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ALX-4000 Automatic Stamping Production Line Of Photovoltaic Frame

ALX-4000 photovoltaic frame automatic stamping production line is a new generation of photovoltaic frame automatic processing equipment launched by our company, integrated with automatic feeding, automatic transmission, automatic sawing, automatic stamping, automatic embossing, automatic dusting, automatic recovery, and automatic detection on aluminum profile. The modular design improves production efficiency, high product precision and a high degree of automation, safe and reliable.

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Description

The photovoltaic frame automatic stamping production line consists of short frame automatic line and long frame automatic line with energy saving and environmental protection design of low power consumption, low noise, and tail material recycling, etc. It is suitable for the production and processing of existing frame specifications in the market.

Product Features

A: Efficient and economical: The highly automated and intelligent design requires only one operator for feeding.

B: Precise cutting: double-material cutting with an accuracy up to ±0.1°.

C:Strong functionality: equipped with automatic length and hole detection, industrial Ethernet interface and information interaction expansion capabilities.

D: User-Friendly operation: The electrical control system has a very user-friendly full-parameter human-machine interface, which makes it extremely easy for operators to use.

E: Energy saving and environmental protection: It is equipped with negative pressure dust collection, sound insulation and noise reduction room, and centralized tail material recycling device, ensuring a clean and tidy site.

F: Safe and stable: DC24V voltage circuit is adopted, the stamping is equipped with a grating, and the moving machinery is equipped with a protective cover.

G: Technological innovation: intelligent operations such as rear-push feeding, double-axis alignment, aluminium angle track switchover, and transfer are adopted.

H: Advanced configuration: high-end control system is adopted, and advanced controller is selected.

Technical Parameters

The photovoltaic frame automatic stamping production line consists of a short frame automatic line and a long frame automatic line.

Name	Photovoltaic frame automatic stamping production line (long frame )	Photovoltaic frame automatic stamping production line ( short frame )
Model	AGBZX-25	AGBZX-15
Processing length range (mm)	1600～2500	990～1500
Processing section range (mm)	B side width : 30-40, C side width : 10-35
Work cycle (s)	≤3.2	≤3.2
Angel accuracy (°)	±0.1	±0.1
Cutting length accuracy (mm)	±0.15	±0.15
Qualified rate of processing	99.8%	99.8%
Staffing (person/station)	2.5	2.5
Rated Power(KW)	20	20
Boundary dimension (mm)	21500×5000×2200	18500×5000×2200

Main structure

A: Feeding unit

a. Manual placement of materials, automatic feeding, automatic transmission via five groups of belts.

b. The clamped material is turned over. Single aluminium profile, the pneumatic clamping jaws automatically turn over once the raw material is clamped.

c. Alignment. Double aluminium profiles, the cylinder pushed the tail end flat and automatically align.

d. Step-by-step material moving. Double aluminium profiles, horizontal moving and telescopic, automatic material moving.

e. Automatic pushing material. Double aluminium profiles, automatic material pushing via motor intermittent motion.

B: Sawing unit (double-head saw, sawing manipulator, double-wheel conveying)

a. Automatic positioning, automatic cutting.

b. Double-material feeding, Double-material sawing.

c. Automatic dust removal, automatic transmission.

d. Cutting angles: 35°, 45°, 55°.

e. Centralized collection of scrap material.

C: Punching unit (punch press, punch tool, lifting manipulator, feeding manipulator, unloading manipulator)

The loading manipulator clamps the product from the loading mechanism and moves it to the punching station. After the product is automatically aligned and positioned, the upper and lower template are driven by the punch press automatically to close the dies and to punch holes in the aluminum profile.

D: Stamping unit (single-wheel conveying, stamping, punch tool).

a. After automatic punching, the product is transported by the clamping jaw of the discharging mechanism to the riveting and pressing station. After the product is automatically aligned and positioned, it is automatically riveted and stamped.

E: Discharging unit

a. Finished product output: multiple finished products are fed and conveyed through belt rotation.

b. Automatic material discharging

F: Control unit

a. Stamping unit control cabinet

b. Stamping position touch screen

c. Sawing unit control cabinet

d. Sawing position touch screen

Products Advantage

A: Feeding unit

a. The feeding platform adopts 5 conveyor belts and 2 support designs to ensure smooth running from feeding to flipping; other manufacturers mostly use 4 conveyor belts, which have poor stability.

b. The stepping lifting base block adopts the combination method, which is compatible with all profiles on the market at present and does not need to be replaced; Most of the base blocks of other manufacturers are not combined, and the support blocks must be replaced when changing the type.

c. The guide wheels are upgraded; double-row guide wheels are set at the front end of the feeding, and multiple guide wheels are set at the sawing station to ensure that the workpiece is pushed to the sawing station smoothly; the guide wheel structure of other manufacturers is different and the stability is slightly worse.

d. The feeding platform uses 4 motors +4 reducers. The first 2 motors have the function of aligning the profiles, and the last 2 motors have the function of accelerating separation. There is no relative movement between the profiles and the conveyor belt, and no displacement will occur. In the case of full material, no friction marks will be occurred on the surface of the profiles. Other manufacturers do not have the functions of aligning and accelerating separation.

B: Sawing unit

a. It adopts a combined structure of upper compaction and side compaction. The upper compaction cylinder comes with a solenoid valve to improve the sawing speed, with side compaction and lower jacking in place detection to ensure that the profile will not be displaced while sawing, thereby improving stability. Other manufacturers have upper positioning without side compaction or lower positioning.

b. The flipping of the material sorting manipulator has been changed from the original ordinary cylinder structure to servo control, which has improved the operation accuracy and shortened the work cycle time; most of other manufacturers adopt a cylinder combination structure.

c. Fully automatic production line, automatic alarm pause, intelligent safety protection, artificial intelligence.

C: Transmission unit

a. The power of the double-wheel conveying motor has been increased from 400W the commonly used in the market to 750W, and the line speed has been increased from the original 2m/s to 2.5m/s, reserving speeding up space for the production line.

b. Install a pressing roller device at the double-wheel and single-wheel transmission position to prevent the profile from jumping and derailing during transmission;

c. Single-wheel and double-wheel transmission adopts combined wheels. The wheels are adjusted through combination to adapt to 30mm, 35mm and 40mm profiles on the market, and are compatible with all profiles with and without C edges.

D: Punching unit

a. The lifting manipulator of punch press adopts a single cylinder structure, which fundamentally solves the fault occurrence at this position (the original double cylinder structure will cause a fault when the cylinders are not synchronized); the cylinders of most of other manufacturers act at the same time, which is not conducive to fault handling.

b. The punch press structure is optimized and compatible with most punch tools on the market to save costs for customers. Punch tool maintenance or adjusting sizes can be done at the workstation, saving time and labor intensity.

c. The hydraulic station uses a vane pump and air cooling method, which makes the equipment less noisy, can optimize the working environment. It has a large oil tank to ensure more stable equipment operation. The hydraulic cylinder is controlled by a synchronous motor to ensure synchronously lifting and lowering of the hydraulic cylinder body, extend the service life of the linear axis and linear bearing, and save costs. Other manufacturers' hydraulic stations use gear pumps and have no air cooling, which are noisy and have high oil temperatures.

E: Stamping unit

a. The bottom plate of the stamping unit is specially designed with strong compatibility, can save costs for customers;

b. There are two storage methods for aluminium angle: ammunition clip type and hollowed-out type, which are convenient for customers to choose according to their own situation. The hollowed-out type structure is simple and flexible to feed materials, and the feeding personnel can load aluminium angles with spare time, which is suitable for enterprises with few production lines. The ammunition clip type has a more beautiful appearance and requires a dedicated person to load the aluminium angles, which is suitable for enterprises with many production lines.

c. The connection method between the aluminium angle and the frame can realize interference connection and riveting functions.

F: Good compatibility

a. Adopt multi-angle, multi-specification precise control scheme, first , it can be compatible with various appointed profile specifications. Second, it can realize processing of profiles with and without film. Third, it can be cut at angles of 35°, 45°, 55°.

b. The tail material is easy to collect

c. The sawing and punching units are equipped with tail material centralized recovery device, material head and aluminum scrap are collected separately.

G: Fast replacement

a. Through adjusting the feeding transfer wheel base and adding pads on the incoming material conveying wheels, can realize the rapid switching of profiles; it will take about 0.5-2 hours (2 people) depending on the switched product.

H: Detection function

a. It has the function of automatic length and missing hole detection, automatic identifying and sorting the unqualified products