Automatic Laminated Glass Autoclave Equipment

LIJIANG Glass Automatic Laminated Glass Autoclave Equipment

Figure 1 LIJIANG Glass Automatic Laminated Glass Autoclave Equipment

Equipment data

1.1 Processed glass size

1.1.1. Maximum glass size: 2500mm*8000mm

1.1.2. Minimum glass size: no requirement

1.1.3. Tempered glass thickness: no requirement

1.1.4. Original glass thickness: 2.8~19mm

1.2 Power distribution requirements

Power requirements: 220/380VAC, 3P+PE, 50/60Hz, transformer margin>=500 KVA

Total power distribution: 470Kw (including air compressor unit)

Among them: the total power of the glass autoclave is 380Kw, and the total power of the air compressor unit is about 90Kw.

1.3 Water and air source requirements

1.3.1. Water supply: 0.7 cubic meters/minute, pressure >=3kgf/sqm (minimum pool capacity. 30cbm or more)

1.3.2. Cooling tower flow requirement: 50 cubic meters/hour

1.3.3. Air source requirements: pressure 0.6~1.3Mpa, flow rate >=7.5m³/min

1.4 Building Basic Requirements

1.4.1. Coverage area: 15000mm*5000mm (length*width).

1.4.2. Basic load-bearing: >=40 tons

Figure 2 The Structure of Automatic Laminated Glass Autoclave Equipment 1

Figure 3 The Structure of Automatic Laminated Glass Autoclave Equipment 2

Equipment composition

Overall characteristics

The forced cross-convection glass autoclave is a sealed pressure vessel with forced dual-system convection internal circulation heating. The temperature, pressure, and vacuum are effectively controlled inside. Using PID control, precise control of temperature and pressure can be achieved, so that The temperature and pressure can be changed completely according to the design curve; it is suitable for the synthesis and production of laminated glass according to various process requirements. Especially products with intermediate films made of PVB or SGP materials can ensure perfect product quality and yield.

There are six stages in the standard working process of LIJIANG Glass architectural glass autoclave equipment, which are the preheating and preprocessing stage, medium temperature and medium pressure stage, high temperature and high-pressure stage, heat preservation and pressure holding stage, pressure holding and cooling stage (graded cooling), and pressure relief stage. The entire operation process of temperature and pressure adopts a PLC-based PID control system. The temperature and pressure realize real-time online monitoring and are equipped with fully automated operating procedures and manual-automatic switching shortcut keys.

Figure 4 LIJIANG Glass architectural glass autoclave equipment

Technical features

1. Kettle body

It is completely designed and manufactured by the international standard "Pressure Vessel" standard. The kettle cover and cylinder are pressed/rolled from Q345R steel plates. The kettle cover flange and kettle body flange are made of 16Mn integral forging.

2. Quick door opening system

The door opening and closing system of LIJIANG Glass automatic glass autoclave equipment has undergone strict quick opening stress and life calculations. Designed and manufactured under the premise of ensuring maximum safety and longevity, the entire system consists of three parts, namely a pair of toothed flanges, a driving device, and a sealing ring.

The door opening method is: hydraulic door opening

3. Insulation system

3.1 Insulation method: internal insulation

3.2 Insulation material: aluminum silicate + rock wool

3.3 Insulation layer package version: stainless steel brushed plate, 0.8mm

3.4 Insulation layer thickness: 80mm

4. Floor supports and rails

4.1. Track loading weight: 20,000kgs. If overloaded, the user needs to specify otherwise.

4.2. Track form: unequal angle steel

4.3. Loading weight of the bottom support of the kettle: 6000kgs. If the weight is increased, the user will specify otherwise.

4.4. Kettle bottom support form: anti-slip pattern steel plate (4mm)

5. Electric heating system

5.1 The heating system consists of a main heating area, an auxiliary heating area, and a temperature supplement area. The heating elements are distributed at the tail of the kettle, the air ducts on both sides and the bottom of the kettle to ensure the uniformity of the temperature in the kettle during the heating process and shorten the heating time, achieving the purpose of energy saving.

5.2 Inside the air duct, heating elements are arranged, and hot air circulates from back to front. During the advancement process, the heated glass loses heat. This part of the heating element allows the circulating hot air to replenish heat again, achieving uniform temperature throughout the heating process. The heating of ultra-long glass kettles is particularly important.

5.3 Adopt nickel-chromium alloy fin heating elements with high electrothermal conversion rate and service life. The electrothermal conversion rate is above 95% and the service life is 15,000 hours.

5.4 The heating element conduction control adopts silicon-controlled rectifier (SCR) regulation to ensure the stability of the power system when starting and stopping the heating system and also improves the service life.

6. Pressure system

6.1 The air intake and exhaust adopt pneumatic ball valves controlled by solenoid valves, one each, with a carbon steel structure, which can realize automatic control.

6.2 Manually controlled exhaust ball valves, 2 pieces, carbon steel structure.

6.3 Two high-temperature-resistant special pressure sensors ensure accurate feedback of the pressure in the kettle at all times. Measurement accuracy: 0.5% F.S.

6.4 The pressure relief system is equipped with a silencer (used during installation and purchased by the customer at his option).

Figure 5 The pressure system of LIJIANG Glass Automatic Laminated Glass Autoclave Equipment

7. Heat exchange system (also called cooling system)

7.1 There are coolers evenly distributed on both sides of the kettle (inside the air duct) as auxiliary cooling. The overall galvanized seamless boiler tube + aluminum fins have high heat exchange efficiency, long service life, and easy maintenance. This structure is used for extra-long kettles, and the cooling effect is very obvious.

7.2 A surface-cooled fin heat exchanger is installed at the rear of the kettle as the main cooler, with a large heat dissipation area and high heat exchange efficiency.

7.3 The cooling system is specially designed with a drainage structure to prevent a large amount of steam from being generated during the heating process and to prevent the cooling system from freezing at low temperatures.

8. Forced convection system (hot air circulation)

8.1. System parameters

Fan power: 37KW, insulation level: H class, connection form: direct connection, fan speed: 970r/min (AC frequency 50Hz). Impeller type: centrifugal impeller, wind pressure: 2000pa, circulating air volume: 35000m³/h

8.2 Shaft seal form

Direct-connected convection system, the shaft rotation seal adopts a mechanical seal, silicon carbide-graphite is used as the static and dynamic ring sealing material, and the bearing adopts high temperature resistant special bearing. During operation, water cooling is used in the cooling cavity to ensure a minimum service life of 8,000 hours. The structure is designed for easy maintenance.

8.3. Wind circulation system

The circulating double U-shaped air duct structure and the specially designed return air structure at the kettle door can ensure the adequacy of hot air circulation, make the forced convection efficiency in the kettle reach more than 90%, and ensure the rate and uniformity of temperature rise.

9. Temperature monitoring component

Air temperature thermocouple: 2-way, K-type thermocouple. Participate in monitoring, data exchange, and control.

10. Vacuum pipeline system

10.1. Vacuum pipelines are reserved in the kettle:

There are 2 independent pipelines inside the autoclave. It can be used with vacuum pumps and vacuum bags to vacuum the glass in the kettle. It is suitable for the synthesis of bent glass, achieving multiple uses in one machine.

10.2. Extensible structure

There are flange interfaces reserved inside and outside each vacuum pipeline, and the number of air extraction interfaces can be expanded according to actual conditions.

11. Control system

11.1 Control system

The touch screen and PLC are all products from Siemens of Germany. They have paperless recording and data storage functions and can check the temperature and pressure changes in the kettle in real-time.

11.2 Proprietary control software

The control software with independent intellectual property rights ensures that during the process of temperature and pressure increase, temperature and pressure have interlocking control functions, which can realize the control process of temperature, pressure, pressure, etc. to ensure that temperature and pressure are synchronized according to the set process curve. and automatic temperature compensation and pressure compensation control during the constant temperature and pressure process to ensure the stability of pressure and temperature. To ensure safe operation, a safety interlock program is added to the program.

The heating and pressurizing program can only be started when the cauldron door is closed and the cauldron door is locked. When cooling water, fans, and other components fail, the heating and pressurizing program will not start. Automatic alarm, exhaust, cooling, etc. for over-temperature and over-pressure.

11.3 The software can realize data exchange, data output, process parameter storage, process parameter call, fault alarm, and other functional requirements. It can store and call 40 sets of process parameters.

11.4 Temperature, pressure, and other data are displayed in real-time and automatically recorded, and the data can be transferred and read.

12. Safety interlocking system

12.1 The opening and closing of the kettle door is equipped with mechanical and electrical interlocking devices to prevent the door from opening when there is pressure in the kettle; automatic alarm for over-temperature and over-pressure; automatic cooling for over-temperature and automatic pressure relief for over-pressure.

12.2 The kettle body is equipped with an alarm, which will automatically alarm in case of over-temperature or over-pressure.

12.3 The kettle body is equipped with two safety valves, one electric automatic pressure relief valve, and one manual auxiliary pressure relief valve, to ensure the safety of the autoclave operation to the greatest extent. The safety valve is provided by the customer.

13. Appearance color

The standard color of LIJIANG Glass Automatic Laminated Glass Autoclave Equipment is "white on top and blue on the bottom". If the user has special requirements, color cards, and plans can be provided.

Figure 6 LIJIANG Glass Automatic Laminated Glass Autoclave Equipment

Technical Parameter

Services 

Pre-Sales Service

1. Free inquiry and consulting support.

2. Free sample-making support.

3. Manufacturing process inspection.

4. Free quotation.

5. Troubleshooting. 

After-Sales Service

1. Offering the specifications for the entry-level glass deep-processing machine with 1 years warranty.

2. English software, user manual, and engineer guide.

3. 7/24 technical support by email or call, if you have any problems, we will help you to solve them within 12 hours.

4. During the warranty period, if any part is broken, we will provide it for free.

5. Free remote service and support, if it is necessary, our engineer will come to your country for training.

6. 7 working days to produce the machine, in the meanwhile, we will report the production process in time. 

FAQs 

1. Is it easy to operate for a beginner?

We provide an English manual or live video guide that will show how to set up and use the machine. Whether you are a beginner or an expert, you can quickly learn to operate. If you still have any problems, please contact us directly via calling or mailing. 

2. How to choose the right entry-level glass deep-processing machine?

Yes, to give you a suitable entry-level insulating glass producing machine, please tell me the max working area, materials for processing, and the thickness for the materials to be cut. Then an affordable glass deep-processing machine will be recommended to fit your requirements. 

3. If the glass deep-processing machine have any problem after I ordered it, what could I do?

3.1. Free parts will be sent to you in the warranty period if the machine has any problem.

3.2. Free after-sales service life for the machine, please feel free to contact us if you have any problems.

3.3. We will offer 7/24 free service and support by phone, WhatsApp, skype, and mail. 

4. What about quality control? 

The whole production procedure will be under regular inspection and strict quality control. The complete machine will be tested to make sure it can work very well before being out of the factory. The testing video and pictures will be available before delivery. 

5. What about the MOQ?

Our MOQ is 1 set glass deep-processing machine. We could send the glass deep-processing machine to your country port directly, please tell us your port name. There will be the best shipping freight and machine price for you. 

6. What about the payment terms?

6.1. 30% by T/T in advance, 70% by T/T before shipping.

6.2. L/C is acceptable, if the amount is big, please issue the draft for our confirmation at first. 

7. What about the delivery terms?

We will arrange the delivery on the terms we both agreed upon after the confirmation by the buyer. For standard machines, it would be 7-10 days. For special ordered machines, it would be 15 to 30 days depending on the factory arrangement. 

8. What about the packing?

Waterproof plastic film package with foam protection in each corner. Plywood case package with steel belt. It saves space as much as possible for container loading. 

9. What about the documents after shipment?

After shipment, we will send original documents to you by DHL which include the packing list, commercial invoice, bill of landing, and other certificates as required by clients. 

International Shipping Around the World 

All the glass deep-processing machines can be shipped worldwide by sea, by air, or by international express logistics via DHL, FEDEX, UPS. You are welcome to get a free quotation by filling up the form with your name, email, detailed address, product, and requirements, we will shortly contact you with the full information including the most suitable delivery method (fast, secure, discreet) and freight.