New Trend in Polyurethane Foaming Industry: How Can Robotic Automation Reduce 30% Scrap Rate?

1. Core Function and Industry Value of Equipment

The six-axis robot two-component polyurethane high-pressure foaming machine is a modern foaming equipment that integrates high-precision metering, dynamic mixing and intelligent trajectory control. Its core function is to solve the problems of low efficiency and unstable quality in traditional manual or low-pressure foaming processes. Through high-pressure injection and robot collaborative control, the equipment can achieve precise foaming of complex three-dimensional paths. It is widely used in automobiles, home appliances, construction and other fields, significantly improving product consistency and production efficiency.

Comparison of Technical Advantages

Efficiency Improvement: High-pressure mixing shortens the reaction time of raw materials by more than 50%, and the foaming speed can reach 3 times that of traditional low-pressure equipment.

Quality Optimization: The uniformity of the foam cells is more than 95%, and the density deviation is controlled within ±2%, avoiding the common defects of manual foaming such as shrinkage and collapse.

Environmental Compliance: Adapt to environmentally friendly foaming agents.

2. Working principle and technical composition

High-pressure foaming system

The equipment completes foaming through the following process:

Raw material supply: Material A (polyether polyol) and material B (isocyanate) are stored in constant temperature material tanks respectively, and the material level is monitored by a magnetic flap level gauge, and the stirring motor prevents deposition and stratification.

High-pressure metering: The high-precision metering pump pressurizes the raw materials to 8-13MPa, and removes impurities through a self-cleaning filter to ensure flow stability.

Dynamic mixing: In the hydraulically driven mixing head, the large and small pistons work together, and the A/B materials collide at high speed in the mixing chamber to form a homogeneous mixture and then inject it into the mold. After the injection is completed, the gun is automatically cleared.

Six-axis robot control system

Trajectory planning: Based on model or touch screen programming, the robot can complete the continuous casting of special-shaped surfaces (such as car dashboards and seats).

Intelligent linkage: Integrated photoelectric detection and glue supply system, realize multi-station automatic switching, support 200 sets of process parameter storage, and adapt to small batch customized production.

3. Application fields and typical cases

Automobile manufacturing

Seats and interiors: high-resilience foam molding, adjustable density (30-80kg/m³), meet the needs of comfort and lightweight.

Sealing strip production: two-component polyurethane is seamlessly sealed by robot glue coating to improve waterproof and sound insulation performance.

Home appliances and building materials

Refrigerator insulation layer: high-pressure foaming ensures closed-cell rate>90%, and thermal conductivity as low as 0.022W/(m·K).

Building wall panels: vertical surface spraying thickness error <1mm, avoiding flow problems in manual construction.

Medical and electronics

Medical equipment cushion: solvent-free formula meets biocompatibility requirements, and the robot accurately controls the foaming area.

4. Operation precautions and maintenance points

Safety regulations

Personal protection: Operators need to wear protective glasses and rubber gloves, and the environment is well ventilated to avoid inhalation of B material vapor.

Emergency treatment: When A material contacts the skin, wash with soapy water. If B material splashes into the eyes, rinse immediately for 15 minutes and seek medical attention.

Equipment maintenance

Daily maintenance:

Clean the filter before each startup (the filter for material B needs to be soaked in DMF) and discharge 200g of raw materials.

Check the oil pressure (14-16MPa) and oil temperature (≤60℃) of the hydraulic station to prevent abnormal movement of the gun head.

Troubleshooting:

Clean the high-pressure filter element when the filter high-pressure alarm sounds to avoid crystallization and blockage of material B.

Idling the metering pump will damage the equipment. Ensure that the liquid level in the material tank is above the lower limit.

Environmental control

The raw material temperature must be constant (20-25℃ for material A and 15-20℃ for material B). The hot and cold water machine should be set to a temperature ≥10℃ to prevent crystallization of material B.