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MINGHUNG
Ⅰ.Continuous flat-press hot-press machine
1. Core Concept:
Continuous Production: Unlike traditional batch-operated multi-daylight presses, continuous flat presses operate uninterruptedly. Formed fiber mats are fed continuously into the press inlet, undergo heating, pressing, and curing while moving through the press, and emerge as solid panels continuously from the outlet.
Flat Pressing: Pressure is applied perpendicularly to the panel surface, ensuring uniform thickness and smooth, flat surfaces – essential for high-quality MDF.
Hot Pressing: Simultaneously with pressure, heat (typically from oil- or steam-heated platens) is applied to rapidly cure the resin binder (e.g., urea-formaldehyde) and bond the wood fibers.
2. Main Components & Working Principle:
Steel Belt System: The defining feature. Two long, robust, high-strength continuous steel belts (upper and lower) form the conveying and pressure-transfer surfaces for the mat/panel.
Heated Platen System: Positioned inside the steel belts along the press length are large heated platens (often divided into multiple heating zones). These platens contain channels circulating hot oil or steam, transferring heat through the belts to the mat. They are the primary heat source.
Hydraulic Cylinder System: Generates the immense pressure. Hundreds or even thousands of hydraulic cylinders are densely arranged along the length and width outside the platens. Their piston rods act through pressure beams or frames to apply force uniformly to the platens, which transmit it via the steel belts to the mat.
Drive System: Powerful motors drive sprockets or rollers that synchronously and steadily move both steel belts, pulling the mat through the entire hot pressing zone.
Inlet/Outlet Sections: Precise feed mechanisms (e.g., leveling rolls, metering rolls) ensure uniform, continuous mat entry. Discharge mechanisms remove the pressed panel at the outlet.
Frame: Massive, robust steel structure designed to withstand enormous pressures and equipment weight.
Control System: Highly automated PLC system integrating control of pressure, temperature, belt speed, panel thickness, and other critical parameters.
Ⅱ. Technical Principle and Workflow
1. Thickness Control Target
Core Metric: Finished board thickness tolerance ≤ ±0.1mm (far superior to the traditional ±0.3mm standard).
Significance: Reduces sanding allowance (can be lowered to below 0.2mm), saving 3%-5% of raw materials, and improves surface processing quality.
2. Workflow (Closed-Loop Control)
Real-time Thickness Detection: Sensors continuously measure the actual thickness of the board exiting the press zone.
Data Comparison with Target Value: The measured thickness is instantly compared to the preset target thickness value.
Deviation Check: The system determines if the deviation between the measured thickness and the target value exceeds the allowable ±0.1mm tolerance.
Actuator Adjustment (If Deviation > Tolerance): If the deviation is too large, the system sends commands to the thickness adjustment actuators.
Dynamic Adjustment Execution: The actuators dynamically adjust the distance between the hot platens or apply localized pressure compensation.
Feedback Loop: After adjustment, the system returns to Step 1, continuously monitoring the new thickness to close the control loop. If the deviation is within tolerance, monitoring continues without adjustment.
III. Detailed Explanation of Core Subsystems
1. High-Precision Thickness Detection System
Detection Method | Principle | Accuracy | Application Scenario |
Beta-ray Thickness Gauge | Calculates thickness based on material absorption of beta radiation | ±0.05mm | High-speed lines (>10 m/min) |
Laser Scanner | Non-contact scanning of board surface profile using triangulation | ±0.03mm | Boards requiring extreme surface flatness |
Contact Probe | Continuous measurement using diamond-tipped stylus (requires cooling system) | ±0.01mm | Low-speed precision lines |
2. Actuators: Dynamic Platen Gap Adjustment System
Hydraulic Servo Cylinders
Response Time: <50 ms
Displacement Resolution: 0.005 mm
Layout: Zoned control along the press length (typically 8-16 zones)
Platen Structure Innovations
Thermal Expansion Compensation Design: Platens embed temperature sensors for real-time correction of thermal deformation errors.
Honeycomb Reinforcement Ribs: Ensure platen flatness ≤ 0.05mm/m even at 200°C.
3. Intelligent Control System
Algorithm Core: Adaptive PID (Proportional-Integral-Derivative) + Feedforward Compensation
Feedforward Compensation: Pre-adjusts pressure based on detected mat density fluctuations at the inlet.
Multi-variable Coupling Control: Synchronously coordinates temperature, pressure, and speed parameters.
Hardware Platform: Industrial Real-time Ethernet (EtherCAT) + Multi-core PLC
IV. Key Technologies Enabling ±0.1mm Accuracy
1. Dynamic Thermal Deformation Compensation
Fiber Bragg Grating (FBG) temperature sensors embedded within the platens build real-time thermal expansion models. The control system automatically counteracts deformation errors caused by temperature gradients.
2. Multi-Zone Independent Pressure Control
A 60-meter long press is divided into 12 independent pressure zones. Each zone is equipped with 4 servo cylinders.
3. Vibration Suppression Technology
Utilizes accelerometers + active dampers to eliminate thickness fluctuations caused by steel belt vibration, controlling amplitude within ±5 micrometers (μm).
V. Production Benefit Analysis
Metric | Traditional Press (±0.3mm) | High-Precision Press (±0.1mm) | Improvement Effect |
Sanding Allowance | 0.5-0.8mm | 0.15-0.25mm | Raw Material Saving ≥4% |
Premium Product Rate | 85%-90% | 96%-99% | Value Add ≥US$10/m² |
Line Speed | ≤8 m/min | 12-15 m/min | Capacity Increase 30% |
Thickness CpK | 1.0-1.2 | ≥1.67 | Six Sigma Capability |
The ±0.1mm thickness automatic adjustment technology represents the core competitive advantage of fiberboard continuous presses, directly determining product value-add. The system's capabilities in hydraulic servo precision, thermal deformation compensation algorithms, and multi-zone coordinated control have ushered the artificial board industry into the era of precision manufacturing.
Founded in 1983, Shandong MINGHUNG OSB&MDF Machinery Equipment Manufacturing Co.,Ltd., specializes in continuous press solutions for over 40 years.
MINGHUNG is a leading company in the industry of OSB&MDF making machine. With a strongfocus on producing high-quality machinery, we specialize in manufacturing thecomplete production line of Medium density fiberboard (MDF), High densityfiberboard (HDF),Particle board (PB), Oriented strand board (OSB), andVeneerable super strong particle board (LSB).
For more information, welcome contact us, we will reply you quickly and offer working videos with you.
Whatsapp: +8618769900191 +8615589105786 +8618954906501
Email: osbmdfmachinery@gmail.com
Ⅰ.Continuous flat-press hot-press machine
1. Core Concept:
Continuous Production: Unlike traditional batch-operated multi-daylight presses, continuous flat presses operate uninterruptedly. Formed fiber mats are fed continuously into the press inlet, undergo heating, pressing, and curing while moving through the press, and emerge as solid panels continuously from the outlet.
Flat Pressing: Pressure is applied perpendicularly to the panel surface, ensuring uniform thickness and smooth, flat surfaces – essential for high-quality MDF.
Hot Pressing: Simultaneously with pressure, heat (typically from oil- or steam-heated platens) is applied to rapidly cure the resin binder (e.g., urea-formaldehyde) and bond the wood fibers.
2. Main Components & Working Principle:
Steel Belt System: The defining feature. Two long, robust, high-strength continuous steel belts (upper and lower) form the conveying and pressure-transfer surfaces for the mat/panel.
Heated Platen System: Positioned inside the steel belts along the press length are large heated platens (often divided into multiple heating zones). These platens contain channels circulating hot oil or steam, transferring heat through the belts to the mat. They are the primary heat source.
Hydraulic Cylinder System: Generates the immense pressure. Hundreds or even thousands of hydraulic cylinders are densely arranged along the length and width outside the platens. Their piston rods act through pressure beams or frames to apply force uniformly to the platens, which transmit it via the steel belts to the mat.
Drive System: Powerful motors drive sprockets or rollers that synchronously and steadily move both steel belts, pulling the mat through the entire hot pressing zone.
Inlet/Outlet Sections: Precise feed mechanisms (e.g., leveling rolls, metering rolls) ensure uniform, continuous mat entry. Discharge mechanisms remove the pressed panel at the outlet.
Frame: Massive, robust steel structure designed to withstand enormous pressures and equipment weight.
Control System: Highly automated PLC system integrating control of pressure, temperature, belt speed, panel thickness, and other critical parameters.
Ⅱ. Technical Principle and Workflow
1. Thickness Control Target
Core Metric: Finished board thickness tolerance ≤ ±0.1mm (far superior to the traditional ±0.3mm standard).
Significance: Reduces sanding allowance (can be lowered to below 0.2mm), saving 3%-5% of raw materials, and improves surface processing quality.
2. Workflow (Closed-Loop Control)
Real-time Thickness Detection: Sensors continuously measure the actual thickness of the board exiting the press zone.
Data Comparison with Target Value: The measured thickness is instantly compared to the preset target thickness value.
Deviation Check: The system determines if the deviation between the measured thickness and the target value exceeds the allowable ±0.1mm tolerance.
Actuator Adjustment (If Deviation > Tolerance): If the deviation is too large, the system sends commands to the thickness adjustment actuators.
Dynamic Adjustment Execution: The actuators dynamically adjust the distance between the hot platens or apply localized pressure compensation.
Feedback Loop: After adjustment, the system returns to Step 1, continuously monitoring the new thickness to close the control loop. If the deviation is within tolerance, monitoring continues without adjustment.
III. Detailed Explanation of Core Subsystems
1. High-Precision Thickness Detection System
Detection Method | Principle | Accuracy | Application Scenario |
Beta-ray Thickness Gauge | Calculates thickness based on material absorption of beta radiation | ±0.05mm | High-speed lines (>10 m/min) |
Laser Scanner | Non-contact scanning of board surface profile using triangulation | ±0.03mm | Boards requiring extreme surface flatness |
Contact Probe | Continuous measurement using diamond-tipped stylus (requires cooling system) | ±0.01mm | Low-speed precision lines |
2. Actuators: Dynamic Platen Gap Adjustment System
Hydraulic Servo Cylinders
Response Time: <50 ms
Displacement Resolution: 0.005 mm
Layout: Zoned control along the press length (typically 8-16 zones)
Platen Structure Innovations
Thermal Expansion Compensation Design: Platens embed temperature sensors for real-time correction of thermal deformation errors.
Honeycomb Reinforcement Ribs: Ensure platen flatness ≤ 0.05mm/m even at 200°C.
3. Intelligent Control System
Algorithm Core: Adaptive PID (Proportional-Integral-Derivative) + Feedforward Compensation
Feedforward Compensation: Pre-adjusts pressure based on detected mat density fluctuations at the inlet.
Multi-variable Coupling Control: Synchronously coordinates temperature, pressure, and speed parameters.
Hardware Platform: Industrial Real-time Ethernet (EtherCAT) + Multi-core PLC
IV. Key Technologies Enabling ±0.1mm Accuracy
1. Dynamic Thermal Deformation Compensation
Fiber Bragg Grating (FBG) temperature sensors embedded within the platens build real-time thermal expansion models. The control system automatically counteracts deformation errors caused by temperature gradients.
2. Multi-Zone Independent Pressure Control
A 60-meter long press is divided into 12 independent pressure zones. Each zone is equipped with 4 servo cylinders.
3. Vibration Suppression Technology
Utilizes accelerometers + active dampers to eliminate thickness fluctuations caused by steel belt vibration, controlling amplitude within ±5 micrometers (μm).
V. Production Benefit Analysis
Metric | Traditional Press (±0.3mm) | High-Precision Press (±0.1mm) | Improvement Effect |
Sanding Allowance | 0.5-0.8mm | 0.15-0.25mm | Raw Material Saving ≥4% |
Premium Product Rate | 85%-90% | 96%-99% | Value Add ≥US$10/m² |
Line Speed | ≤8 m/min | 12-15 m/min | Capacity Increase 30% |
Thickness CpK | 1.0-1.2 | ≥1.67 | Six Sigma Capability |
The ±0.1mm thickness automatic adjustment technology represents the core competitive advantage of fiberboard continuous presses, directly determining product value-add. The system's capabilities in hydraulic servo precision, thermal deformation compensation algorithms, and multi-zone coordinated control have ushered the artificial board industry into the era of precision manufacturing.
Founded in 1983, Shandong MINGHUNG OSB&MDF Machinery Equipment Manufacturing Co.,Ltd., specializes in continuous press solutions for over 40 years.
MINGHUNG is a leading company in the industry of OSB&MDF making machine. With a strongfocus on producing high-quality machinery, we specialize in manufacturing thecomplete production line of Medium density fiberboard (MDF), High densityfiberboard (HDF),Particle board (PB), Oriented strand board (OSB), andVeneerable super strong particle board (LSB).
For more information, welcome contact us, we will reply you quickly and offer working videos with you.
Whatsapp: +8618769900191 +8615589105786 +8618954906501
Email: osbmdfmachinery@gmail.com
