1. Definition  

Industry 4.0, a strategic framework initiated by Germany in 2011 , represents the Fourth Industrial Revolution. It centers on Cyber-Physical Systems (CPS) to achieve smart manufacturing by integrating physical machinery with digital technologies such as IoT, AI, big data, and cloud computing.  

2. Significance  

Efficiency leap: Real-time process optimization  

Flexible manufacturing: Support small-batch customization  

Predictive maintenance: Reduce downtime by 25–40%  

Servitization: Shift from selling machines to lifecycle services  

II. Continuous Press for Wood-Based Panels  

1. Basic Concept  

A continuous press is the core equipment for producing wood-based panels (e.g., MDF, particleboard). It replaces batch-type hot presses with continuous high-pressure/high-temperature forming, enabling non-stop production.  

2. Working Principle

(1) Mat Formation: Wood raw material spread uniformly on steel belts  

(2) Pre-pressing: Initial compaction to remove air  

(3) Hot Pressing: Zone-controlled heating (180–220°C) for resin curing  

(4) Cooling & Setting: Dimensional stabilization  

(5) Cutting: Sawing to required dimensions

mat forming machine

pre press machine

continuous hot press

trimming sawing and cutting machine

3. Key Parameters

Parameter	Typical Range
Width	2.5–8.5 meters
Pressure	500–1500 MPa
Line Speed	500–2000 mm/s
Daily Output	1000–3000 m³

4. Major Components  

4.1 Structural Innovations  

Twin-Belt Precision Drive  

  Ni-based alloy steel belts (1.5±0.03mm) with laser-etched anti-stick patterns  

  Tension control accuracy: ±0.5kN, real-time thermal expansion compensation  

Zoned Pressure Control  

  20-36 independent hydraulic zones (300-500mm/zone)  

  High-frequency servo valves (response time <5ms), pressure fluctuation <±0.7MPa  

4.2 Thermodynamic System

Gradient Temperature Field  

Zone	Temperature	Function
Entry	180-190℃	Activate resin fluidity
Mid-section	200-220℃	Core curing (UF resin crosslink)
Exit	170-180℃	Prevent surface cracking

Heat Recovery  

  Waste heat utilization >85% (flue gas → raw material drying)

4.3 Thickness Control Technology  

Multi-sensor Fusion  

  γ-ray densitometer: Profiles density distribution (resolution 0.5%)  

  Laser thickness scanner: 128 points/sec, accuracy ±0.03mm  

Real-time hydraulic gap adjustment  

1. Industry 4.0 Integration  

Digital Twin Optimization  

  Virtual press model with 12,000+ parameters (thermal conductivity, rheology, etc.)  

  Guides reality: e.g., initiates pressure release at 92% resin cure  

AI Defect Prediction  

Adaptive Control  

Raw Material Response  

  NIR moisture detection (±0.3% accuracy)  

  Press time auto-adjust: +1.2 sec per 1% moisture increase  

Energy Management  

  Off-peak production mode: +15% output at night  

  Hydraulic VFD control: 30% power at idle  

Predictive Maintenance  

Component Health Monitoring  

  Steel belt fatigue: Acoustic emission for micro-cracks (alarm >25dB)  

  Cylinder seal: Pressure sensor detects leakage (alarm at >3% error)  

Intelligent Maintenance  

  Big-data fault library (100,000+ cases) recommends optimal solutions  

  Spare parts auto-replenishment (accuracy >89%)  

2. Key Advantages  

15% Energy Saving: Dynamic heating power adjustment  

12% Higher Yield: Closed-loop control eliminates thickness variation  

40% Faster Product Changeover: One-click recipe switching  

30% Lower Maintenance Cost: Predictive upkeep avoids breakdowns