Polyurethane automotive shock absorber disc solution
Industry Pain Points
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
Core of the Solution
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.
Core Solution Modules
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. | Name | 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 | |
| Auxiliary Equipment | ||||
| 1 | Air Storage Tank (Prepared by Customer) | 1 Set | Approx. (Unit mm) 500×500×2000 | |
| Air Compressor (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 | Chiller | 1 Set | Approx. (Unit mm) 900×600×1100 | |
| EXW Total Price | ||||
| Shipping: 2×40' Container | ||||
Configure Directory Table of Contents
| Category | 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 | ||
| Control System | 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 |
| Power Supply | 3×380V ± 5%, 50Hz, Reliable grounding (Provided according to actual site needs) |
| Operators | 2-3 trained operators (Including pouring control, sampling, trimming, air blowing) |
Full-Process Automated Production System
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.
Comprehensive Quality Verification and Compliance Assurance
Intelligent quality inspection
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.
Solution Value and Effects
| Dimension | Traditional Process | Haifeng Automation Solution | Improvement Effects |
|---|---|---|---|
| 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 Emissions | Excessive | Near zero | Achieve environmental compliance and obtain international certifications |
| R&D Cycle | 30-45 days | 7-15 days | Shorten by over 60% for rapid market response |
Implementation Process
Demand Research
Technical team conducts on-site investigations to formulate personalized solutions.
Formula and Process Design
Complete customization and feasibility verification relying on the R&D Center.
Equipment Customization/Transformation and Commissioning
Factory completes production, with engineers conducting on-site installation and commissioning.
Small-Batch Trial Production
Technical team tracks and optimizes parameters.
On-Site Installation and Mass Production
Implement the production line and start mass production, providing technical guidance.
Quality Inspection and Certification Support
Assist in completing testing and certification applications.
After-Sales Operation and Maintenance
Provide maintenance and upgrading services relying on the national service network.
