M-ACP5： FRA2 ACP PRO
|
M-ACP5A2 GRADE FIREPROOF ACP PRODUCTION LINE TIPS：FR A2/B1 PRO |
ALL KINDS OF M-ACP
M-ACP1
M-ACP1 is the most common and regular aluminum composite panel production line, which is primarily used for billboard. M-ACP1 special property gives particular advantage to producing ACP in less than 0.1mm thick, but the disadvantage is big energy consumption. And there is harsh requirement of operator's qualification. One with less than 5 years of operating experience will be likely to damage the equipment. If you don't produce FR B1 ACP, M-ACP1 is one of the most cost-efficient model.
M-ACP2
M-ACP2 is the modified version of M-ACP1 with 20% less energy consumption. Three-roller laminating machine is exchanged to four-roller laminating machine for the purpose of more user-friendly operation. Compared to more than 5 years of operating experience that is required by M-ACP1, only 3-month training is enough for M-ACP2.
M-ACP3
M-ACP 3 is specifically used for making FR B1 production line, which is much more cost-efficient than that of M-ACP 2, but the price is more or less the same. While FR B1 panel is easily fabricated using M-ACP2, its requirement is much higher than that of M-ACP3. When using the 70% higher fire-retardant material, M-ACP2 cannot be normally produced. In contrast, 80% fire-retardant material can be used for the production of M-ACP 3, which outputs FR B1 panel close to FR A2. In terms of linear speed, M-ACP3 is also hard to reach 3m/min, but energy consumption is at 132kw/h, compared to 52.8% of that M-ACP2; its speed is compared to 166% of that M-ACP2.
M-ACP4
Professional ACP production line, which can make PE ACP, FR B1 ACP, and aluminum coil thickness can reach the range from 0.08mm to 0.5mm, but laminating part is equipped with three-roller, the operation will be more difficult than M-ACP3, so this machine is suitable for the customers who has been few years in this field.
M-ACP5
The fifth generation of ACP line is the latest technology ACP lines. This line can make panels of Germany A2 Grade Fire Resistant standard, this is the first choice in high-end markets.
BASIC PARAMETER
Range of Application:
1. This machinery is to make FR B1 and PE core aluminum composite panel.
Specification of Coil:
1. Inner diameter of coil: Ф405/505mm
2. Outer diameter of coil: Max.Ф1600mm
3. Weight of coil: Max. 3tons
4. Thickness of coil: 0.21mm~0.6mm
5. Width of coil: 800~1600mm
6. Coil material: Aluminum coil,GI,SS
Specification of Finished Panel:
1. Thickness: 3mm~6mm
2. Width: 800mm~1600mm
Line Speed:
1. For FR B1 panel, the Max. speed is 3m/min. Steady speed is 2.5m/min, line speed depends on core material's quality and thickness of core.
2. For PE core panel, the Max. speed is 3m/min. Steady speed is 2.5m/min, line speed depends on core material's quality and thickness of core.
CLIENT PREPARE
Power Request:
1. Total power(refer to final confirmed drawing)
2. Main power: AC 380V*3P*50Hz, one set of 380KVA transformer.
3. Power of operation: AC 220V*1P*50Hz
Workshop Request:
1. Size: at least 50m length and 9m width. (smaller than it should be custom made)
2. The height from crane hook to ground should be at least 5.5m.
3. Water pressure: 2~3kg/cm2, water consumption is 2Ton/day, please build 20tons cooled water pool or 50ton water tower.
4. Air pressure: 4~6kg/cm2, air consumption is 0.5~1m3/min, please provide air compressor.
5. Cement thickness must be over 150mm.
6. At least one 5 tons crane.
Raw Materials:
1. Core material: FR B1 core, new brand PE, recycle core material, etc.
2. Coil material:
Aluminum coil( thickness should be 0.21~0.6mm)
GI(thickness should be 0.1~0.3mm)
SS(thickness should be 0.1~0.3mm)
3. Adhesive film:
Thickness is 0.08mm
Width is 800~1610mm
Weight is 60~80kg/roll
4. Protective film:
Thickness is 0.03~0.08mm
Width is 800~1630mm
Weight is 60~80kg/roll
EQUIPMENT LIST
| NAME | QTY |
| BLENDER | 1SET |
| VACUUM MATERIAL SETTING MACHINE | 1SET |
| T-DIE | 1SET |
| EXTRUDER | 1SET |
| FOUR-ROLLER LAMINATING MACHINE | 1SET |
| ADHSIVE FILM UNREELING MACHINE | 2SETS |
| UNREELING MACHINE | 4SETS |
| HOT KEROSENE MACHINE | 2SETS |
| COOLING OVEN | 2SETS |
| PROTECTIVE FILM COVER MACHINE | 2SETS |
| TRIMMER | 1SET |
| EVENER | 1SET |
| DRIVING MACHINE | 1SET |
| CUTTING MACHINE | 1SET |
| AUTOMATIC COIL PEELING MACHINE | 2SETS |
| AUTOMATIC STACKER | 1SET |
| TROLLEY | 2SETS |
| CONTROL ELECTRIC CABINET | 1SET |
SPECIFICATION
1. Blender, 1set, Type:200
Motor power: 5.5kw
Capacity: 1250L/h( or 800kg PE)
Material: SS
Function: the capacity is 800kg/h, it can guarantee the different PE material and color material blend equably. It controls easily and can clear out the waste timely.
2. Hot air dry hopper, 1set
Material: SS
Function: it is drying the core material to avoid bubble in the panel by wet material.
3. Vacuum material setting machine, 1set, type: 1000
Motor power: 7.5kw
Capacity: 1000kg/h
Function: feeding materials tirelessly.
4. Screw and barrel use the nitriding steel and 38CrMOAL steel, the thickness of nitriding is 0.4~0.6mm, this twin barrel is professional for producing FR B1 panels. The detailed physical parameter is as below:
Strength of extension σb (MPa)：≥980(100) |
Yield strength σs (MPa)：≥835(85) |
Elongation δ5 (%)：≥14 |
Percentage reduction of area ψ (%)：≥50 |
Akv (J)：≥71 |
αkv (J/cm2)：≥88(9) |
Pencil(hardness)：≤229HB v |
Function: the advantage of twin barrel is more suitable to extrude FR B1 material, the capacity of extrusion is double times than single barrel's. As the resistance of extruding FR B1 is low enough, the power consumption is half only than single barrel's.
5. M-ACP3 and M-ACP2 comparison as below(while producing FR B1 ACP):
ITEM |
M-ACP3 |
M-ACP2 |
Power consumption for FR B1 |
132Kw, Power save |
250Kw |
Raw materials |
No requirements |
Must be high quality |
Steady line speed |
2.5m/min |
1.5m/min |
6. The extruder has 8 areas of heating loops, the power is 8.75kw/area, total 70kw.
Function: melt the core material.
7. The extruder has 8 areas of cooling fans, the power is 250w/area, total 2kw.
Function: constant temperature of heating loops, the temperature difference less than 1℃.
8. Extruder motor, power is 132kw. AC SIEMENS motor.
The temperature is displayed by RKC meters digitally from Japan.
9. Hydraulic screen exchanger, 1set.
Function: screen exchanger is regularly pushed by hydraulic cylinder, clean the impurities before compounding.
10. Mold ,1 set.
Material: SS
Width: 1700mm ( Adjustable)
Thickness: 1~10mm (Adjustable)
Heating zone: 7 areas, heating power is 6KW/area
Total power: 42kw
Function:Thickness and width of the mold mouth can be adjusted. It
can adjust the thickness of extruded core panel exactly. Mold inside with mirror polishing chromium plating processing,which good for discharging core material and maintaining discharging stability.
Total power of double screw extruding machine : 298.7Kw
1. Four-roller compound machinery
Function: Use 2pcs of Ф400×1800 mm big diameter metal rollers, heating by hot oil, inner gallbladder construct can make sure the temperature difference of the surface small than ±3℃, then the polymer film and aluminum roll are bonded uniformity.
2. Co-extrusion compound machinery
Function: Use 2pcs of Ф400×1800 mm big diameter metal rollers, constant temperature by water, inner gallbladder construct can make sure the temperature difference of the surface small than ±3℃. This machine is to compound the aluminum coil with the PE in high temperature. Use the high temperature of the PE to make the film compound to the PE hard. Use 2 pcs of big diameter roller is more suitable for fire-proof ACP (B1).
3. Four rollers and Three rollers composite machine comparison as below:
Why we recommend Four-roller laminating machine |
||
Item |
Four-roller(M-ACP3) |
Three-roller(M-ACP1) |
Technology |
The core is very hot after T-die, use this temperature to laminate core/adhesive film and coil. Power consumption is low through this way. |
First, use three rollers to cool the core, and make the core surface smoothly, then laminate core/adhesive film and coil by heating. So this part's power consumption is higher. |
Power Consumpiton |
200KW/H |
400KW/H |
Specification |
Latest technology |
Old technology |
Operation |
Easy to operate, a beginner can control is after 2 weeks training. |
Difficult to operate, a beginner can control it with at least 3 years' experience. |
When make FR B1 ACP |
Fast and easy |
Very difficult. Usually we don't recommend. |
Coil Thickness Range |
0.21-0.6mm |
0.1-0.3mm |
Summary |
Outdoor ACP |
Indoor ACP and billboard |
1. Upper adhesive film unreeling machine , 1 set
Function: The unreeling roller is automatic inflatable, film coil can be locked by this roller , total 2 pcs. when one roll of film coil end up, the other one can replace it in a short time.
2. Lower adhesive film unreeling machine , 1 set
Function: The unreeling roller is automatic inflatable, film coil can be locked by this roller , total 2 pcs. when one roll of film coil end up, the other one can replace it in a short time.
3. Brake: 50N∙M magnetic brake,2 sets
1. Upper unreeling machine , 2 sets
Material: 10mm thick steel
Brake: 400N∙M magnetic brake
Function: Use the Germany technology--slave system, it can adjust the position accuracy. The maximum distance between the chucks is 1700mm, concentricity≤ 1mm. Inflatable chuck can make sure the aluminum coil running without slipping.
2. Lower unreeling machinery, 2 sets( same as the above one)
Hot oil machinery, 2 sets
Function: Use 8 pcs of Ф400*1800mm large diameter seamless metal mirror rollers, heating by hot oil, inner gallbladder construct can make sure the temperature difference of the surface small than ±3℃. If the surface temperature difference is too large, it will reduce peeling strength of ACP because of heating unevenly.
Function: Use three groups of water air-condition cooling fans to make ACP cooled, the optimum temperature of air for the composite panels is 20 ~ 25 ℃, usually the temperature in workshop is not belong to it, if people will pay much money if they set a constant temperature environment for workshop. Use this part we can help you to save much money in electric charge.
Function: It consists of 5 mirror rollers which can make the bending plates to flat. After years of research and development equipment, we found that it's not easy to hire workers with rich experience, but it fully depends on the skills of workers to make panel smooth, then we design a simple device to help working.
1. The unreeling roller is automatic inflatable, film coil can be locked by this roller , total 2 pcs. when one roll of film coil end up, the other one can replace it in a short time.
2. Use two rubber rollers Ф150mm to make the protective film bond evenly on the surface of the aluminum composite panel.
3. The surface and the back can be bonded at the same time.
1. Trimmer
Function: Use 4 round cutting knifes to trim aluminum composite panel edge smoothly and no dust result. The adjustable width is 800~1650mm.
2. Automatic aluminum peeling machine.
Function: Is to recover the crippled aluminum from the tape after trimming.
1. AC motors, the power is 5.5kw, Siemens.
2. Driving rollers consists of two rubber rollers with Ф400 * 1800mm.
3. Inverter is ABB brand.
Function: It's the main driving power in the whole line.
1. Total power: 7.5Kw
2. Transportation Platform, 1 suit
3. Servo tracking system, 1 suit
Function: People can enter all cutting length through a 7-inch touch screen, then the machinery running and automatic cutting as per those data. No need to adjust cutting length frequently.
1. Specification
Required finished products width of machinery should be less than 2000mm, required line speed of machinery should be less than 4m/min, required center height of machinery should be 1150mm. One completed recycle period of the stacker is less than 40s, the maximum speed of transport platform is 6m/min.
2. Transport platform
Size :7450L*2208W*1020H
Power: 1.5kw
Consist of:
Shelves:10#box iron,100*50 Rectangular Tube etc
Driving System:Motor+Reducer+Chain Wheel
Transport Roller:Ф60 Driving Roller,62pcs
3. Stacker
Specification:
Size:5300L×2000W×3700H
Journey: X axis 3500mm
Y axis 2000mm
Load capacity:80Kg
Recycle speed: one single journey is less than 40s
Installed power: 3.7 KW
4. Composition:
Body: aluminum alloy frame section 90(lifting upright column) 100x100 rectangular pipe ,Q2345 panels etc.
Power system:
X axis frequency conversion motor+ rack (M=3)transmission
Y axis frequency conversion motor+ rack (M=3)transmission
Pneumatic system: vacuum pump(vacuum generator), Vacuum sucker
Suckers have 5 class,15 pcs in total and the first two classes can flip 90 degrees.
Slide unit: round lead rail
5. Trolley
Function: Stack the panel from stacker.
1. Main control cabinet
Size:W600*H2100*L600,L1300*H2100*W600mm
Consist of:
Name |
Brand |
Air Switch |
LG |
Thermal Protection Air Switch |
MOELLER |
Contactor |
Schneider |
Inverter |
ABB |
PLC |
SIEMENS |
Relay |
OMRON |
2. Operation cabinet
Size: L1250*W500*H1080mm
Can view the data and operate through a 10-inch touch screen
Consist of:
Name |
Brand |
Switch |
Schneider |
Indicator Light |
Schneider |
Emergency Stop Switch |
Schneider |
Touch Screen |
SIEMENS |
3. Extruder control cabinet
Size: L800*H2100*W600mm, L1000*H2100*W600mm
Consist of:
Name |
Brand |
Air Switch |
LG |
Contactor |
Schneider |
Thermal Relay |
Schneider |
Inverter |
ABB |
4. Automatic stacker control cabinet
Size: L1300* W500 * H1080mm
Automatic stacker can be operated by 7 inch touch screen
Consist of:
Name |
Brand |
Switch |
Schneider |
Air Switch |
LG |
Button |
Schneider |
Contactor |
Schneider |
Thermal Protection Air Switch |
MOELLER |
Inverter |
ABB |
PLC |
SIEMENS |
CONFIGURATION LIST
1. Motor: SIEMENS
2. Bearing: NSK
3. Temperature gauge: RKC
4. Roller: Rounder bar steel.
5. Unreeling machine: inflatable appliance
6. Frequency: ABB
7. Air cylinder: AIRTAC
DRAWING
