the production line. The solenoid valve is linked to the control system, and the blowing frequency and duration can be adjusted according to parameters such as the production line operating speed and trolley dwell time, ensuring that the blowing action matches the rhythm of debris generation and trolley movement, achieving a "directional, timed, and quantitative" blowing effect. This ensures both high efficiency in debris blowing and energy saving and system compatibility. Figure 1 The main air pipe 20 is also provided with a secondary air pipe 200 to increase the adaptability of the device.

[0032] The air duct 30 is laid at the bottom of the polyurethane foam production line 1 and is located on the corresponding side of the main air duct 20. The air duct 30 and the main air duct 20 have opposite air blowing directions. The suction hood is used to collect debris blown by the airflow generating component. Figure 1As shown, the air duct 30 and the main air duct 20 are located on opposite sides and face each other. The air blowing direction of the main air duct 20 points directly towards the area of ​​the air duct 30, forming a layout where the blowing path and the collection area overlap. Both the air duct 30 and the main air duct 20 are laid at the bottom of the production line, utilizing the unused space below the equipment for installation. This avoids occupying the production line table or the space above it, and does not affect core production processes such as trolley operation and product loading and unloading, achieving spatial compatibility between the collection function and the production process. Figure 2 As shown, the structure of the duct 30 can be configured as a multi-segment structure, dividing the duct 30 into a main duct 30 and a secondary duct 300. Setting multiple collection ports can better adapt to the polyurethane foam production line 1, such as... Figure 2 The preferred embodiment shown is an inclined baffle along the edge of the collection port, allowing debris falling onto the baffle to be guided into the suction hood at an angle. For example... Figure 6 As shown, if it is necessary to activate the debris collection of the corresponding secondary air duct 300, the valve core of the pneumatic valve 301 is activated, connecting the main air duct 30 with the secondary air duct 300. The negative pressure or blowing airflow in the main air duct 30 can act on the secondary air duct 300 to collect debris from the corresponding area (such as a specific trolley position or foaming station). If collection is not required, the pneumatic valve 301 is closed, blocking the passage between the main and secondary air ducts 300 and avoiding ineffective airflow distribution. This method makes zone control more flexible. If a secondary air duct 300 is blocked by debris or a component fails, closing the corresponding pneumatic valve 301 will not affect the operation of the main air duct 30 and other secondary air ducts 300, enabling the use of more diverse production scenarios.

[0033] The dust collection and discharge unit 4 includes an automatic unloading dust collector 40 and a debris collection bin 41. The automatic unloading dust collector 40 is connected to the suction hood, and the debris collection bin 41 is connected to the automatic unloading dust collector 40. The automatic unloading dust collector 40 includes a sealing movable cover and a discharge valve. The sealing movable cover is located on the top of the automatic unloading dust collector 40 and is used to seal the inside of the automatic unloading dust collector 40. The discharge valve is located at the bottom of the automatic unloading dust collector 40 and is connected to the debris collection bin 41.

[0034] like Figures 3-5As shown, the automatic unloading dust collector 40 also includes a fan 400, an inlet 401, a filter 402, a blow pipe 403, a pneumatic gate valve 404, and an unloading port 405. After the fan 400 is started, a negative pressure environment is formed inside the automatic unloading dust collector 40. Dust-laden gas is quickly drawn into the automatic unloading dust collector 40 through the inlet 401. After the dust-laden gas enters the dust collector, the airflow impacts the filter (such as a filter bag / filter element), and the dust is intercepted on the surface of the filter medium. The clean gas passes through the filter element and is discharged from the outlet. As filtration proceeds, dust accumulates on the surface of filter 402, reducing its efficiency. At this time, the blowpipe 403 periodically sprays high-pressure airflow (triggered by the control system) to back-purge filter 402, causing the accumulated dust to fall off and restoring filtration capacity (i.e., "pulse cleaning"). The fallen dust falls into the unloading area at the bottom of the dust collector due to gravity. When the dust in the unloading area reaches a certain amount, the pneumatic gate valve 404 automatically opens (linked by the control box or sensor), and the dust is discharged through the unloading port 405 to the debris collection bucket 41, completing "automatic unloading" without manual intervention.

[0035] The suction hood is connected to the automatic unloading dust collector 40 via a duct. The automatic unloading dust collector 40 has an air volume of 9000 m³ / h. 3 The system operates at a wind pressure of 3700 Pa and an inlet diameter of 35 cm. The control system is a PLC system, which is configured with blowing parameters. The PLC system presets blowing parameters (such as blowing frequency, duration, and interval) and links them with the dust collector's operating status. When a trigger signal is activated, the PLC synchronously starts the solenoid valve to control the main air pipe 20 for blowing, while ensuring the dust collector operates at the set wind pressure and airflow, matching the power parameters of "blowing and pushing" with "negative pressure adsorption" to form an efficient debris transport path. For example... Figure 1 The structure shown has the following blowing parameters: the number of blowing times is 2, each blowing lasts for 5 seconds, and the interval between the two blowing times is 1 second.

[0036] It should be noted that, in order to further reduce the noise of the device, a noise-reducing nozzle can be installed at the outlet of the main air pipe 20 to buffer, divert or rectify the high-speed airflow, thereby reducing noise by changing the airflow pattern. Similarly, a noise-reducing nozzle can also be installed at the outlet of the auxiliary air pipe 200 on the main air pipe 20 to comprehensively reduce the intermittent jet noise of the entire blowing unit.

[0037] The above embodiments only illustrate one or more implementations of this utility model, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of this utility model. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model should be determined by the appended claims.

Claims

1. A scrap collecting device for a polyurethane foaming production line, characterized by, include: Triggering unit, blowing unit (2), collecting unit (3) and dust collection and discharge unit (4); The triggering unit is used to detect the operating status of the production line and generate trigger signals; The blowing unit (2) is used to generate airflow to blow away debris on the production line, including a main air pipe (20) and a solenoid valve, which receives the trigger signal to control the opening and closing of the main air pipe (20); The collection unit (3) includes a duct (30) for receiving blown debris and a suction hood with a negative pressure generating element, the duct (30) being connected to the suction hood to transport the debris downstream; The dust collection and discharge unit (4) is connected to the air duct (30); The triggering unit is connected to the solenoid valve signal. The blowing direction of the main air pipe (20) corresponds to the receiving area of ​​the air pipe (30). The suction hood sends the debris in the suction hood into the dust collection and discharge unit (4) through negative pressure.

2. The scrap collecting device for a polyurethane foaming production line according to claim 1, characterized in that, The triggering unit includes a trigger block and a detection switch. The trigger block is installed on the trolley of the polyurethane foaming production line (1). The detection switch is located outside the polyurethane foaming production line (1) and corresponds to the movement trajectory of the trigger block. The detection switch is used to send a signal to the control system when it is touched by the trigger block. The control system controls the opening and closing of the solenoid valve.

3. The scrap collection device for a polyurethane foaming production line according to claim 2, characterized in that, The main air pipe (20) is laid at the bottom front end of the polyurethane foam production line (1). The solenoid valve is electrically connected to the control system. The control system is used to control the opening and closing of the solenoid valve to achieve intermittent blowing of the main air pipe (20).

4. The scrap collection device for a polyurethane foaming production line according to claim 1, characterized in that, The air duct (30) is laid at the bottom of the polyurethane foam production line (1) and is located on the corresponding side of the main air duct (20). The air duct (30) and the main air duct (20) are aligned in the blowing direction. The suction hood is used to receive the debris blown by the airflow generating component.

5. The scrap collection device for a polyurethane foaming production line according to claim 1, characterized in that, The dust collection and discharge unit (4) includes an automatic unloading dust collector (40) and a debris collection bucket (41). The automatic unloading dust collector (40) is connected to the suction hood, and the debris collection bucket (41) is connected to the automatic unloading dust collector (40).

6. The debris collection device for a polyurethane foaming production line according to claim 5, characterized in that, The automatic unloading dust collector (40) includes a sealing movable cover and an unloading valve. The sealing movable cover is located on the top of the automatic unloading dust collector (40) and is used to seal the inside of the automatic unloading dust collector (40). The unloading valve is located at the bottom of the automatic unloading dust collector (40) and is connected to the debris collection bucket (41).

7. A debris collection device for a polyurethane foaming production line according to claim 6, characterized in that, The air suction hood is communicated with an automatic unloading dust collector (40) through a pipeline, air volume of the automatic unloading dust collector (40) is 9000m 3 / h, air suction inlet (401) diameter is 35cm.

8. The debris collection device for a polyurethane foaming production line according to claim 3, characterized in that, The control system is a PLC control system, and the PLC control system is set with air blowing parameters.

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