The automated control of the gypsum block production line is centered on a PLC system, integrating a central hydraulic station with multiple devices to achieve efficient, stable, and environmentally friendly continuous production.
PLC Control System: As the "brain" of the production line, a Programmable Logic Controller (PLC) is used for full-process control. The system uses industrial bus networks such as CC-Link to achieve high-speed and stable data transmission between the main PLC and various slave devices (such as the batching system, mixer, and molding machine). The PLC receives sensor signals, accurately executes logic, timing, and counting operations, and controls the start, stop, and linkage of equipment such as robotic arms and conveyors, ensuring consistent cycle times for each process and guaranteeing production continuity and product consistency. The system features fault alarms, a human-machine interface (HMI), and remote monitoring functions, offering convenient operation and strong anti-interference capabilities.
Central Hydraulic Station: Provides the core power for molding and demolding, with high pressure up to 300 bar, low pressure up to 150 bar, and a maximum ejection force of 1350 kN. The system includes high/low pressure oil pumps, oil tanks, solenoid valves, and oil filters to ensure stable pressure output. Its automatic high/low pressure switching device effectively prevents gypsum slurry from clogging the mold cavity, ensuring smooth production. The hydraulic system is linked with the PLC to achieve precise control of hydraulic mold opening and closing, ejection, and other actions.
Automation Equipment Integration: The modern fully automated production line integrates automatic metering, feeding, mixing, slurry injection, molding, demolding, gripping, and packaging processes. Through a circular track, multi-mold circulating production line, and automatic palletizer, it achieves "one-stop" production from raw materials to finished products. Servo hydraulic and vibration systems ensure molding accuracy, while intelligent cloud services and AR maintenance technology improve operational efficiency. Under the unified scheduling of the PLC, the entire system forms a highly efficient and organic whole, requiring only 3-4 operators, significantly reducing labor costs.
Environmental Performance: The production line itself meets environmental protection requirements, and the production process produces no waste. The equipment can utilize large quantities of industrial by-products such as desulfurized gypsum and phosphogypsum as raw materials, realizing the resource utilization of solid waste. It features low energy consumption and low carbon emissions, representing a green building materials production method promoted by the state. The fully enclosed operation, combined with a pulse bag filter system, effectively controls dust emissions, meeting national environmental protection standards.