Molded Foam Production Line

AUTOMATED MOLDED FOAM PRODUCTION

MODULAR SYSTEMS FOR EXTENSIVELY AUTOMATED S MANUFACTURE OF MOLDED FOAM PRODUCTS

Considering the fact that there is now a vast range of models but fewer lot sizes and shorter production cycles, systems are required that can be used to manufacture different products in all kinds of quantities in an extensively automated and, above all, profitable manner. Our manufacturing know-how in this field gives you a high degree of investment security. This is also true for special requirements. Apart from oval conveyors and rotary tables, We can also supply highly specialized TRANSFER, TRANSFLEX, SHUTTLE and POLYSHUTTLE lines. Flexible oval conveyor systems for varied products and large quantities

MOLDED FOAM PRODUCTION

PU raw materials are processed into molded foam parts for cars per year using molded foam systems technology. Apart from seats, head and backrests, there are many other applications in which the focus is on damping, insulation and the look and feel of a material. We provides its customers with efficient system concepts for all conceivable applications and the most diverse product ideas in all kinds of quantities. Regardless of the system concept you decide on, excellent mixing quality is standard with thanks to the sophisticated mixhead technology and first-class metering pumps. Our oval conveyors use an oval transport system. The main area of application is the production of PU foam parts for car seating and head and backrests. Smaller parts as well as other products from different fields of application can also be made with the flexible systems technology. Because processors are often confronted with the challenge of using different formulations for a whole range of products depending on the manufacturer and type of car and because the number of seating variations is increasing steadily, a mold change is often required. oval conveyors are appropriate here especially because they have an automated in and out feed station (QCD or ECD system) which enables the exchange of mould carriers during production and at a conveyor speed of up to 15 m/min.

Stationary systems

Low production volumes Large / heavy moulds Short curing times

Different cycle times Bumpers Rocker panels

Spoilers Back-foamed carpeting Back-foamed instrument panels

PUR- CSM spray technology ClearRIM Variable arrangement of

mould carriers / moulds, i.e. in line, semi-circle or full circle Use of built-on mixheads

(multi-point metering) Hand-held mixhead Filling manipulator

Robot (with an additional linear axis, if necessary) Operator himself determines the

cycle time No need for a transport system Easily expandable

Versatile fields of application

Rotary tables

• Medium To High Production Volumes • Applications, Where Defined

Work Stations Always Carry Out The Same Operations • Headrests

• Sun Visors • Seats / Backrests • Instrument Panels

• Furniture Parts • Back-Foamed Components • Gearshift Knobs

• Different Rotary-Table Diameters Available Depending On Mouldcarrier Size And Number

• Either For Continuous Or Cyclioperation • Energy Supply Through A Rotary

Column In The Rotary-Table Axis • Automatic Mould-Carrier Infeed And Outfeed (Available As An

Option) • Filling Manipulator • Robot

• Cycle Defined By The Rotary Table • Each Work Station Is Specialised And Needs To Be Equipped Only

Once • Straightforward Material Flow • Versatile Fields Of Application

Oval conveyors

• Medium To High Production Volumes • Applications, Where Defined

Work Stations Always Carry Out The Same Operations • Seats / Backrests

(Typically Dual-Hardness Foaming) • Oval Track Conveying System

• Designed For Continuous Operation • Energy Supply To The Additional

Units Through Slip-Ring Collector • Mould-Carrier Opening And Closing Either Hydraulically,

Mechanically By Skids Or By Opening/Closing Station • Automatic Mould-Carrier Infeed

And Outfeed (Available As An Option) • Filling Manipulator

• Robot • Cycle Defined By The Oval Conveyor

• Easily Expandable Production Line Based On Extension • Each Work Station Is Specialised

And Needs To Be Equipped Only Once • Straightforward Material Flow

Shuttle Systems

• Low production volumes (pilot or sample lots) • Applications, where curing and

processing times are more or less identical • laboratory plant

• Sprayed skins • Back foamed instrument panels and vehicle carpeting

• Seats • Central PU cabin served by two independent, laterally moving

shuttles, on which (bottom) moulds are mounted • Hand-held mix head

• Filling manipulator • Robot • Clear complexity

• Low concatenation factor • Space-saving design

Poly Shuttle systems

• Complex Or Time-Consuming Insertion Work Or Mould Preparation

(Foam-In-Cover Method) • Substantially Varying Curing Times

• Vehicle Seats, Backrests • Radial Rail System Arranged In A Three-Quarter Circle With

Radial Mould-Carrier Movements • Mould Filling At The Centre Of The System

• Filling Manipulator • Robot • Operator Has Control Over Cycle

• Operator Personally Responsible For Quality, Performance-Related Pay Therefore Feasible

• Fewer Rejects

Transfer and Trans Flex systems

• Large Variety Of Different Product Designs Feasible • Two PU Processing Steps On

One System • Differently Coloured Spray Skins For Instrument Panels, Centre

Consoles, Etc. • Differently Coloured Spray Skins For Backfoamed Inner Door

Panels • Alternative Work Stations Connected By Conveyor With

Pre-Defined Priorities For Each Mould • Mould Transport On Pallets

• Different Routes For Alternative Operations • Self-Driven Mould Carriers

• Modular Shunting Tracks • Filling Manipulators • Robots

• Maximum Flexibility In Terms Of Product Diversity And Expandability

• Fully Automatic And Process controlled Operation

AUTOMATED MOLDED FOAM PRODUCTION

Modular Foam Line For Automobiles

Flexible oval conveyor systems for the continuous production

of high-quality moulded foam products Every year, several thousand tons of PU raw materials are processed

into moulded foam parts all over the world moulded foam systems technology. When it comes to realizing

their product ideas, well-known manufacturers from various fields of application opt for the highly efficient system for a wide range of moulded foam products in different quanitites. Apart from extremely

fast cycle times, customers benefit from state-of-the-art multi-component mix head technology and intelligent systems for carrying the moulds.

A great variety of product ideas in different quantities – the range of application

The main application of oval conveyors is to produce PU foam parts for the automotive industry. In this sector, users are Faced with a growing number of car models but smaller lot sizes and shorter production cycles. As a result, processing systems are required that can be used to manufacture a great variety of products in different quantities automatically and profitably. In this field, manufacturing know-how offers you a high degree of investment security. Apart from seats, backrests, headrests and armrests, there are also numerous applications from other areas where the focus is on comfort and/or look and feel and which are successfully produced with the flexible WKH systems technology all over the world.

Features

Oval conveyors use an oval transport system. Thanks to its consistent modular design, it can easily be expanded

and flexibly adjusted to suit changing production requirements. Of course, the same applies when the plant is already in operation. The advantages of the sophisticated design are also evident in terms of maintenance. For example, the operator's access to all plant modules has been facilitated because the guide and control elements of the mould carrier trolleys have been reduced significantly. In the plant version with the mould carrier trolley, the need for guide and control elements has almost completely been eliminated. This is especially advantageous for cleaning. In addition, WKH systems are compelling because of various other USPs:

Perfect alignment of all mechanical components of the trolley chain for a smooth and jerk-free movement Optional use of a cleaning module (Cleaning Carrier) which can be introduced instead of a mould carrier trolley and effectively removes foam residues from the floor

Metering Machines

Metering Machines are a synonym for top class polyurethane processing and the heart of countless PU processing

systems all over the world. The machine concept incorporates a well

thought-out arrangement of the individual assemblies as well as

first-class quality components. systems rely on a further

development of the it has

been optimized to meet the specific requirements of moulded foam

production and is suitable for processing up to six reactive components

in a plant network. Users benefit from an extremely compact machine

frame that incorporates all elements of a reactive component and,

compared with the classical scores points because

the pipework has significantly been reduced. Combined with a

temperature control system in the component feed line, a very precise

temperature control is thus ensured. When using two mix heads or

two injection robots, is employed as a twin module.

Especially when it comes to multi-component applications with up to

twelve metering lines, this again means that a considerable amount

of precious footprint is saved. Apart from the efficient raw material

temperature control system,

Axial Piston Pumps are included in the

standard scope of delivery of the unit. If desired, users can opt

for state-of-the-art magnetic coupling technology and other features

Molded Foam Line For Automobiles