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JYCH-2536 Inflatable Line
JYCH-2536 Insulating Glass Production Line
Elevate your glass manufacturing process with the JYCH-2536 Insulating Glass Production Line, tailored to maximize efficiency and quality in large-scale production environments. Designed to automate and streamline key tasks, this production line excels in producing insulating glass for various applications, including tempered, curtain wall, and solar photovoltaic glass. With features that ensure precise handling and optimal sealing, the JYCH-2536 empowers you to deliver superior glass products faster and more reliably, ensuring you stay ahead in a competitive market.
- Automatic Inflation Production Line
- 01. Loading Section
Universal Wheel Structure
Your loading section is equipped with a universal wheel structure that enhances mobility and practicality, especially when loading and transporting large glass panels using a crane. This flexibility is crucial in handling various sizes and weights of glass, allowing for smooth entry into the production line and improving operational efficiency.
Advanced Coating Detection Technology
With new coating detection technology, your system automatically identifies the front and back sides of LOW-E and coated glass. If glass is incorrectly placed, the system halts transmission, preventing potential damage and ensuring that each piece is processed correctly. This safeguard not only protects the material but also optimizes the processing sequence for quality assurance.
Large and Small Head Structure
To prevent jamming and potential damage to the glass, your loading section incorporates a large and small head structure. This design strategically prevents glass panes from getting stuck in the bearings during transit, thereby protecting the glass from scratches or breakage. This mechanism is essential for maintaining high-quality standards throughout the processing.
Transmission Pause Function
This section includes a transmission pause function that allows for a temporary halt in movement when loading large glass sheets. This pause ensures that the glass is positioned steadily and safely before entering the cleaning machine. This feature is critical for safely handling large and heavy glass, reducing the risk of damage and enhancing overall workplace safety.
- 02. Glass Cleaning Section
Stainless Steel Construction
Your cleaning section is constructed using top and bottom plates welded from 10mm and 8mm thick stainless steel, respectively. All components within the chamber are also made from stainless steel, ensuring durability and resistance to corrosion. This structural integrity is essential for longevity and reliability in the moist conditions typical of glass cleaning processes.
Specialized Brush Design
Equipped with a 200mm diameter brush made from nylon silk soft hair, your section can effectively clean both single and double silver LOW-E glass. This material choice ensures gentle yet effective cleaning, preventing scratches while handling delicate coatings.
Brush Bearing Structure
The brush bearings in your cleaning section feature a special design that prevents water ingress, enhancing durability and ensuring smooth operation over long periods. This feature reduces maintenance frequency and costs by protecting critical components from water damage.
Optimized Water Nozzle Layout
Your cleaning section includes eight strategically placed water nozzles, with four at the front and four at the rear. This setup ensures comprehensive cleaning coverage, efficiently removing contaminants from all glass surfaces.
Rubber Conveyor Rods
The conveyor rods in your system are made from pure rubber, chosen for its durability and non-abrasive properties. This design helps protect the glass from any secondary damage during transit through the cleaning section.
Independent Motor Control for Brushes
Your cleaning section's brush system is powered by six independent motors, allowing for individual adjustment and alignment. This flexibility is beneficial for maintenance and consistent cleaning performance as brushes wear over time.
Inclined Wind Knife Structure
The wind knife system features an inclined design, crafted from an aluminum profile that is integrally formed. This structure ensures a large air volume and uniform air output, which aids in rapidly drying the glass post-cleaning.
Adaptive Wind Knife Bracket
Made from aluminum alloy, the wind knife bracket automatically adjusts its opening based on the glass's thickness. This adaptability is crucial for effectively drying different types of glass, from laminated to ordinary hollow, thereby improving overall drying efficiency.
Automatic Air Valve in Fan
The fan in the cleaning section is equipped with an automatic air valve that closes when the conveyor halts. This feature prevents the creation of wind marks on the glass and conserves energy by reducing unnecessary air flow when the system is not in active transport mode.
Dual Heating Function
The cleaning section includes a dual heating function, which accelerates the cleaning and drying processes. This feature is particularly useful in increasing throughput and efficiency in high-demand production environments.
Optional Noise Reduction and Dust Prevention
An optional feature in the fan system offers noise reduction and dust prevention. This enhancement is designed to improve the operational environment by reducing noise levels and preventing dust accumulation, which can impact machine performance and worker safety.
Secondary Bag Water Circulation Treatment
Another optional feature is the secondary bag water circulation treatment in the water tank. This advanced water treatment improves the quality of circulating water, which is crucial for maintaining high cleanliness standards and prolonging the lifespan of the cleaning system.
- 03. Cleaning and Discharging Section
Dual Motor Operation Mode
This section can be optionally equipped with a dual motor operation mode, which significantly enhances the efficiency of your cleaning machine. By utilizing two motors, you can handle higher throughput, thereby increasing your overall production capacity. This feature is particularly beneficial for scaling up production without compromising on the quality of glass cleaning.
Wake-Up Mode for Energy Conservation
Equipped with a wake-up mode, your section optimizes energy usage and enhances safety. The transmission wheel halts when there is no glass to process, conserving power. However, it promptly resumes operation when glass is detected, ensuring continuous production without unnecessary energy waste. This feature not only saves energy but also reduces wear and tear on the machinery, contributing to longer equipment life.
Enhanced Glass Transport System
The back plate features a specially designed backrest wheel equipped with non-marking wheels. These wheels are meticulously selected to transport glass with minimal contact, effectively reducing the risk of marks or abrasions. This feature is particularly crucial for maintaining high standards in glass processing, ensuring that each piece progresses to the next stage in pristine condition.
- 04. Aluminum Frame Checking Section
Aluminum Profile Construction
Your aluminum frame checking section utilizes one-piece aluminum profiles to ensure structural integrity and prevent deformations. This meticulous construction guarantees that every glass panel and aluminum frame aligns precisely, resulting in high-quality insulating glass units. This precision contributes significantly to reducing waste and rework in your production process.
Variable Speed Control with Frequency Converter
Equipped with a frequency converter, your section finely controls the motor's speed, syncing perfectly with the photoelectric switch for optimal glass transport. This technology allows you to streamline your production flow, enhancing throughput while maintaining quality, and reducing the likelihood of bottlenecks.
Large Hollow Rear Panel Design
A large hollow design at the rear of the panel provides easy access for routine maintenance and quick resolution of issues like stubborn stains. This feature ensures that your operations run smoothly with minimal downtime, keeping productivity high and maintenance costs low.
Pause Switch for Immediate Control
A strategically placed pause switch in your section allows immediate stopping of operations, enabling quick intervention in case of anomalies. This capability not only prevents potential damage to materials but also ensures the safety of your operations, maintaining continuity and quality across the production line.
Elevated Motor Installation
By elevating the motor installation, your design smartly frees up space at the rear of the unit, facilitating easier and more efficient maintenance access. This thoughtful placement reduces downtime during routine checks and ensures that maintenance tasks are less disruptive to your production schedule.
- 05. Transition Section
The transition section of your production line plays a critical role in the seamless movement of glass between production stages. This section is equipped with multi-sensors and dual motors that operate in a coordinated fashion to expedite the transfer of glass to the next section. The sophisticated control system ensures that the front glass is moved out swiftly and then halted precisely to prepare for the arrival of the subsequent glass panel.
This meticulous timing prevents the rear glass from colliding with the front panel, a result of unanticipated speed variations. By optimizing the movement and timing of glass panels, this section significantly enhances the efficiency of your production process while maintaining the highest safety standards to avoid any damage to the glass.
Multiple Photoelectric Sensors
Your transition section is equipped with multiple photoelectric sensors that enhance precision in glass handling. These sensors meticulously monitor the position and speed of the glass panels as they move through the section. This high-density sensor environment allows for refined control of the production flow, ensuring that each glass panel is accurately tracked and managed.
Dual Motor Segmented Operation
Featuring dual motor segmented operation, this section offers superior handling and control of the glass panels. Each motor is programmed to operate independently, allowing for segmented and precise movement of the glass. This capability is crucial for managing varying speeds and loads, ensuring that the glass is transported safely and efficiently without risk of collision or bottlenecks.
Utilization of Dual Motors
The use of dual motors in this section provides additional power and control for handling glass panels. This setup allows for a balanced distribution of mechanical force, which enhances the stability and consistency of glass movement. The dual motors ensure that even large or heavy glass panels can be moved with ease, reducing strain on the system and increasing the longevity of the machinery.
- 06. Plate Pressing Section
Precision-Machined Back Plate
Your plate pressing section benefits from a back plate finely planed by a machining center, ensuring minimal error in glass joining. This precision engineering ensures each insulating glass unit is flawlessly assembled, enhancing the final product's structural integrity and visual clarity.
Four-Axis Servo Linkage
Equipped with four-axis servo linkage, your system efficiently handles joining, pressing, and inflating processes. This integration allows for seamless operation and greater control over the assembly process, ensuring that each unit meets stringent quality standards with increased throughput.
Automatic Glass Positioning
The automatic glass positioning feature drastically reduces manual handling, ensuring each pane is perfectly aligned before the pressing process. This not only speeds up production but also minimizes the risk of human error, contributing to consistent quality across your product line.
Intelligent Glass Dimension Detection
With automatic detection of glass length and height, your equipment adjusts to create the optimal space for inflation, saving gas consumption and reducing operational costs. This smart adjustment enhances resource efficiency and ensures each unit is produced with precision.
Servo Motor with Synchronous Belt Drive
Your pressing mechanism includes a servo motor paired with a synchronous belt drive, linear guide rail, and ball screw for precise opening and closing actions. This configuration results in highly accurate and controlled pressing, crucial for achieving the perfect seal in insulating glass units.
Openable Door Design for Maintenance
The openable door design of your plate pressing section simplifies access for inspection and maintenance. Additionally, all guard plates are coated with durable, aesthetically pleasing plastic, combining functionality with a sleek appearance that withstands the rigors of an industrial environment.
Customizable Appearance
Offering an option to customize the appearance color of your plate pressing section, we allow clients to tailor the equipment to fit their factory aesthetic or corporate branding. This personalization enhances the visual integration of your equipment within client facilities, adding an extra layer of client satisfaction.
- 07. Unloading Section
The unloading section of your production line is strategically designed to enhance the efficiency and smoothness of glass handling as it transitions to the glue coating stage. This section is outfitted with advanced induction photoelectric sensors and densely arranged backrest and transmission wheels. These components work together to ensure rapid and smooth transfer of glass panels.
The precise coordination of the sensor inputs with the mechanical movement minimizes delays and maintains a steady flow of glass, preparing it accurately and efficiently for subsequent coating applications. This setup not only boosts throughput but also reduces the risk of glass damage during handling, maintaining the high quality of the final product.
- Electrical Control System
Advanced HCFA Bus System
Your equipment incorporates the HCFA bus system, a state-of-the-art digital control technology that enhances your production line with high automation and straightforward operation. This system ensures precision in every task, improving the consistency and accuracy of your operations. With this system, you can enjoy a smoother, more efficient production flow, minimizing errors and boosting productivity.
Touch Screen Human-Machine Interface
Equipped with a touch screen human-machine interface (HMI), your equipment offers an intuitive platform for seamlessly toggling between manual and automatic modes. The interface displays the operating status in real-time, allowing you to efficiently monitor and manage your production processes. This feature is vital for maintaining continuous operation and swiftly addressing any potential issues, ensuring minimal downtime and maximum efficiency.
Aviation Plug Connections in Electrical Cabinet
The electrical cabinet in your system uses aviation plug connections, renowned for their safety and exceptional anti-interference properties. These connections are not only secure but simplify both the initial installation and ongoing maintenance. Aviation plugs provide reliable and durable connections, critical for enduring the demands of an industrial setting and sustaining high performance without interruptions.
| Parameter | Specification |
|---|---|
| Processing glass size | Minimum: 280×450mm, Maximum: 2500×3600mm |
| Original glass thickness | 3-18mm |
| Processing insulating glass thickness | Maximum: 50mm |
| Power supply | 380v, 50Hz |
| Total power | 45.0kw (including heating power 4kw) |
| Working direction | Right in and left out/left in and right out |
| Working speed | Cleaning: 3-9m/min, Post-cleaning: 8-45m/min |
| Overall dimensions | 26500×2000×3700mm (Customized models may vary) |
| Total weight | 11000kg |
- Main Components
| No. | Component Name | Brand |
|---|---|---|
| 1 | 01-stage height measuring servo | HCFA |
| 2 | 02 cleaning machine opening and closing servo | HCFA |
| 3 | 03 measuring lifting servo | HCFA |
| 4 | 04 measuring lifting servo | HCFA |
| 5 | External forward and backward servo | HCFA |
| 6 | Plate press-1 pressing servo | HCFA |
| 7 | Plate press-2 curtain control servo | HCFA |
| 8 | Plate press-3 positioning rod servo | HCFA |
| 9 | Plate press-4 lower support servo | HCFA |
| 10 | 04-1 aluminum frame positioning rod servo | HCFA |
| 11 | 04-2 aluminum frame lower bracket lifting servo | HCFA |
| 12 | PLC | HCFA |
| 13 | Cleaning transmission inverter | HCFA |
| 14 | 03-1 transition section transmission inverter | HCFA |
| 15 | 03-2 transition section transmission inverter | HCFA |
| 16 | 04-1 aluminum frame section transmission inverter | HCFA |
| 17 | 04-2 aluminum frame section transmission inverter | HCFA |
| 18 | Beam lifting frequency conversion | HCFA |
| 19 | 05-1 external section control frequency conversion | HCFA |
| 20 | 05-2 external section control frequency conversion | HCFA |
| 21 | Variable speed motor | Xinchao reducer |
| 22 | Limit switch | Japan Omron |
| 23 | Circuit breaker series | Schneider |
| 24 | Photoelectric switch | Biduke |
| 25 | Terminal block series | Germany Phoenix |
| 26 | Push button switch | Mingwei |
| 27 | Touch screen | Fanyi |
| 28 | Solenoid valve series | Taiwan AirTac |
| 29 | Foot switch | Chint |
| 30 | Cylinder series | Chint |
| 31 | Water pump | Hanlun |
| 32 | Plate compressor | Anyi |
| 33 | Brush | Haoernuo Rubber Roller Brush Co., Ltd. |
| 34 | Transmission wheel | Jiayuan Rubber and Plastic |
| 35 | Bearing | Harbin Group |
| 36 | Gear | Xingyu |
| 37 | Drive | Beijing Jicheng Weiye |
| 38 | Duplex | Taiwan AirTac |
| 39 | Hydraulic station | Jingyou |
| 40 | Capacitive proximity switch | Swiss Carlo Gavazzi |
| 41 | High-pressure blower | Shanghai Hanshuo |
- Vertical Gluing Production Line
Designed for Large-Scale Operations
The vertical gluing production line is ideal for large-scale glass deep processing enterprises, significantly reducing labor intensity and enhancing operational efficiency. This system is tailored to meet the high-volume requirements of your industry, streamlining processes and boosting productivity.
Intelligent Touch Human-Machine Interface
Equipped with a fully intelligent touch human-machine interface, your production line offers ease of operation. This intuitive interface simplifies the control of the gluing process, making it accessible and manageable, even for operators with minimal technical experience.
Advanced Three-Layer Glass Gluing Capability
Your system supports three-layer glass gluing, capable of forming either once or twice with a quick interval of 3-4 seconds between moldings. This feature not only speeds up production but also enhances throughput significantly, making it a time-efficient solution for your glass processing needs.
Versatility in Glass Sizing
The production line is designed to handle both large and small pieces of glass, providing versatility across various project requirements. This adaptability ensures that your equipment can meet a wide range of production demands, from large building panels to smaller decorative pieces.
Servo Control System from a Renowned Brand
The servo control system in your production line uses components from world-renowned brands, ensuring stable performance and reliability. This high-quality system guarantees precision in gluing applications, crucial for maintaining consistent product quality.
Synchronous Belt Transmission
Featuring synchronous belt transmission, your equipment offers smooth glass conveying and precise positioning. This mechanism ensures that each piece of glass is handled gently and accurately placed for gluing, reducing the risk of errors and material waste.
Durable Key Components
Key components of your production line are made from special materials that ensure stable operation and an extended service life. This durability is critical in maintaining operational efficiency and reducing downtime due to maintenance or component failure.
High-Quality Gluing Results
After gluing, the periphery of the glass is uniformly covered with no air lines, and the corners are well-formed. The flatness of the finished product is such that it does not require corner trimming, showcasing the precision and effectiveness of your gluing technology.
Pre-Storage and Assembly Line Operation
The third section of your line can pre-store glass, enabling true assembly line operation and integration with online sealing processes. This feature allows for continuous production flow, reducing stoppages and enhancing overall line efficiency.
Dual Independent Glue Supply Systems
Equipped with two sets of safe and independent glue supply systems, including mixers, your production line allows for quick switching between two sealants. This system can be operated with the push of a button, providing flexibility and reducing downtime when changing glue types or refilling.
- Technical Parameters
| Parameter | Specification |
|---|---|
| Power supply | 380v, 50Hz |
| Total power | 15KW |
| Maximum glue extrusion pressure | 32Mpa |
| Air source pressure | 0.4-0.6mm |
| Gluing speed | 5-40m/min |
| Maximum glass size | 2800×4500mm |
| Minimum glass size | 280×450mm |
| Overall dimensions | 11100×1500×3600mm (Customized models may vary) |
- Main Components
| No. | Component Name | Brand |
|---|---|---|
| 1 | Rotary servo | Yaskawa |
| 2 | Lifting servo | Yaskawa |
| 3 | Suction cup servo | Yaskawa |
| 4 | 01 Conveyor servo | Yaskawa |
| 5 | 02 Conveyor servo | Yaskawa |
| 6 | 03 Conveyor servo | Yaskawa |
| 7 | 04 Conveyor servo | Yaskawa |
| 8 | 01 Module controller | Yaskawa |
| 9 | 02 Module controller | Yaskawa |
| 10 | Servo motor | Yaskawa |
| 11 | Touch screen | Fanyi |
| 12 | PLC | Yaskawa |
| 13 | Inverter | Hechuan |
| 14 | Circuit breaker | Schneider |
| 15 | Contactor | Schneider |
| 16 | Relay | Schneider |
| 17 | Photoelectric switch | Biduke |
| 18 | Proximity switch | Biduke |
| 19 | Reducer | Xinchao reducer |
| 20 | Solenoid valve (single) | AirTac |
| 21 | Solenoid valve (double) | AirTac |
| 22 | Cylinder | AirTac |
| 23 | Electric proportional valve | AirTac |
| 24 | Precision pressure reducing valve | AirTac |
| 25 | Switching Power Supply | Mingwei |
- Butyl Rubber Coating Machine
Automatic Nozzle Width Adjustment
Our machine automatically adjusts the glue nozzle to match the width of the aluminum strip. This precision ensures optimal glue application and reduces material waste, enhancing both the efficiency and quality of your production line.
Swing-Out Glue Cylinder
The glue cylinder of our machine swings out easily, allowing for quick and efficient glue loading. This design enables you to process up to 14KG of glue at a time, minimizing downtime and maintaining a steady production flow.
Accommodates Various Strip Widths
Our machine efficiently processes aluminum strips ranging from 4mm to 30mm in width. This capability allows you to meet diverse production needs with one piece of equipment, increasing your operational flexibility and reducing the need for multiple machines.
Stainless Steel Construction
Our machine is constructed from high-quality stainless steel with a brushed finish, providing a durable and aesthetically pleasing workspace. This robust design ensures longevity and maintains a professional appearance in your production environment.
Imported Gas-Liquid Booster System
You benefit from an imported gas-liquid booster system that delivers stable pressure for even glue application. This feature ensures consistent quality in every piece you produce, reducing errors and improving overall product quality.
Five-Speed Variable Frequency Speed Regulation
Our machine features a five-speed variable frequency speed regulation, which automatically updates the glue application times. This adaptability leads to higher production efficiency and quicker response times to changing production demands.
Glue Cylinder Alarm System
Equipped with a glue cylinder alarm system, our machine alerts you when glue levels are low, preventing production interruptions. Additionally, the machine's ability to be turned on 24 hours a day saves preheating time, ensuring it's always ready when you need it.
Touch Screen Human-Machine Interface
Our machine includes a touch screen interface that simplifies machine operation. This easy-to-use interface allows for quick adjustments and reduces training time for operators, enhancing both usability and productivity.
Convenient Glue Head Adjustment Mechanism
The specialized glue head adjustment mechanism on our machine makes it easy and quick to adapt to different sizes and types of production runs. This flexibility improves machine uptime and ensures you can swiftly meet varying customer demands.
- Technical Parameters
| Parameter | Specification |
|---|---|
| Power supply | 380V, 50HZ |
| Gluing speed | 0-40m/min |
| Air supply pressure | 16-20MPa |
| Glue head adjustable range | 4-27mm |
| Temperature | 130-160℃ |
| Air source pressure | 0.6-0.8MPa |
| Glue cylinder diameter | 195mm |
| Overall dimensions | 3000×700×1250mm |
- Glass Unloader
Versatile Glass Handling
Our unloader is designed to handle a diverse range of glass types, including insulating glass, tempered glass, glass curtain walls, deep-processed glass, and solar photovoltaic glass. This versatility makes it an essential tool for businesses that operate across different segments of the glass industry, enabling you to meet varied client requirements with a single piece of equipment.
Multi-Angle Flipping Capability
Equipped to handle multi-angle flipping, our unloader facilitates the safe and efficient manipulation of glass sheets. This feature is particularly beneficial in environments where space is limited or where glass needs to be oriented precisely for further processing or installation, enhancing operational flexibility and safety.
High Load Capacity
Our machine boasts a maximum load capacity of up to 350kg, accommodating glass lengths of up to 6 meters and widths up to 4 meters. This high capacity allows you to manage large and heavy glass panels, reducing the need for manual handling and thus minimizing the risk of injury and product damage.
- Technical Parameters
| Parameter | Specification |
|---|---|
| Power supply | 380V, 50HZ |
| Gluing speed | 0-40m/min |
| Air supply pressure | 16-20MPa |
| Glue head adjustable range | 4-27mm |
| Temperature | 130-160℃ |
| Air source pressure | 0.6-0.8MPa |
| Glue cylinder diameter | 195mm |
| Overall dimensions | 3000×700×1250mm |
