Technical Description

 

Solar Panel Pc Back Sheet - Pvdf Resin Over Pet Film/Sheet Coating Lamination Machine

 

1.2. Application Substrates:

1st Unwinder:

Substrates Min. Max.

Pet 125μm 300μm

2nd Unwinder:

Substrates Min. Max.

Pvf 15μm 50μm

Pvdf 15μm 50μm

 

1.3. Operating Environment

 

1.3.1. Environment Condition

 The Machine Assembled Altitude ≤ 1000m

 Temperature Of Machine Surrounding Should Be Around 5- 40°C

 Temperature Of The Control Cabinet Surrounding Should Be Around 10- 40°C

 Air Humidity Should Be 50-70%

 Purification Degree Of Workshop: 100000 Grade

 

1.3.2. Power Source

 Main Voltage: 3 Phases, 380v

 Max. Voltage Fluctuation: -10/+5%

 Frequency: 50hz (China)

 

1.3.3 Cooling Water

 Water Pressure: Min. 0.15mpa, Max.0.25mpa

 Water Temperature: 20～25℃

 Water Filter : Less Than 20μ

 Water Hardness (Caco3): 2.5～4mg/L

 Water Quality(Ph): 7～8.5

 Consumption: Cooling Roller 200l/Min

1.3.4. Compressed Air

 Requirements: No Oil, Dry, Filter Treated

 Cleanness: Less Than 20μ

 Air Pressure: 7bar±1bar

 Freezing Point: 2℃

1.3.5 Others

● Foundation Construction Work Will Be Done By Customer. Foundation Will Be Made According

To Standard Concrete And Steel Foundation.

● Embedded Ground, Grounding Resistance ≤4ω

2.Description Of Machine Structure And Function

 

2.1 Description Of Machine Structure

 Unwinder 2 Sets

 Corona Treatment (Optional) 2 Sets

 Dust Cleaner (Optional) 2 Sets

 Infeed 2 Sets

 Micro Gravure Coating 1 Set

 Heating Oven And Hot Air System 10 Units

 Web Guide At Exit Of Heating Oven 1 Set

 Lamination Unit 1 Set

 Cooling Unit 1 Set

 Web Accumulator 1 Set

 Rewinder 1 Set

 Frame 1 Set

 Electrical Control System 1 Set

 Pneumatic System 1 Set

 Safety Device 1 Set

 

2.2 Description Of Machine Function

This Machine Working Principle Is To Coat On Substrate, Then Pass By The Heating Oven. Under

The Heating Impressing Situation To Laminate With Other Substrate To Form A New Laminated Film.

 

2.2.1 Process Routing

1st Unwind--Corona Treatment(Option)—Dust Remove (Option)-- Infeed--Coating--Heating Oven--

Web Guide --Lamination --Cooling--Accumulator--Rewinder

2nd Unwindercorona Treatment(Option)—Dust Remove (Option)

 

3. Main Technical Data

3.1 Specification

Machine Direction From Right To Left (See From Operation Side)

Max. Mechanical Speed 80m/Min

Max. Working Speed 60m/Min (According To Coating Technics)

Max. Web Width 1350mm

Unwinder Dia. Max. Φ1000mm(Max. Loading Capacity 1000kg)

Rewind Reel Dia. Max. Φ1000mm(Max. Loading Capacity 1000kg)

Paper Core For Unwinder/Rewinder Unwinder: 6" (Φ152mm×Φ168mm)

Rewinder: 6" (Φ152mm×Φ168mm)

Guiding Roller Length 1400mm, Alu. Type, Mirror Surface Hard Oxidize

Treated

Web Fixing Method Air Chuck With Air Expanding Shaft

Glue Type Fluoro Coating Or Polyamine Resin Adhesive

Solid Content 30%-40% (Polyamine Resin Adhesive,

According To Coating Technics)

40%-50% (Fluoro Coating, According To Coating

Technics)

Viscosity Below 50cps (According To Coating Technics)

Solvent Ethyl Acetate (Polyamine Resin) Or Butyl Acetate

(Fluoro Coating)

Coating Volume (Dry) 5-8gsm(Polyamine Resin)

3-6gsm (Fluoro Coating)

Coating Method Macro Gravure

Heating Oven Length 10×4000mm=40000mm

Heating Method Thermal Oil (Oil Boiler, Pipes And Other

Connection Parts Out Of Machine Will Provide By

Buyer)

Heating Oven Temp. Max. 180 ºc

Temp. Control Accuracy ±2℃

Tension Control Range 1st Unwinder: 3-30kgf

2nd Unwinder: 3-30kgf

Rewinder: 5-50kgf

Others: 3-30kgf

Tension Control Accuracy Speed Up/Down ±0.5kgf

Constant Running ±0.3kgf

Air Pressure 0.55mpa≤P≤0.8mpa

Total Power Approx. 155kw (Not Include Heating Part)

Overall Dimension Approx.50000x6700x7400mm (Lxwh)

Machine Weight Approx. 70000kg

 

3.2 Machine Stop

There Are Two Conditions For Machine Stop Function Use

● Emergency Stop

● Normal Stop

3.3 Noise Control

 

Whole Machine Noise Level Less Than 85db A, Under The Following Condition:

● No Environment Noise

● Detect At 80% Of Machine Max. Speed

● While Web Width Is 80-100% Of Max. Web Width

● From Unwinder To Coating, 1m From Machine, 1.6m From Floor, Take Average Data.

4. Components Details

4.1 Mechanical Description

 

4.1.1. Unwinder (2 Units)

 Including The 1st Unwind & 2nd Unwinder

 Equipped With Upper And Lower Cutter For 1st And Lower Cutter For 2nd Unwinder

 Equipped With Seat Type Web Guide System For 1st And 2nd Unwinder

 Ultra Sonic Type Sensor For Web Guide, Web Guide Move Range ±75mm

 Independent Double-Armed Turret

 The Turret Can Rotate Forward And Backward By 360°

 Double Unwinder Shafts Driven By Two Separate Motors

 The Driving System Adopt High Precision Vector Inverter System With Encoder Close Loop

Control To Make Sure Reliable And Stable Speed

 Web Fix By Air Chuck With Air Expanding Shaft. Equipped With 2 Pcs 6'' Air Expanding Shaft.

 The Pneumatic Chucking Clips The Air Rising Shaft, And The Air Expanding Shaft Is Equipped

With A Safety Anti-Fall-Off Bracket. The Bracket Is Welded By Q235-A Steel Plate To Prevent

The Material From Falling Down

 The Web Roll Horizontal Adjust By Manual

 Seat Moving By Rolling Wheel With Limitation

 The Seat Is Made Of Q235-A Type Steel Welding, Roller Support, The Bottom Installation To

Adjust The Bottom Plate, The Bottom Plate Paint Treatment

 Splice System Frame Steel Type, Thickness 50mm

 With Machine Run Button, Easy To Operate

 Empty In Line Run Control, Rotate Direction Could Choose Easy To Pack

 Web Guide And Machine Interlocked, When Machine Stop, Web Guide Also Locked To Prevent

Film Slip

Specification:

-- Min. New Web Changing Dia. Φ300mm

-- Turret Speed Approx. 1r/Min

-- Driving Motor For Unwinder Ac5.5kw+Encoder+Fan (Fix After

Design)

-- Driving Motor For Turret Ac2.2kw

-- Web Guide Accuracy ±1mm

--Static Eliminator Rope 1 Set

 

4.1.2. Corona Treatment And Dust Remove Device (Option) ● Equipped With Dust Remove Device. (Option) ● Equipped With Corona Treatment Device (Option)

4.1.3. Infeed Unit (1 Set)

● Equipped With Feeding Unit Before Unwinder

● Steel Type Frame, Thickness 50mm

● Feeding Unit Consists Of A Steel Roller And A Rubber Roller To Make Sure Stable Tension.

● The Steel Roller Is Active Type, Driven By Separate Motor

● The Steel Roller Power Achieve By Ac Inverter Control System

● The Nip Roller Pressure Adjust By Pneumatic Component ● The Nip Roller Pressure Adjust By Precision Pressure Valve

● Separate Driving System With Vector Control ● Dancer Roller Tension Detecting System With Close Loop Control

Specification:

--Steel Roller Φ185mm

--Rubber Roller Φ130mm, Butyronitrile , Shore 65°～70°, White Color, Low

Stickness

--Driving Motor Ac2.2kw+Encoder+Fan

 

4.1.4. Micro Gravure Coating Unit (1 Set)

● The Tension Detection And Control By Tension Sensor For Coating Section

● The Coating Method Is Micro Gravure Reverse Coating, The Coating Roller Is Shaft Type

● The Micro Gravure Coating Roller Drive By Ac Servo Motor, Could Change Easily

● The Web In/Out Adjustable Roller Fix On Sliding Device, Guide By Linear Track, Air Cylinder To

Control The Adjustable Roller Up/Down And Adjust The Web And Micro Gravure Angle

● The Glue Tank Is Circulation Type

● Equipped With Stainless Board At Down Side Of The Frame

● The Glue Tray Up/Down By Worm Wheel And Shaft Manually

● The Doctor Press By Double Air Cylinder, With Three Direction Adjust, The Doctor Fix On Frame

● The Doctor Oscillation Speed With Certain Ratio As The Machine Speed, Separate Motor

Driving

● The Glue Supply System Provide By Buyer (Include Glue Pump, Glue Tank, Glue Pipe, Filter

And Etc.)

 

Specification:

 

--Coating Roller Dia. Φ120mm

--Doctor Oscillation ±5mm

--Driving Motor Servo Motor, Approx. 3kw (Fix After Design)

 

4.1.5. Oven And Hot Air Drying (1unit)

 Full Close Type Oven, Upper And Lower Structure, Pneumatic Control, With Heat Insulation

System

 10 Section Heating Oven With Temp. Control

 There Is Mechanical Type Drop-Proof Structure When Oven Is Open

 The Inner Side And Static Pressure Oven Material Sus201

 The Inner Side And Which Contact With Hot Air Are Adopted Stainless Steel

 The Oven And Hot Air System Air Volume Adjust By Manual Damper

 The Guide Rollers In Oven Driven By Independent Inverter Motor And Synchronized With Main

Machine

 The Guide Rollers Are Arranged As Large Camber Type

 The Fresh Air From Out Side After Pass The Primary And Middle Efficacy Filter Provide By Buyer

 The Temp. Accuracy Of Oven Is ±2℃

 The Air Nozzle At Web In And Out Of The Heating Oven Has Certain Angle, Prevent Hot Air

Leakage

 There Is Web Guide At The Exit Of Oven, Motorized Following Edge Type, Ultrasonic Detecting

Sensor

 The Guiding Roller Inside Oven Is Alu. Type With Hard Oxydize Treated, Each Section With 8

Pcs Guiding Roller And 15 Pcs Nozzle

 Equipped With One Fresh Air Blower For Each Section, With Inverter Control

 Main Exhaust Blower Provide By Buyer

 The Out Side Of Oven Painted With Painting

 The Heating Oven With Heat Insulation Device, The Insulation Device Thickness 100mm, The

Insulation Layer Adopts Glass Fiber Insulation Cotton, The Insulation Layer Filling Density Of 1

Cubic Meter Inside 42kg

 The Air Nozzle Is Movable Type With Lock Mechanism, Easy To Operate And Clean

 Negative Oven Pressure Prevent Air Leakage

 Oven Top Side With Explosion Discharge Vent

 Lel System (Option)

 

Specification:

--Web Length In Heating Oven 10x4000mm=40000mm

--Temp. In Oven Max. 180℃

--Temp. Control Accuracy ±2℃

--Max. Air Volume 10x4000m3/H

--Fresh Air Blower 10x5.5kw

4.1.6. Web Guide At Exit Of Heating Oven (1 Set)

 Single Roller Fix On Rotary Frame

 The Web Position Detected By Ultra Sonic Type Sensor

 Manual Type Edge Position Fixing

 Reliable Driving System

 With Separate Control Panel

 

4.1.7. Laminating Unit (1 Set)

 Three Roller Type Impressing System (Heating Roller At Upper Side, Lamination Roller And Back

Pressing Roller At Bottom Side, Press From Bottom To Upper)

 Independent Driving System

 Lamination Roller With Thermal Heating Function

 Pneumatic Type Pressing

 Pressing Roller Is Heating Resistant Type Silicon Rubber

 Equipped With Two Sets Adjustable Roller Before Lamination Nip Roller

 

Specification:

--Laminating Steel Roller Dia. Φ300mm

--Rubber Roller Dia. Φ160mm Harness Shore 90°±2°Heat

Resistance 110℃ Silicon Rubber, White Color, Low

Stickness

--Lamination Back Impressing Roller Φ200mm

--Lamination Steel Roller Temp. Max. 100℃

--Tension Control Accuracy ±0.3kg

--Lamination Pressure 20kg/Cm

--Driving Motor Ac5.5kw+Encoder+Fan

--Thermal Heater Temp. 60-100℃

 

 Double S Type Cooling Structure

 Cooling Roller Drive By Motor And Synchronized With Main Machine

 Adopt Water Cooling (Cooling Water Provide By Buyer)

 Cooling Water Circulated In Side The Roller, Compulsory Circulated

 Will Provide Steel Soft Pipe And Rotary Joint

 Chiller Provided By Buyer

 

Specification:

--Cooling Roller Dia. Φ600mm, 2pcs

--Cooling Water Pressure No Less Than 3kg/Cm2

--Cooling Water Temp. 20-25℃, Water Chiller (Optional)

--Driving Motor Ac7.5kw+ Encoder+Fan (Fix After Design)

 

4.1.9 Accumulator Unit (1 Set)

 Guiding Roller Type Accumulator

 The Accumulator Guiding Roller Drive By Screw Bar

 Steel Frame Type Structure

 Equipped With Safety Limitation

Specification:

--Accumulator Web Store Length Meet Machine Running At 80m/Min

--Accumulator Motor Ac5.5kw+Encoder+Fan

4.1.10. Outfeed Unit (1 Set)

● Steel Type Frame

● Feeding Unit Consists Of A Steel Roller And A Rubber Roller To Make Sure Stable Tension.

● The Steel Roller Is Active Type, Driven By Separate Motor

● The Steel Roller Power Achieve By Ac Inverter Control System

● The Nip Roller Pressure Adjust By Pneumatic Component

 

● The Nip Roller Pressure Adjust By Precision Pressure Valve ● Separate Driving System With Vector Control ● Dancer Roller Tension Detecting System With Close Loop Control

Specification:

--Steel Roller Φ185mm

--Rubber Roller Φ130mm, Butyronitrile , Shore 65°～70°, White Color, Low

Stickness

--Driving Motor Ac2.2kw+Encoder+Fan

4.1.11 Rewinder (1 Set)

 Equipped With Auto. Splice Function, Upper Cutter, With Accumulator System Achieve Zero

Speed Splice

 Machine Stop To Do Splice

 Turret Type Double-Armed Disc Turret

 The Turret Can Rotate Forward And Backward By 360°

 Double Rewinder Shafts Driven By Two Separate Motors

 The Driving System Adopt High Precision Vector Inverter System

 Web Fix By Air Chuck With Air Expanding Shaft. Equipped With 6'' Air Expanding Shaft 2pcs.

 The Web Roll Horizontal Adjust By Manual

 Close Loop Tension Control With Tapper Tension Function

 Equipped With Rewinding Nip Roller, Pneumatic Control

 

Specification:

-- Turret Speed Approx. 1r/Min

-- Driving Motor For Unwinder Ac11kw+Encoder+Fan

--Turret Driving Motor Ac2.2kw

--Tapper Tension Range 0-100%

4.1.12. Pneumatic System

● The Pneumatic System Is Safe And Reliable.

● Each Unit And Pneumatic Components Joint Point Have Water Filter

4.2. Electrical Details

 

4.2.1 Electrical Cabinet

● There Is Weather Strip On The Cabinet Door To Make Sure The Closeness

● Equipped With Blower At The Bottom Side And Top Side Of The Cabinet To Take Away Hot Air.

● Separate Lighting And Plug In Cabinet, Easy To Do Maintenance.

● Interlock Between The Door Of The Cabinet And Lighting, Blower.

● All Cabinet Have Grounding.

4.2.2 Electrical Control System

● Separate Transformer For Control Power, Safe And Stable.

● Heating, Blower Has Interlock, Safe And Save Energy.

● Led Type Indictor Light For Control Panel, Save Energy.

● Continuous Temp. Control With High Accuracy.

● Warning, Machine Run Interlock Control, Safe And Humanization.

● Several Section Close Loop Tension Control For Whole Machine

● Tension Control Adopt Vector Inverter Close Loop Control

● Non-Contact Type Sensor For Dancer Roller With High Accuracy, Reliable.

● Convenient Communication Between Operator And Machine By Using Hmi.

4.2.3. Safety

● All The Impression Rubber Roller Will Up And All Motor Will Stop Running If Machine Is In E-Stop

Situation.

● If Press E-Stop Button, Tension Control Inverter And All Servo Drive Will Stop By Our Side Hard

Ware To Make Sure All Motor Will Stop Within 5s.

5. Main Components List

5.1. Main Components With Machine

 

Detail Description Brand And Specification

 

1) Plc (With Internet Port) Innovance/Mitsubishi/Siemens

2) Hmi Rewinder Unit, Weinview 15''

Feeding, Weinview 15''

Coating Unit, Weinview 7''

3) Inverter Motor Cdqc

4) Inverter Yasakawa/Innovance

5) Low Voltage Components Schneider

6) Servo Motor Mitsubishi/Innovance

7) Servo Drive Mitsubishi/Innovance

8) Tension Control Sensor Mitsubishi

9) Precision Pressure Valve Smc

10) Main Pneumatic Parts Airtac/Easun

11) Web Guide System Xinqiao

12) Main Bearing Nsk/Ntn/Koyo

13) Temp. Controller With Heating System (Setting In Hmi)

14) Temp. Control Valve

15) Low Friction Air Cylinder Xinlinda

14) Air Blower China Made

15)Clean System China Made (Option)

5.2. Accessories On The Machine

 

Name Quantity

1) Tool Box 1 Set

5.3. Spare Parts

 

Detail Description Quantity

 

1) Bearing For Guiding Roller 5 Pcs

2) Synchronous Tooth Belt For Heating Oven 2 Pcs

3) Solenoid Valve 1pc

4) Pressure Valve 1 Pc

5) Quick Joint 10 Pcs

6) Relay 2pcs

7) Button (Green) 2pcs

8) Knob 1pc

9) Indicator Light Green 5pcs

10) E-Stop Button 1pc

6. Other Components Out Side Machine (Customer Provide)

 

1) Unloading, Transportation Assembly Use Crane And Other Tools

2) Test Material At Buyer Side

3) Air Compressor And Air Clean System

4) The Main Exhaust Blower And The Main Exhaust Duct

5) Water Chilling System And Circulation System

6) Foundation And Grounding

7) Wiring And Piping Outside Of The Machine

8) Heating System And Heating Resistance System Pipes

9) Other Items Not Specified In This Specification Sheet

10) Internet Connection Speed 2m To 4m For Remote Control Connection

7. Machine Safety

7.1 Machine Protection

 

● All The Rotary Part, Pressing Part, Cutter Part Should Have Protection (Press Roller, Plate

Cylinder Pressing Part, Unwinder And Rewinder Interlock, Transmission Belt, All Should Have

Cover Or Other Protection)

● Equipped With Light Beam For Unwinder/Rewinder

● Equipped With Emergency Pull Switch

7.2 Working At High Position

● Machine Has Plat Form

● Safety Guard (Option)

 

7.3 Static Eliminator

● Self-Discharge Electrostatic Eliminating Rope (20m)

● Electrostatic Eliminating Brush And Independent Grounding (The Grounding Need To Be

Supplied By The User.)

● Active Type Static Eliminator (Machine Equipped With 4 Sets)

 

8. Technical Documents

8.1 Operating Manual 1 Set

8.2 Manual For Main Purchased Parts

8.3 Lay Out Drawing

8.4 Foundation Drawing

8.5 Water System Drawing

8.6 Steam Or Thermal Oil Piping Drawing (When Heating Method Is Steam Or Thermal Oil)

8.7 Exhaust System Drawing

8.8 Coating Roller Drawing