Industry Introduction
Solution casting machines are widely used in the mass production of thin films in the electronic ceramics (alumina, aluminum nitride ceramic substrates, LTCC, HTCC, etc.), fuel cell, and polymer materials industries. From a process perspective, solution casting mainly consists of steps such as solution preparation, extrusion casting, drying, and winding.
The main components of a casting machine are: a casting nozzle for stable liquid flow, a steel belt (or drum) for film formation, and a drying system (infrared, steam, microwave, etc.). The film thickness is determined by the liquid viscosity, feed rate, and machine speed. Film precision primarily depends on the precision of the casting nozzle and steel belt. Of course, the smoothness of equipment operation is also a crucial factor affecting product quality.
Process requirements
This system uses automated control for processes such as liquid preparation, extrusion casting, drying, and winding. It requires operating consoles to be set up at both the head and tail of the machine, allowing operation from either position.
Ingredient preparation: A stepper motor is used to control the size of the feed opening, thereby controlling the speed of liquid inflow. The inflowing liquid passes through the liquid tank and then flows out for casting. Customers only need to set the liquid level height of the liquid tank, and the system will automatically perform PID control. Regardless of changes in vehicle speed, casting speed, or liquid material, the liquid level can be controlled at the set height, improving the precision of the produced products.
Extrusion casting: The liquid flowing out of the material tank passes through a horizontal blade holder, and the liquid after passing through the blade holder will form a thin film. This system only needs to set the production thickness of the film, and the blade holder will automatically adjust its height. If the casting thickness deviates during the casting process, the system will also automatically compensate for the blade holder height.
Rewinding: Utilizing the tension rewinding function of the frequency converter, the equipment can automatically change the rewinding speed when the production speed is changed.
This ceramic casting machine system can significantly reduce the number of workers required and improve product manufacturing precision and efficiency, thereby greatly reducing production costs for enterprises. Specific process and functional requirements for the ceramic casting machine.
Requirement 1: Automatic control of the liquid level in the batching process (accuracy ±0.5mm)
Requires automatic control of the height of the casting tool holder.
Requires 3-stage film take-up tension winding
Requirement 4: The equipment can be operated and monitored from both the head and tail of the machine.
Requirement 5…
Configuration Scheme
The control unit of the ceramic casting machine uses Yonghong FBs-40MAT2-AC, FBS-4AD expansion modules, and FBs-CB5 (communication) modules. The operation unit consists of two Yonghong 10-inch touchscreens. The control unit has five servo drives. The execution unit includes cylinders, drain valves, air blowing valves, and relays. The detection unit uses temperature and pressure sensors. This complete configuration helps customers save significant system costs and improve production efficiency.
mechanical mechanism
Main structure diagram of ceramic casting machine
Solution casting, from a technological perspective, mainly consists of processes such as solution preparation, extrusion casting, drying, and winding. The main components of a casting machine are: a casting nozzle for stable liquid flow, a steel belt (or drum) for film formation, and a drying system (infrared, steam, microwave, etc.). The film thickness is determined by the liquid viscosity, feed rate, and machine speed. The film precision mainly depends on the precision of the casting nozzle and steel belt. Of course, the smoothness of equipment operation is also an important factor affecting product quality.
Programming
I. Manual Operation of the Fan
After entering the "Welcome Homepage" interface, click "Manual Test Screen" to enter the "Fan Section" control interface. On this interface, you can control the operating frequency of each fan individually, monitor the real-time operating frequency of each fan, and control the start and stop of each fan.
II. Sensor Calibration Operation
After entering the "Welcome Home" interface, click "Sensor Debugging Interface" to enter the interface where you can calibrate the sensor parameters.
Hydraulic hopper distance measurement: Simply enter the current liquid level height in the input box corresponding to "Actual Value", and then click the "Calculate" button to complete the calibration.
Left/Right Servo Position: The tool holder height needs to be manually adjusted to 0. Then, click the "Tare" button. After tareing, the tool position needs to be manually adjusted to its highest position. Enter the actual height of the tool holder in the "Actual Value" input box, and then click the "Calculate" button to complete the calibration.
Photos from the scene
Debugging results
Through on-site debugging, the ceramic casting machine has significant advantages over the original equipment.
1. The level control error accuracy can be guaranteed to be within ±0.4mm, which is a high level of control precision.
2. The machine can be operated and monitored from both the head and tail of the machine to maintain its overall operation and running status.
3. The entire production process can be fully automated, requiring no manual operation.
