Sandwich Panel Production Process
1. Raw Material Loading Stage
Steel coils are precisely positioned on the uncoiler via an automated hoisting system, with photoelectric sensors monitoring the material’s position in real time. During loading, a preliminary surface quality inspection is conducted to reject materials with rust spots or scratches, ensuring the substrate meets the requirements of GB/T 12754.
2. Panel Forming Process
The panels are gradually shaped through 12 sets of precision roller molds. The initial stage involves dimensional cutting (accuracy ±0.5mm), while the subsequent stage uses a hydraulic system to complete corrugation pressing. The forming process employs constant-temperature cooling technology to ensure the hardness of the galvanized layer remains within the HRB 50-55 range.
3. Core Material Preprocessing and Layup
The rock wool core is cut three-dimensionally using a CNC cutting system (tolerance ±1mm). After cutting, automatic surface dust removal is performed. The layup process uses a vacuum adsorption device to ensure precise alignment between the core material and the bottom panel, with joint gaps controlled within ≤2mm.
4. Composite Curing Process
A two-component polyurethane adhesive is applied via a high-pressure spray gun (coating amount 250±10g/㎡). The composite panel enters a hot press for curing, with a set temperature of 65±5°C, pressure of 0.3MPa, and pressing time of no less than 30 minutes.
5. Precision Dimensional Processing
A CNC gantry cutting machine equipped with a diamond saw blade is used for precise cutting (diagonal error ≤1.5mm). Water-cooled dust removal is implemented during cutting to ensure smooth edges without burrs, meeting the dimensional accuracy standards of GB/T 23483.
6. Intelligent Logistics Transfer
Laser-guided AGVs are used for automatic panel transfer, with weight sensors monitoring the load in real time. Special clamps are employed during transfer to ensure the surface protective film remains intact, with adjustable transport speeds ranging from 0.3-1.2m/s.
7. Quality Inspection System
A three-tier inspection system is implemented:
Surface defect detection via line-scan CCD cameras (resolution 0.1mm)
Cross-sectional uniformity check using ultrasonic thickness gauges
Destructive testing by quality inspectors to verify bond strength ≥0.12MPa
8. Smart Packaging and Warehousing
The packaging system automatically generates packaging solutions based on order requirements, adopting a three-level protection system (air cushion film-corner guards-steel straps). Each batch of panels is affixed with an RFID tag for real-time product information tracking and automatically sorted to designated storage areas via conveyor lines.
The production line integrates an MES system for data traceability, with SPC statistical process control points at key stations. The annual production capacity reaches 3 million square meters, with a first-pass yield consistently above 99.2%, complying with ISO 9001 quality management system certification requirements.
