High Pressure Foaming Machine

1.     Features

EMM078 series high pressure foaming machine is high-tech model combined with international technology and after market research for polyurethane industry application. Main parts are imported and the whole equipment has reliable performance and high safety standard.

EMM078-A100-H ，adopts one tank for POLY.、one tank for ISO.；Two metering units adopt independent variable-frequency motor drive, to control output flow of metering pump by changing speed of high pressure metering pump. Professional in foam industry manufacture.

2. Technical capacity

2.1 Model： EMM078-A100-H       

2.2 Foam type：hard foaming、half-hard foaming

2.3 Viscosity： (22℃)

        POLY：~2000mPas

ISO：~1000mPas

2.4 Pouring output:  150-1530g/sec (1:1),adjust range of mix ratio：5：1~1：1

2.5 Injection time：0.5~99.99 (accuracy reach 0.01s)

2.6 Injection Program No.：

Hand-injection：9

Auto-injection：99

2.7Measure unit：measure accuracy ≤0.5%

Component material	POLY	ISO.
Quantity	1	1
Pump model	A2VK28	A2VK28
Variable-frequency motor power(kw)	11	11
Motor speed(rpm)	1450	1450
Pump shaft seal lubricate	DOP	Magnetic connect (free-maintain)

For component’s measurement, it includes bracket with vibration pads, variable frequency motor, coupling, axial piston pumps and valves, electronic pressure switches, etc.

2.8 Pressure limitation & control system

Working pressure range is 6~22MPa for components，if beyond setting range, machine stop injection automatically, alarm and display error message “working pressure is no normal”

Component metering pump’s limit setting of safe pressure is 25MPa, double-protection, make sure safety of metering pump and system

Electrical protection: When the pressure reaches settings, the device automatically shut down, alarm and displays the error message "pump over pressure"

Mechanical protect: when reach 25Mpa, safe valve overflow

Metering pump lowest pre-pressure to protect POLY pump. 0.25MPa, ISO pump 0.15MPa。When the pre-pressure below the set value, the device automatically stop and alarm and display the "pre-pressure is too low," error

2.9 Component Flow Control and Test Unit

   According to requirement of pump output flow and mixture ratio of components, in the casting process will set relevant parameters of two components separately.；Components flow, through adjustment of metering pump displacement, to change the pump output flow. Test two components’ flow and mix-ration through mix ratio measure units, and fix to reach control of flow

2.10 Component filter

Ensure that foreign bodies cannot enter the circulatory system

Equipped with independent mesh filter, POLY 1 inch, ISO 2 inch,  accuracy 330μm. Regular change and sewage removal

2.11 Hydraulic unit

Pump Flow（L/min）：23

Motor power（kw）：7.5

Motor speed（rpm）：1450

l        One oil tank capacity 80L，Mounting plate above the support；

l        Mounting plate to install drive motor, oil pump, buffer coupling, hydraulic manifold block, which is installed with the booster valve, safety valve, pressure gauge, pressure switch and manual load-release valve

l        One 10L High-pressure accumulator, to ensure rapid mixing head quick-change and absorbed oscillation；

l        One precision scavenge filter with sender

l        One set of oil cooler, water valve and so on to make sure the hydraulic system temperature will not too high work when continuous working （≤60℃）

l        One set liquid level display shows the oil level inside the oil tank；

l        Two NG6 solenoid valve separately control L-shape mixing head, mix room and clean piston’s open and close

2.12 High pressure mixing head

Mixing head        1piece

Use high-pressure self-clean L-shaped from DUT Korea Technology and needle adjustable nozzle. For excellent mixing, materials mix collision from two different directions nozzles. Assembly of imported components, and more than 50 million times use has been proved by our customers

2.13 Mixing head flyarm

To support piping system and install mix head and procedures button box, 2000mm from rotatory center to end.

1.        A spring balance device to make mix head freely up and down；

2.        Horizontal rotation range 160°

2.14 High and low pressure cycle switch unit  

Control high and low pressure cycle switch separately, save energy

One hydraulic magnetic valve control separately two meter units’ high and low pressure cycle switch unit  

2.15 POLY Tank：                     1unit

l        Effective capacity：250L；

l        Layered type: inner SUS304 S/S；

l        Max. working pressure：0.6MPa；

l        One jacket water safe valve, set working pressure 0.30MPa；

l        One safe valve, set pressure 0.60MPa；

l        One relief valve with pressure gauge, set pressure 0.35 ~ 0.40MPa control max. pressure of input compressed-air of tank

l        Automatic feed exit installed check valve

l        Two manual shut-off valves (including bypass valve for sewage)

l        Liquid gauge: with visible liquid level

l        Heat exchanger: calandna

l        Thermo-sensor：PT100

l        Mechanical seal mixer, power 0.55KW, speed 46rpm; airtight enough to meet the foaming process requirements;

l        With insulation layer outside

2.16 ISO Tank                   1set

l        Effective capacity：250L；

l        Layered type: inner SUS304 S/S；

l        Max. working pressure：0.6MPa

l        One jacket water safe valve, set working pressure 0.30MPa；

l        One safe valve, set pressure 0.60MPa；

l        One relief valve with pressure gauge, set pressure 0.35 ~ 0.40MPa control max. pressure input compressed-air of tank；

l        Automatic feed exit installed check valve；

l        Manual shut-off valves (including bypass valve for sewage)；

l        Liquid gauge：fully computer control with visible liquid level

l        Heat exchanger: calandna

l        Thermo-sensor：PT100

l        Mechanical seal mixer, power 0.55KW, speed 46rpm; airtight enough to meet the foaming process requirements；

l        With insulation layer outside

2.17 Temperature control unit：

     Heating：2×3KW

Cooling unit〖Cooling Capacity（Kcal/h）〗；18000

Two heating units can separately control the heating of material in two tanks automatically (water cooler by user)

2.18 Automatic lubrication of metering pumps

    Supply auto lubrication & clean for transmission shaft & hand wheel shaft seal of POLY and ISO metering pumps, Lubricating medium is DOP

2.19 Auto-feeding unit

POLY Feeding pump（SET）           1

ISO Feeding pump（SET）           1

Flow:40L/min, feeding liquid level control, manual/auto both ok

2.20 Electric control system

Adopt Korea LG PLC, input and output modular, Delta (Taiwan)5.7 inch touch OP operator, have powerful function, easy-operation. Main electric parts are imported to ensure reliability

Equipment manual, automatic features, dry / wet injection selection function, auto circulation, equipment function and hand function and dry injection is mainly used for device debugging. Normal working conditions opt for wet injection automatic function. Automatic circulation device is mainly used to maintain normal production conditions after long time no use. Various functions Parameters operate in the Actions Menu. Control system has strong fault-alarm function, display every test points’ failure information on operation screen, with sound and light alarm devices, automatically shut down when necessary Control cabinet includes；

l        Korea LG PLC controller；

l        Delta Inverter controller；

l        Omron Relay；

l        Schneider low pressure electric parts

l        External Communication Interface；

l        System software and control program

2.21 Pipe system

    Including various components pipe and hydraulic pipe for transport components and hydraulic oil.

2.22 Machines with electric mobile system, guide by the user provide and install.

2.23 Power supply and equipment weight, area:

Voltage： 3×380V/50HZ (customized)

Input power： ～38KW 

Weight: 2500KG

Cover size: 2800X1400MM

3．Configuration and fitting parts

3．1 high pressure foaming machine configuration