Polyurethane automotive shock absorber disc solution
업계 고충 사항
01
Creeper Deformation and Dimensional Stability (Material Fatigue)
Creep mechanism:
Phase 1 (Initial Creep):
Poor uniformity:Rapid deformation occurring within hours or days after installation (accounting for 30–50% of total creep)
Stage 2 (Secondary Creep):Stable, gradual deformation over a period ranging from several months to several years, which accounts for the majority of the service life.
Stage 3 (Final Creep):
Accelerated deformation under high stress and high temperature until failure.
02
Material Aging and Surface Cracking
As a polymeric material, polyurethane inherently has the drawback of insufficient resistance to aging.
Surface cracking:
After prolonged use, exposure to ultraviolet rays, ozone, and cyclic temperature and humidity fluctuations causes microcracks to form on the surface, which subsequently develop into through-cracks.
Rebound damping:
The cellular structure collapses after repeated compression, resulting in a decrease in cushioning capacity.
Rebound damping:
During high-speed compression, internal friction generates heat, and the accumulation of heat leads to a deterioration in material properties.
03
Extremely narrow process windows and monopolies on high-end materials
Reaction speed is too fast:
The NDI system has an extremely short reaction time (completed within seconds), and the raw materials tend to cure and clog the mixing chamber.
Sensitive to process parameters:
Even the slightest fluctuations in temperature, pressure, or mixing ratios can result in product scrap.
Technology Monopoly:
Currently, this sector is primarily controlled by foreign manufacturers such as Germany's BASF, including material formulations and production processes
솔루션의 핵심
Haifeng Automation, a veteran in the polyurethane automation equipment industry, focuses on the core demands of “comprehensive protection, long-lasting durability, green environmental protection, and intelligent efficiency”. It integrates independently accumulated solvent-free/water-based PU technology, precision manufacturing processes, and intelligent quality control systems, integrating core equipment and process solutions into the entire industrial chain of safety shoes. Leveraging technical experience in PU foaming equipment, precision metering systems, and other fields, it achieves four core goals, adapts to multi-scenario needs, and provides integrated “technical solution + equipment implementation” services.
핵심 솔루션 모듈
R&D of Scenario-Specific Specialized Materials
Ingredients and formulation：
PU polyurethane raw materials (Material A is generally polyester polyol; Material B is generally isocyanate)
The approximate ratio of the ingredients is 100:80–120.
Raw material preheating temperature: 35–45°C (Note: A raw material oven is required.)
Other ingredients: Demolding agent (function: prevent adhesion), pigment (function: for coloring), (MC) dichloromethane (function: clean the nozzle), (DOP) dioctyl phthalate (function: clean the tank).
Castability：
Maximum instantaneous flow rate: 20–40 g/s.
Measurement accuracy: ±0.1%.
Number of workstations:
108 workstations (diameter 9.5 m) or 77 workstations (diameter 6.5 m).
Specific Process
| Step | Detailed Description | Corresponding Step Image |
|---|---|---|
| 1 | Place inserts or skeletons into the mold |  |
| 2 | Automatically spray release agent (If the mold cavity is complex, manual touch-up with a spray gun may be required) |  |
| 3 | Polyurethane pouring machine automatically pours |  |
| 4 | Mold automatically closes |  |
| 5 | Setting and curing |  |
| 6 | Mold automatically opens |  |
| 7 | Part removal, trimming, quality inspection, packaging |   |
Equipment List and Unit Price
| No. | 이름 | Quantity | Dimensions | Unit Price (USD) |
|---|---|---|---|---|
| 1 | Mold Opening/Closing Machine | 2 Sets | Approx. (Unit mm) 1100×760×1000 | |
| 2 | Release Agent Spray Gun | 1 Set | Approx. (Unit mm) 105×155 | |
| Air Blow Gun | 1 Set | Approx. (Unit mm) 105×155 | ||
| 3 | Automatic Release Agent Spraying Machine | 1 Set | Approx. (Unit mm) 1100×760×1000 | |
| 4 | Low Pressure Foaming Machine (2A2B) | 1 Set | Approx. (Unit mm) 1500×1500×2700 | |
| 3-Axis Automatic Pouring Machine | 1 Set | Approx. (Unit mm) 3000×1500×2700 | ||
| 5 | Heating Device (Mold Temp. Controller) | 1 Set | Approx. (Unit mm) 900×600×1100 | |
| 6 | 108-Station Rotary Disc Machine | 1 Set | Approx. (Unit mm) 9200 × 9200 × 2350mm | |
| 7 | Mold Frame | 1 Set | Inner size 90*90, Total 108 pcs | |
| 보조 장비 | ||||
| 1 | Air Storage Tank (Prepared by Customer) | 1 Set | Approx. (Unit mm) 500×500×2000 | |
| 공기 압축기 (Prepared by Customer) | 1 Set | Approx. (Unit mm) 1800×1000×2000 | ||
| * The basic air consumption required for our company's equipment. The air storage tank requires a single supply and should be close to the equipment. | ||||
| 2 | Cold Dryer | 1 Set | Approx. (Unit mm) 900×600×1100 | |
| 3 | Raw Material Drying Oven | 1 Set | Approx. (Unit mm) | |
| 4 | 냉각기 | 1 Set | Approx. (Unit mm) 900×600×1100 | |
| EXW Total Price | ||||
| Shipping: 2×40' Container | ||||
Configure Directory Table of Contents
| 카테고리 | Component Name | Model / Spec | Remarks |
|---|---|---|---|
| Pouring System | Metering System | Component A: 20cc High-precision metering pump | Motor is 1.3KW servo motor with planetary reducer |
| Component B: 20cc High-precision metering pump | |||
| Color Dosing System | 0.6cc High-precision metering pump | Drive motor is 0.75KW servo motor, 50L storage tank | |
| Gantry System | Left-right data movement | Movement motor is 1.3KW servo motor | |
| Up-down data movement | Movement motor is 1.0KW servo motor | ||
| Mixing Head System | Needle valve mixing head | With independent cooling system | |
| Temperature Control System | Hot water tank | ||
| Material tank temperature | Independently control material tank temperature | ||
| 2 HP Water Chiller | Mixing head cooling | ||
| Mixing Head Cleaning System | 20L cleaning tank | ||
| Machine Frame Assembly | Frame structure | ||
| 제어 시스템 | PLC & Modules | Brand: Shenzhen Inovance H3U series PLC & modules | |
| 10-inch Touch Screen | Brand: MCGS | ||
| Low Voltage Electricals | Brand: DELIXI | ||
| Sensors | Brand: Inovance | ||
| Mold Opening/Closing Machine | Pneumatic cylinder drive opening/closing mold | Cylinder stroke: determined by mold weight and required force Stroke: depends on mold opening angle and height, generally upper mold opening angle needs ≥90° | |
| Mold Release Spray Gun | Model: MRS-R/F, Brand: Taiwan Baoli, Nozzle size ±20 | Air pressure: 2.0Mpa, Weight: 320g | |
| 24-Station Polyurethane Carousel Line | Overall dimensions: Total length approx. 8 meters, Number of stations: 24 | ||
Technical parameters
mould
| Function: First select the mold for the product to be manufactured (standard mold). Materials: Aluminum alloy, Cr12MoV alloy, tool steel. The mold measures approximately 90 mm in length, 90 mm in width and 146 mm in thickness. | |
Oven system
| Function: Raw material oven for preheating and drying of AB material. Model: XHG×3-2.5; Volume: 2.5 m³; Temperature range: 90°C; Temperature control mode: Automatic; Total power: 6.55 kW. |  |
Automatic opening and closing die machine
| Function: Automatic mold opening and closing Power (KW): 2 |  |
Coiling device system
| Function: Automatic application of release agent before mold pouring | |
| Function: When the cavity is relatively complex, manual supplementary spraying may be required. |  |
gating system
| Function: The casting machine performs casting based on the selected formula. Maximum instantaneous flow rate: 40 g/s, rated voltage V: 380 V | |
108 automatic conveyor lines
| Function: Supports the mold's uniform cyclic operation. Total power of the production line: approximately 85 kW. | |
cooling-water machine
| Function: Cooling power for the pouring head and mixing chamber kW: 1.91 kW |  |
air pump
| Functions: Cleaning and valve control provide power and cooling source pressure for the pneumatic system and nozzle cooling (requires continuous power supply). Power: 22 kW |  |
Production output and production efficiency
| Production Mode | 108 Stations | 77 Stations |
|---|---|---|
| Production Cycle | Production cycle per station is approx. 5-6 seconds. Different mold cavities, process temperatures, and material characteristics may cause variations in cycle time. (108 Stations) | Production cycle per station is approx. 5-6 seconds. Different mold cavities, process temperatures, and material characteristics may cause variations in cycle time. (77 Stations) |
| Avg. Time per Rotation | Approx. 9-11 minutes | Approx. 6.5-8 minutes |
| Hourly Output | ≈ 590-720 pcs | ≈ 580-710 pcs |
| Daily Output (8 Hours) | ≈ 4720-5760 pcs | ≈ 4640-5680 pcs |
Working Conditions
| Project | Requirements |
|---|---|
| Workshop Requirements | Level ground (Area approx. 11m × 11m), Power supply, Compressed air, Cooling water, Ventilation |
| Temperature & Humidity | ≤40°C, Non-condensing environment |
| 전원 공급 장치 | 3×380V ± 5%, 50Hz, Reliable grounding (Provided according to actual site needs) |
| Operators | 2-3 trained operators (Including pouring control, sampling, trimming, air blowing) |
전 공정 자동화 생산 시스템
Integrated production line
Provide customized complete production lines covering all processes from raw material pretreatment to intelligent sorting. Core equipment adopts Haifeng's independently developed imported configuration, ensuring material mixing uniformity ≥98% and stable and reliable operation.
Customized adaptation
Rely on the CAD modeling and 3D printing capabilities of the Mechanical Design Research Institute to quickly produce customized molds and non-standard components, shortening the R&D cycle of new styles to 7-10 days.
Existing equipment transformation
Install Haifeng's intelligent temperature control, precision proportioning, and automated conveying modules to realize the transformation from solvent-based to solvent-free/water-based processes, reducing labor and raw material losses.
포괄적인 품질 검증 및 규정 준수 보장
지능형 품질 검사
Equip Haifeng's independently developed integrated testing equipment, covering thickness, defect, bonding strength, and key performance tests. With an efficiency of ≥50 pairs per minute, defective products are automatically sorted out.
Real-time control
Adopt Haifeng's intelligent production control system to dynamically adjust parameters, controlling the defect rate at 2-3%; integrate environmental monitoring modules to achieve near-zero VOC emissions.
Certification support
Cooperate with authoritative testing institutions to assist in completing multi-standard certifications, providing technical parameters and sample support to help obtain CE and LA certifications and break through high-end market barriers.
솔루션 가치 및 효과
| 차원 | 기존 프로세스 | 하이펑 자동화 솔루션 | 개선 효과 |
|---|---|---|---|
| Compliance Rate of Protective Performance | Below 85% | Above 99% | Meet national/international standards and eliminate safety hazards |
| Defect Rate | 10-15% | 2-3% | Reduce by over 75% and minimize rework losses |
| Raw Material Waste Rate | ≥15% | ≤5% | Reduce by 67%, saving over 300,000 yuan in raw material costs per line annually |
| Labor Requirement | 8-10 people/line | 2-3 people/line | Reduce by 75% and lower the risk of operational errors |
| VOC 배출량 | 과도한 | 제로에 가까운 | 환경 규정 준수 및 국제 인증 획득 |
| R&D Cycle | 30-45 days | 7-15 days | Shorten by over 60% for rapid market response |
구현 프로세스
수요 조사
기술팀이 현장 조사를 실시하여 맞춤형 솔루션을 수립합니다.
공식 및 프로세스 설계
R&D 센터를 통해 완벽한 커스터마이징 및 타당성 검증을 수행합니다.
장비 커스터마이징/변형 및 시운전
공장에서 생산이 완료되면 엔지니어가 현장에서 설치 및 시운전을 수행합니다.
소량 시험 생산
기술팀은 매개변수를 추적하고 최적화합니다.
현장 설치 및 대량 생산
생산 라인을 구현하고 대량 생산을 시작하여 기술 지침을 제공합니다.
품질 검사 및 인증 지원
테스트 및 인증 신청서 작성을 지원합니다.
판매 후 운영 및 유지보수
전국 서비스 네트워크에 기반한 유지 관리 및 업그레이드 서비스를 제공합니다.
