The operation process of the gypsum board forming machine follows the industrial standards of standardization, automation, and safety priority. It is mainly divided into six stages: start-up preparation, raw material preparation, forming operation, pipe extraction and demolding, subsequent processing, and shutdown maintenance. The entire process is controlled by a PLC system in coordination.
Preparation before operation
Personnel protection: Operators must wear dust masks, safety helmets, protective goggles, anti slip shoes, and anti-static gloves. It is strictly prohibited to wear loose jewelry or expose long hair.
Equipment inspection:
Check if the hydraulic system oil pressure is normal and if there is no leakage in the pipeline;
Confirm that the electrical circuit is not exposed or short circuited, and that the emergency stop button function is effective;
Verify that the silicone pressure core tube is not aged or damaged, and that the pressure of the pressure system is stable at 0.4-0.6MPa;
Check that the fastening bolts of the vibration platform are not loose and that the motor is running without any abnormal noise.
Environmental requirements: The workshop temperature should be controlled at 15-25 ℃, with a relative humidity of ≤ 60%, to ensure the stability of gypsum slurry solidification; The ground is dry without standing water, and the ventilation system continues to operate.
Raw material confirmation: Gypsum powder fineness ≥ 200 mesh, moisture content ≤ 3%; Foaming agents, accelerators, and retarders should be pre prepared according to the process ratio, and it is strictly prohibited to mix expired or damp raw materials.
Raw material preparation and slurry transportation
Put gypsum powder, water, modified starch, retarder, foaming agent, etc. into the mixer according to the proportion set by the automatic metering system. The mixing time is controlled at 3-5 minutes, and the slurry is uniform and free of lumps.
The slurry is pumped through a pipeline to the buffer hopper above the forming machine, and the flow rate is adjusted by a frequency converter to synchronize with the production line speed, avoiding overflow or flow interruption.
Forming operation
The protective paper is smoothly fed onto the vibrating platform through an automatic correction device, and the bottom paper is synchronously laid on the vibrating platform;
The slurry uniformly falls from the hopper onto the lower protective paper and enters the plate forming mold cavity;
The vibration platform vibrates at a frequency of 20-40Hz for 3-5 seconds to fully compact the slurry and expel bubbles, ensuring uniform internal structure of the board;
The upper mold is hydraulically closed, with a stable pressure of 0.8-1.2MPa. The holding time is adjusted according to the plate thickness (approximately 15 seconds for 60mm plates and 40 seconds for 150mm plates).
Pipe drawing and demolding
After the molding is completed, the silicone pressure core tube automatically inflates and expands, releasing the adsorption force with the inner cavity of the gypsum board, and the resistance is zero;
The core tube is synchronously and smoothly extracted under pneumatic drive, without the need for flushing throughout the entire process, to avoid secondary pollution;
After the pumping is completed, the hydraulic system slowly opens the mold, and the formed plate is smoothly removed by the conveyor belt and enters the initial setting zone.
Subsequent processing
The board is finally solidified on the conveyor roller (about 10-20 minutes), and then cut by a fixed length cutting machine according to standard sizes such as 2400mm and 3000mm;
After cutting, the board is directed horizontally by a turning system and enters the drying kiln in parallel with two boards. The drying temperature is controlled at 80-100 ℃, the humidity is 30% -50%, and the drying cycle is about 45-60 minutes.
Shutdown and maintenance
Stop feeding before stopping the machine, and after the slurry in the forming machine is emptied, turn off the vibration platform and hydraulic system;
Clean the residual slurry in the mold cavity, wipe the stainless steel forming plate with a damp cloth, and strictly prohibit the use of hard objects for scraping;
After each shift, add high-temperature lithium grease to the lubrication points, check for scratches on the surface of the core tube, and record the equipment operating time and abnormal events.
Security and Exception Handling
Emergency stop: In case of abnormal equipment noise, smoke, slurry splashing, or personnel entering the danger zone by mistake, immediately press the emergency stop button and cut off the main power supply;
Response to abnormal phenomena:
Board cracking → Check if the foaming agent ratio or pumping speed is too fast;
Surface roughness → Check if the amplitude of the vibration platform is unbalanced or if there are foreign objects in the mold cavity;
If the suction pipe is stuck, stop immediately and check if the silicone tube is aging or if the air pressure is insufficient.