WO2014146378A1 - 一种适用于建筑外墙的图码保温板的辊涂生产方法 - Google Patents

一种适用于建筑外墙的图码保温板的辊涂生产方法 Download PDF

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Publication number
WO2014146378A1
WO2014146378A1 PCT/CN2013/078422 CN2013078422W WO2014146378A1 WO 2014146378 A1 WO2014146378 A1 WO 2014146378A1 CN 2013078422 W CN2013078422 W CN 2013078422W WO 2014146378 A1 WO2014146378 A1 WO 2014146378A1
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WO
WIPO (PCT)
Prior art keywords
roller
roll
treatment
roll coating
pattern
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/CN2013/078422
Other languages
English (en)
French (fr)
Inventor
唐月平
周建平
伍良
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
LIAONING CHAOSHUO TOMA TECHNOLOGY STEEL PLATE PRINTING Co Ltd
Original Assignee
LIAONING CHAOSHUO TOMA TECHNOLOGY STEEL PLATE PRINTING Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by LIAONING CHAOSHUO TOMA TECHNOLOGY STEEL PLATE PRINTING Co Ltd filed Critical LIAONING CHAOSHUO TOMA TECHNOLOGY STEEL PLATE PRINTING Co Ltd
Priority to KR1020147028952A priority Critical patent/KR101684043B1/ko
Priority to US14/385,079 priority patent/US9364851B2/en
Priority to EP13878531.6A priority patent/EP2823967B1/en
Publication of WO2014146378A1 publication Critical patent/WO2014146378A1/zh
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41F—PRINTING MACHINES OR PRESSES
    • B41F33/00—Indicating, counting, warning, control or safety devices
    • B41F33/0036—Devices for scanning or checking the printed matter for quality control
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41F—PRINTING MACHINES OR PRESSES
    • B41F13/00—Common details of rotary presses or machines
    • B41F13/004—Electric or hydraulic features of drives
    • B41F13/0045—Electric driving devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41F—PRINTING MACHINES OR PRESSES
    • B41F13/00—Common details of rotary presses or machines
    • B41F13/08—Cylinders
    • B41F13/10—Forme cylinders
    • B41F13/12—Registering devices
    • B41F13/14—Registering devices with means for displacing the cylinders
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41F—PRINTING MACHINES OR PRESSES
    • B41F17/00—Printing apparatus or machines of special types or for particular purposes, not otherwise provided for
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41F—PRINTING MACHINES OR PRESSES
    • B41F23/00—Devices for treating the surfaces of sheets, webs, or other articles in connection with printing
    • B41F23/002—Devices for treating the surfaces of sheets, webs, or other articles in connection with printing cleaning devices for sheets or webs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41F—PRINTING MACHINES OR PRESSES
    • B41F23/00—Devices for treating the surfaces of sheets, webs, or other articles in connection with printing
    • B41F23/007—Devices for treating the surfaces of sheets, webs, or other articles in connection with printing with heat treatment before printing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41F—PRINTING MACHINES OR PRESSES
    • B41F23/00—Devices for treating the surfaces of sheets, webs, or other articles in connection with printing
    • B41F23/04—Devices for treating the surfaces of sheets, webs, or other articles in connection with printing by heat drying, by cooling, by applying powders
    • B41F23/0403—Drying webs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41F—PRINTING MACHINES OR PRESSES
    • B41F23/00—Devices for treating the surfaces of sheets, webs, or other articles in connection with printing
    • B41F23/04—Devices for treating the surfaces of sheets, webs, or other articles in connection with printing by heat drying, by cooling, by applying powders
    • B41F23/0476—Cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41F—PRINTING MACHINES OR PRESSES
    • B41F23/00—Devices for treating the surfaces of sheets, webs, or other articles in connection with printing
    • B41F23/08—Print finishing devices, e.g. for glossing prints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41F—PRINTING MACHINES OR PRESSES
    • B41F33/00—Indicating, counting, warning, control or safety devices
    • B41F33/02—Arrangements of indicating devices, e.g. counters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41F—PRINTING MACHINES OR PRESSES
    • B41F35/00—Cleaning arrangements or devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41F—PRINTING MACHINES OR PRESSES
    • B41F9/00—Rotary intaglio printing presses
    • B41F9/01—Rotary intaglio printing presses for indirect printing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
    • B44C1/24—Pressing or stamping ornamental designs on surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0415—Ornamental plaques, e.g. decorative panels, decorative veneers containing metallic elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M1/00—Inking and printing with a printer's forme
    • B41M1/26—Printing on other surfaces than ordinary paper
    • B41M1/28—Printing on other surfaces than ordinary paper on metals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41P—INDEXING SCHEME RELATING TO PRINTING, LINING MACHINES, TYPEWRITERS, AND TO STAMPS
    • B41P2213/00—Arrangements for actuating or driving printing presses; Auxiliary devices or processes
    • B41P2213/90—Register control
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41P—INDEXING SCHEME RELATING TO PRINTING, LINING MACHINES, TYPEWRITERS, AND TO STAMPS
    • B41P2235/00—Cleaning
    • B41P2235/10—Cleaning characterised by the methods or devices
    • B41P2235/20—Wiping devices
    • B41P2235/24—Wiping devices using rolls of cleaning cloth
    • B41P2235/246—Pressing the cleaning cloth against the cylinder

Definitions

  • the present invention relates to a roll coating production method suitable for a pattern insulation board of a building exterior wall, and belongs to the field of pattern insulation board production and manufacturing. . Background technique
  • External wall insulation can be divided into single material (aerated concrete, sintered insulation brick, etc.) external wall insulation and composite material external wall insulation (internal insulation, external insulation, sandwich insulation and dicing insulation).
  • composite material external wall insulation internal insulation, external insulation, sandwich insulation and dicing insulation.
  • the applicant has repeatedly tried and researched an external wall insulation board which integrates heat preservation and decoration.
  • the insulation board includes a relatively disposed metal finish layer and a substrate, and is disposed on the metal finish layer and the substrate. Insulation core layer.
  • the applicant firstly applies a multi-color pattern on the metal veneer layer by a gravure printing machine, and then bonds the metal veneer layer with the heat-insulating layer and the substrate to form an external wall insulation board, and finally performs external wall construction, as opposed to
  • the traditional method of first installing and refinishing the finish layer provides great convenience for the processing of the finish layer.
  • the gravure printing machine used by the applicant in the roll coating multicolor pattern comprises a feeding device for providing a coating; a suction roller having a circumferential surface connected to the feeding device, the circumferential surface having a use a plurality of depressions forming an image area when the paint is filled; a rubber coating roller having a circumferential surface connected to the suction roller for receiving an image area formed by the coating on the coating roller, and The image area is transferred to a steel sheet to form a desired colored pattern.
  • the Applicant has found during the use of the gravure printing machine described above that the line speed of the coating roll and the suction roll often coincides with the process speed of the entire production line, and the entire production line lacks the suction roll and coating.
  • the speed of the roller is adjusted to the on-line control system, which results in the need to stop the line adjustment after a period of operation of the entire production line, thus affecting the efficiency of the entire production line; and if the line is not adjusted, the speed of transporting the metal plate will be
  • the roll surface speed of the rolls is inconsistent, and often The result is that the metal plate cannot be roll-coated according to the predetermined position; in addition, in order to print the multi-color pattern, several sets of roll coating units are often required to cooperate, and the above-mentioned gravure printing machine lacks one of the adjacent rolls.
  • the technical problem to be solved by the present invention is to provide a roll coating production of a pattern thermal insulation board capable of adjusting the line speed of each roller of a roll coating unit and making it consistent with the process speed to improve production efficiency.
  • the present invention provides a roll coating production method suitable for a pattern insulation board of a building exterior wall, which in turn comprises the following steps:
  • the step of producing the metal veneer in the step A includes the following steps: a. a step of producing a metal plate; b. a process before printing the metal plate; c ⁇ using the first roll coating unit to the metal plate Performing a roll coating transfer; d. after a specific time, the second roll coating unit is used to perform secondary roll coating transfer on the metal plate, and a pattern is formed on the metal plate to produce a metal veneer;
  • step c controlling the first roll coating unit by using a servo control system
  • the control process of the servo control system is:
  • the roll diameter and the process speed of each roller in the first roll coating unit are input into a PLC control module, and the PLC control module calculates a theoretical roll surface linear velocity of each roller according to the process speed and the roll diameter of each roller, so that The theoretical roll surface linear velocity of each roller is consistent with the process speed, and the calculated theoretical roll surface linear velocity signals of the respective rollers are respectively output to a servo control module with an encoder;
  • the servo control module receives a theoretical roll surface line speed signal from each roller of the PLC control module, and drives each roller according to the theoretical roll surface line speed signal;
  • the encoder collects actual roller surface linear velocity of each roller, and outputs an actual roller surface linear velocity signal of each roller to the PLC control module;
  • the PLC control module adjusts a current frequency of a motor driving each roller according to the received actual roller surface linear velocity signal of each roller and a theoretical roller surface linear velocity signal, and further corrects the actual roller surface linear velocity of each roller to When the theoretical roll surface speeds are the same, the roll coating transfer of the first roll coating unit is completed.
  • the distance between the first roller coating unit and the second roller coating unit is further input into the PLC control module, and the PLC control module is based on the process speed and The distance data calculates a specific time for starting the second roll coating unit, and starts the second roll coating unit according to the specific time to complete the roll coating transfer of the second roll coating unit.
  • the printed pattern is collected by the password recognition module, and the offset of the color is determined by computer identification, thereby correcting the process speed of the corresponding roller coating unit.
  • the production process of the metal plate is: hot-rolled steel coil, pickling of the steel coil after hot rolling, cold rolling of the steel coil after pickling, and passing through The steel coil after cold rolling is subjected to continuous hot dip galvanizing treatment to form a metal plate.
  • the process before the printing of the metal plate is: degreasing treatment, cleaning treatment, pre-baking treatment, passivation treatment, post-baking treatment, initial primer treatment, baking curing treatment And cooling treatment.
  • the drying process is performed again, and the drying is performed again. After the treatment, the cooling treatment is performed again.
  • the specific production process in the step B is as follows: firstly, the metal veneer and the substrate are respectively subjected to a lamination process, a molding process, and a gluing process, and the insulating layer is subjected to a gluing process, and then The insulating layer is installed between the metal veneer layer and the substrate and is subjected to a pressing process to form a pattern thermal insulation board.
  • the insulating layer is made of rock wool having a density of 120 kg/m 3 , and the fiber of the rock wool is oriented perpendicular to the metal facing layer and the substrate.
  • the roller coating transfer unit used in the step c and the step d includes a feeding device for supplying a coating; a suction roller having a circumferential surface connected to the feeding device, the circumferential surface having a plurality of depressions forming an image area when filled with the coating; a rubber coating roller having a circumferential surface connected to the suction roller for receiving an image area formed by the coating on the coating roller, and Transferring the image area to a steel sheet; a first doctor blade mounted on the first doctor blade holder to contact the suction roll at a specific angle for scraping the image area of the suction roll And a second doctor blade mounted on the second doctor blade holder to contact the coating roller at a specific angle for scraping the paint outside the image area on the rubber coating roller.
  • the first doctor blade is in contact with the suction roller at an angle of less than 30 degrees; the second doctor blade is in contact with the coating roller at an angle greater than 30 degrees.
  • the production method of the graphic insulation board suitable for the exterior wall of the building provided by the invention has the following advantages:
  • the roll coating production method of the image insulation board suitable for the exterior wall of a building provided by the present invention, first producing a metal veneer, a substrate and printing a pattern on the metal veneer and then attaching the insulation layer to the Between the metal veneer and the substrate to form a pattern insulation board, and finally the pattern defects produced (the finish layer is not easily installed by the roll coating line directly on the insulation board already installed on the wall)
  • the pattern so that the existing insulation board generally has poor decorative effect, is not beautiful, and realizes the integration of heat preservation and decoration.
  • the module calculates the theoretical roll surface linear velocity of each roller in the roller coating unit by the process speed of the enthalpy and the rotation speed of each roller in the roller coating unit, and makes the theoretical roller surface linear velocity consistent with the process rotation speed;
  • the servo control module of the encoder collects the actual roll surface linear velocity of each roller in the roller coating unit, and inputs the actual roller surface linear velocity signal to the PLC control system, thereby enabling the PLC control system to communicate with the actual roll surface linear velocity and the theoretical roller.
  • the line speeds are compared and the current frequency is adjusted until the actual roll line speed is consistent with the theoretical roll line speed.
  • the above control method adjusts the actual roll surface linear velocity to be consistent with the theoretical roll surface linear velocity, and the theoretical roll surface linear velocity is consistent with the process speed, thereby ensuring that the actual roll surface linear velocity is consistent with the process rotational speed, and thus is not in the production process. Need to stop the line adjustment, improve production efficiency.
  • the roll coating production method of the image insulation board applied to the exterior wall of the building provided by the invention, wherein the PLC control module further inputs between the first roller coating transfer unit and the second roller coating transfer unit
  • the distance data and the time to start the second roll coating unit can be calculated based on the process speed and the distance data.
  • the PLC control module calculates the start of the next roll coating transfer unit according to the process speed and the distance data. The time, so that the time is set in advance, so that the next roll coating line is started in a specific time, thereby achieving continuous operation of the adjacent roll coating unit, further improving the production efficiency.
  • the roll coating production method of the image insulation board applicable to the exterior wall of the building provided by the invention further comprises a code recognition module, wherein the code recognition module collects the printed pattern, and determines the dislocation distance of the color by computer identification. Thereby, the process speed of the corresponding roller coating unit is corrected. After the next roll coating line is started and the secondary transfer is completed, the printed pattern is collected by the password recognition module, and the offset of the color is determined by computer identification, thereby correcting the rotation speed of each roller according to the dislocation distance of the color, so that the color is dislocated. The situation is corrected, and the above process can be cycled to ensure that the printed pattern is complete and realistic. In addition, the addition of the code recognition module greatly increases the length of the printed pattern.
  • the roll coating production method of the image insulation board applied to the exterior wall of the building provided by the present invention in the step a, the production process of the metal plate is: hot rolled steel coil, after hot rolling Said
  • the steel coil is pickled, the steel coil after pickling is cold rolled, and the cold rolled steel coil is subjected to continuous hot dip galvanizing to form a metal sheet, and the hot rolling treatment is advantageous for forming the metal sheet.
  • the pickling treatment is beneficial to rust removal and easy to trim.
  • Cold rolling after hot rolling is beneficial to eliminate pores, and continuous hot-dip galvanizing after cold rolling can not only improve the annealing effect but also improve the oxidation resistance of the metal sheet.
  • the roll coating production method of the image insulation board applied to the exterior wall of the building provided by the present invention in the step b, the process before the printing pattern of the metal plate is: degreasing treatment, cleaning treatment, Pre-baking treatment, passivation treatment, post-baking treatment, initial primer treatment, baking curing treatment, and cooling treatment.
  • the above pre-treatment steps effectively increase the adhesion between the coating and the metal sheet to be printed during the roll coating process, and improve the molding performance of the metal veneer in the later stage.
  • the insulation layer uses a rock wool having a density of 120 kg/m 3 , and the rock The fibers of the cotton run perpendicular to the metal finish layer and the substrate.
  • a reasonable choice of density is advantageous for increasing the strength of the insulating layer itself, and setting the fiber direction of the rock wool to be perpendicular to the metal facing layer and the substrate ensures the rock wool and metal facing layer and the substrate. It is not easy to slide the misalignment between them, thereby increasing the rigidity.
  • Example 1 1-feeding equipment; 2-feeding roll; 3-rubber coating roll; 4-first scraper; 5-second scraper; 6-cleaning device; 61-supply tank; 62-transport pump; Pipe; 64-spray pipe; 65-spray hole; 67-recovery tank; 68-filter; 7-support roll.
  • Example 1
  • the embodiment provides a method for producing a pattern thermal insulation board suitable for a building exterior wall, which comprises the following steps in sequence: A. Steps of producing a metal veneer, a substrate and printing a pattern on the metal veneer And B. adding a thermal insulation layer between the metal veneer and the substrate to form a pattern thermal insulation board; the step of producing the metal veneer in the step A comprises the following steps: a. production a step of printing a metal plate; b. performing a pre-printing process on the metal plate; c. performing a roll coating transfer on the metal plate with a first roll coating unit; d. using a second roll after a specific time The coating unit performs secondary roll coating transfer on the metal plate to form a pattern on the metal plate to produce a metal veneer; e. post-treating the metal veneer with a varnish.
  • the production process of the metal plate is specifically: hot-rolled steel coil, pickling of the steel coil after hot rolling with hydrochloric acid, and cold rolling of the steel coil after pickling
  • the steel coil after cold rolling is continuously hot dip galvanized at 650 ° C (other temperature values between 650 ° C and 850 ° C can be selected to form a metal plate, here, 650 ° C
  • the continuous hot-dip galvanizing treatment is equivalent to first annealing and then hot-dip galvanizing, which not only improves the mechanical properties, but also improves the oxidation resistance.
  • the specific process of the pre-printing treatment of the metal plate is: degreasing treatment, cleaning treatment, pre-baking treatment, passivation treatment, post-baking treatment, initial primer treatment, baking Curing treatment and cooling treatment.
  • the cleaning treatment is carried out by using a lye solution having a concentration of 1% and a temperature of 50-65 degrees for degreasing to remove the oil stain and dust on the surface of the steel strip.
  • the ratio of the total alkali to the free base is less than 2.
  • the hot air of the strip is used to dry the residual moisture on the surface of the strip after cleaning, and the hot air is heated by the steam heat exchanger; the passivation treatment is carried out on the cleaned strip surface with a treatment liquid having a chromium point of 22-32.
  • Passivation treatment to increase the adhesion and anti-corrosion properties of the strip and the primer; after drying, the surface after passivation is dried by an electric heating oven to enhance the passivation effect, the baking temperature of the board surface 72-85 degrees; Primer treatment, ⁇ Apply the back coat and primer to the surface of the strip with the first roll coating unit.
  • the color and performance of the primer are determined according to the printed color; baking curing treatment and cooling treatment , baking the strip coated with primer and back paint, The primer and the back coat are fully cured, the curing temperature is 214-232 degrees, and then the baked and cured strip is cooled by water mist and water flow to further stabilize
  • the metal sheet is post-treated in the step e, the post-processing comprises applying a bright lacquer on the surface of the metal sheet, and re-drying after the lacquer is finished. The dry treatment is performed after the drying treatment again.
  • the first roller coating machine is controlled by a servo control system to form a two-color pattern on the metal plate.
  • the specific control process is:
  • the theoretical roll surface line speed signals are respectively output to a servo control module having an encoder;
  • the servo control module receives a theoretical roll surface line speed signal from each roller of the PLC control module, and drives each roller according to the theoretical roll surface line speed signal;
  • the encoder collects the actual roll surface linear velocity of each roller, and outputs the actual roll surface linear velocity signal of each roller to the PLC control module;
  • the PLC control module adjusts the current frequency of the motor driving each roller according to the received actual roller surface linear velocity signal of each roller and the theoretical roller surface linear velocity signal, and further corrects the actual roller surface linear velocity of each roller to When the theoretical roll surface speeds are the same, the roll coating transfer of the first roll coating unit is completed.
  • the PLC control module in order to realize continuous online operation of the adjacent roller coating unit, in the step S1, the PLC control module further inputs between the first roller coating unit and the second roller coating unit. Distance data, the PLC control module calculates the time to start the second roller coating unit according to the process speed and the distance data, and starts the second roller coating unit according to the startup time to complete the printing of the second roller coating unit.
  • the printed pattern in order to print the irregular long-width pattern, after the printing of the second roll coating unit is completed, that is, after the step S4, the printed pattern is collected by the password recognition module, and recognized by the computer. The system determines the offset of the color of the suit, thereby correcting the process speed of the corresponding roller coating unit.
  • the specific correction process is: if the color of the rear roller coating in the pattern collected by the password recognition module is a misalignment distance from the predetermined roller coating position with respect to the color of the first roller coating, for example, relative to the predetermined The roller coating position is 10 ⁇ ahead, which means that the actual process speed (indicated by VI) of the roller that transports the metal plate is 10 mm faster than the process speed (indicated by V2) that should be operated.
  • V2 V1-1 0
  • N V2/ ⁇ * roller diameter diameter
  • N V2/ ⁇ * roller diameter diameter
  • the current frequency of the corresponding motor according to the rotation speed N so as to correspond
  • the rotation speed of the roller is adjusted to adjust the speed of the process, and finally the misalignment accuracy of the color is controlled within ⁇ 0.6 mm, which is a dynamic and repeated adjustment process.
  • the printed pattern is collected by the digital camera in the password recognition module. It should be noted that, in the above production method of the present invention, the step c and the step d need to be carried out by using a roll coating unit, but the structure of the specific roll coating unit is not limited.
  • the present embodiment provides a method for producing a two-color pattern metal veneer.
  • the required roll coating transfer unit is two groups, and those skilled in the art can follow the production method disclosed in this embodiment, especially The adjustment speed in the servo control system, the start time of the second roll coating unit, and the code recognition technology are modified on the basis of the present embodiment to produce a metal veneer of three-color, four-color, five-color or more color patterns.
  • the specific production process of the step B is as follows: firstly, the metal veneer and the substrate are respectively subjected to a lamination treatment, a molding treatment, and a rubber coating treatment, and the thermal insulation layer is coated. Processing, the insulating layer is then applied between the metal finish layer and the substrate and subjected to a press treatment to form a pattern insulation board.
  • the insulating layer is made of rock wool having a density of 120 kg/m 3 , and the fibers of the rock wool are oriented perpendicular to the metal facing layer and the substrate.
  • a polyurethane foaming agent is used in the gluing treatment.
  • the polyurethane foaming agent is used for the image.
  • the insulation board is edge-sealed.
  • Embodiment 2 a structure of a roll coating transfer unit used in the step c and the step d in the embodiment 1 is provided.
  • the specific structure is shown in FIG. 1.
  • the roll coating unit includes a feeding device 1 for Provide paint; suck a roller 2 having a circumferential surface connected to the feeding device 1, the circumferential surface having a plurality of depressions forming an image area when filled with the coating material; a rubber coating roller 3 having a circumferential surface and the suction a roll 1 for receiving an image area formed on the coating roll 3 by the coating, and transferring the image area to the steel plate; further comprising a first scraper 4 mounted on the first scraper holder Contacting the suction roll 2 at a specific angle for scraping off the paint outside the image area of the suction roll 2; the second scraper 5 being mounted on the second scraper holder at a specific angle
  • the coating roller 2 is in contact for scraping off the paint outside the image area on the rubber application roller 3.
  • the working process of the roller coating unit provided in this embodiment is: the suction roller 2 moves, the feeding device 1 supplies paint to the suction roller 1, and a part of the coating enters the suction roller 2 In a recess forming the image area, a portion is located outside the recess on the suction roller 2; after the paint is scraped off by the first scraper 4 in a region other than the recess of the suction roller 2, the suction The roller 2 rotates to transfer the paint in the recess onto the rubber coating roller 3 to form an image area, and the second blade is used to scrape off the paint outside the image area on the rubber coating roller 3; The image roller is further transferred to the metal plate to be printed to form a pattern when the coating roller 3 is rotated, and the support roller 7 is used to support the metal plate to be printed to provide a supporting force for coating the rubber coating roller.
  • the specific control process for printing patterns on the metal plate by the roller coating unit provided by the present embodiment is as follows:
  • the first servo control module receives a theoretical roll surface linear velocity signal from the suction roller 2 of the PLC control module, and drives the suction roller 2 according to the theoretical roll surface linear velocity signal.
  • the second servo control module receives the theoretical roll surface linear velocity signal from the coating roller 3 of the PLC control module, and drives the coating roller 3 according to the theoretical roll surface linear velocity signal;
  • the first encoder collects the actual roll surface linear velocity of the suction roller 2, and outputs an actual roll surface linear velocity signal of the suction roller 2 to the PLC control module, the second encoder ⁇ Collecting the actual roll surface linear velocity of the coating roller 3, and outputting the actual roll surface linear velocity signal of the coating roller 3 to the PLC control module;
  • the PLC control module adjusts the actual roll surface linear velocity signal and the theoretical roll surface linear velocity signal of the suction roller 2 and the coating roller 3 to adjust the current frequency of the motor driving each roller, and then When the actual roll surface linear velocity of the suction roll 1 and the coating roll 3 is corrected to coincide with the theoretical roll surface linear velocity, the printing of the first roll coating unit is completed.
  • the coating roller 3 of the roller coating unit provided by the embodiment is made of rubber, and the structural design is such that the coating roller is in flexible contact with the suction roller 1 and the steel plate to be printed, thereby ensuring the "smooth seam" of the contact.
  • the gravure printing machine provided in this embodiment includes a first scraper 4 and a second scraper 5 (in FIG.
  • the first scraper 4 and the second scraper 5 are respectively associated with the suction roller 2 and the rubber coating roller 3)
  • the first scraper 4 is used to scrape paint other than the recess for forming an image area on the suction roller 2
  • the second scraper 5 is used to coat the rubber
  • the removal of the paint outside the image area on the roller 3 avoids the manual clearing of the above-mentioned paint to cause a defect of low labor efficiency, thereby improving labor productivity; in addition, the first scraper 4 and the second scraper 4 are respectively at a specific angle With the suction roller 2 and Contacting said rubber coated roller 3, to ensure a better scraping effect and to help improve the service life of the blade.
  • the first scraper 4 and the second scraper 5 are respectively fixedly connected to the bracket of adjustable height and angle.
  • the height and angle adjustable can be realized as follows: A pair of slide rails capable of moving up and down are fixed at both ends, and the up and down movement of the slide rails is adjusted by a worm gear device connected thereto, and the worm gears at both ends are connected by a rigid link through the adjusting hand wheel To drive the rotation of the worm, so as to achieve the up and down movement of the blade; the two ends of the blade are provided with a scale indicating the height to display the adjustment amount.
  • the adjustable angle can be realized as follows: The lower end of the slide rail pair at both ends of the scraper has an articulation mechanism, and the slide rail pair can rotate along the hinge mechanism, and slide The rotation of the rail pair is adjusted by adjusting the screw rod.
  • the rotation of the adjusting screw rod is manually operated by an adjusting wrench, and a scale indicating the angle is arranged beside the rail pair to display the angle of rotation.
  • the material of the coating roller provided by the embodiment can be used in addition to the rubber, and other materials capable of ensuring normal coating and being in flexible contact with the suction roller and the steel plate to be printed can be used, for example, A silicone product that satisfies both elasticity, hardness, and transfer performance at the time of coating.
  • the first scraper blade 4 is in contact with the suction roller 2 at an angle of less than 30 degrees; the second scraper blade 5 is in contact with the coating roller 3 at an angle of more than 30 degrees.
  • the scraping position of the paint is different at the same time, the first scraper 4 and the second scraper 5 are set at different angles, and the scraping of the suction roller 2 and the coating roller 3 can be ensured at the same time.
  • the first scraper 4 is a titanium steel plate; and the second scraper 5 is a titanium steel plate. 3 ⁇ The thickness of the blade of the second blade 5 is 0. 3mm.
  • a cleaning device 6 for cleaning the paint on the second blade 5 and the rubber application roller 3 is added.
  • the cleaning device 6 includes a liquid supply tank 61, a cleaning liquid delivery pump 62 for pumping the liquid supply tank 61, a cleaning liquid delivery conduit 63 communicating with the cleaning liquid delivery pump 62, and the cleaning liquid a spray pipe 64 communicating with the transfer pipe, the spray pipe 64 being disposed above the axial direction of the rubber coating roller 3, the spray pipe 64 having a plurality of spray holes 65; the cleaning device 6 further a cleaning liquid recovery tank 66 disposed under the coating roller 3; the cleaning liquid recovery tank 66 is connected to a recovery pipeline 67, the recovery conduit 67 leading to the liquid supply tank 61; the recovery pipeline 67 and A filter 68 is disposed between the liquid supply tanks 61.
  • the working process of the cleaning device 6 provided in this embodiment is:
  • the cleaning liquid in the liquid supply tank 61 is pumped into the shower pipe 64 by the transfer pump 62 to be sprayed through the shower hole 65, and then the cleaning liquid is returned from the rubber coating roller 3 to the cleaning liquid recovery.
  • the tank 66 is filtered by the recovery line 67 and the filter 68 and finally returned to the liquid supply tank 61 for recycling.
  • the feeding device 1 is a tray having a groove.

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Abstract

一种适于建筑物外墙的图码保温板的辊涂生产方法，在生产好的金属饰面板上印刷花纹然后将保温层加装在金属饰面板以及衬底之间形成图码保温板，将辊涂机组中各辊的辊径以及工艺速度输入到PLC控制模块中，根据工艺速度和各辊辊径计算出各辊的理论辊面线速度，并通过带有编码器的伺服控制模块控制实际辊面线速度与理论辊面线速度一致，还能通过暗码识别模块确定花色错位距离对工艺速度进行修正，解决了凹版印刷机印刷过程中辊面线速度与工艺速度不一致的问题。

Description

一种适用于建筑物外墙的图码保温板的辊涂生产方法 技术领域 本发明涉及一种适用于建筑物外墙的图码保温板的辊涂生产方法，属于 图码保温板生产制造领域。 背景技术
制造与使用绿色建材、 建造绿色建筑是建筑领域的未来发展趋势， 在刚 刚闭幕的十八大中也提出了 "推进绿色发展、 循环发展、 低碳发展" 和 "建 设美丽中国" 的概念。 我国在城市化推进的同时每年有大量未达到使用寿命 的房屋由于墙体保温饰面层的损坏而被拆除， 严重的影响了城市的绿色发展。
外墙保温可分为单一材料（加气混凝土、 烧结保温砖等） 外墙保温和复 合材料外墙保温（内保温、 外保温、 夹心保温和切块保温等）。 虽然外墙保温 方式众多， 但是， 现有的外墙保温大多没有实现装饰与保温的一体化， 为了 达到装饰要求， 需要在保温层施工完成后再在其表面施工饰面层， 然而， 由 于保温板以及施工在墙体上， 再在保温板上加装饰面层有艮多不便。
申请人经过反复试验研究出一种集保温与装饰为一体的外墙保温板， 该 种保温板包括相对设置的金属饰面层与衬底， 以及设置在所述金属饰面层与 衬底之间的保温芯层。 申请人先通过凹版印刷机在金属饰面层上辊涂多色花 纹， 然后再将金属饰面层与保温层以及衬底粘合在一起形成外墙保温板， 最 后进行外墙施工， 相对于传统的先安装再加工饰面层的方式来说， 为饰面层 的加工提供了很大便利。 申请人在辊涂多色花纹时釆用的所述凹版印刷机包 括供料设备， 用于提供涂料； 吸料辊， 其圓周面与所述供料设备连接， 所述 圓周面上具有在用所述涂料填充时形成图像区域的多个凹陷； 橡胶涂覆辊， 其圓周面与所述吸料辊连接， 用于承接所述涂料在所述涂覆辊上形成的图像 区域， 并将所述图像区域转印到钢板上以形成所需要的彩色花纹。 然而， 申请人在使用上述凹版印刷机过程中发现， 所述涂覆辊、 吸料辊 的辊面线速度经常与整个生产线的工艺速度不一致， 而整个生产线缺少对所 述吸料辊和涂覆辊的转速进行线上调整的控制系统， 从而导致在整个生产线 运行一段时间后经常需要停线调整， 从而影响了整个生产线的效率； 而若不 停线调整就会导致运送金属板的速度与各辊的辊面线速度不一致， 进而经常 导致不能按照预定的位置对金属板进行辊涂转印； 另外，为了印刷多色花纹， 往往需要几组辊涂机组协同运作， 而现有技术中的上述凹版印刷机缺少一种 使得相邻辊涂机组连续生产的控制系统， 即， 需要工作人员通过人眼观察第 一个辊涂机组是否已经将一种颜色涂覆完成， 确定涂覆完成之后， 再通过人 工启动相邻辊涂机组，从而使得相邻辊涂机组之间无法实现连续生产； 同时， 由于缺少对吸料辊和涂覆辊的转速进行调整的控制系统， 从而无法在相邻辊 涂机组印制的花纹错位时进行纠错。 发明内容 因此， 本发明要解决的技术问题在于提供一种能够对辊涂机组的各辊的 辊面线速度进行调整并使其与工艺转速一致从而提高生产效率的图码保温板 的辊涂生产方法。 为此 ,本发明提供一种适用于建筑物外墙的图码保温板的辊涂生产方法 , 依次包括如下步骤：
A. 生产金属饰面板、 衬底并在所述金属饰面板上印刷花纹的步骤； 以及
B.将保温层加装在所述金属饰面板以及所述衬底之间以形成图码保温板 的步骤；
所述步骤 A中生产金属饰面板时依次包括如下步骤： a.生产金属板的步骤； b.对所述金属板进行印刷花纹前的处理； c釆用第一辊涂机组对所述金属板进行一次辊涂转印； d.特定时间后釆用第二辊涂机组对所述金属板进行二次辊涂转印，在所 述金属板上形成花纹， 以生产出金属饰面板；
e.对所述金属饰面板进行喷涂光亮漆的后处理； 在所述步骤 c中釆用伺服控制系统对所述第一辊涂机组进行控制， 所述 伺服控制系统的控制过程为：
51 ,将第一辊涂机组中各辊的辊径以及工艺速度输入到 PLC控制模块中 , 所述 PLC控制模块根据工艺速度以及各辊的辊径计算出各辊的理论辊面线速 度， 使得各辊的理论辊面线速度与所述工艺速度一致， 并将计算出的各辊的 理论辊面线速度信号分别输出到带有编码器的伺服控制模块；
52 , 所述伺服控制模块接收来自所述 PLC控制模块的各辊的理论辊面线 速度信号， 并根据所述理论辊面线速度信号驱动各辊；
53 , 所述编码器釆集各辊的实际辊面线速度， 并向所述 PLC控制模块输 出各辊的实际辊面线速度信号；
54 , 所述 PLC控制模块根据接收到的各辊的实际辊面线速度信号和理论 辊面线速度信号调整驱动各辊的电机的电流频率， 进而将各辊的实际辊面线 速度修正至与所述理论辊面线速度一致时， 完成第一辊涂机组的辊涂转印。
在所述步骤 c的 S 1步骤中，所述 PLC控制模块中还输入有所述第一辊涂 机组和所述第二辊涂机组之间的距离数据， 所述 PLC控制模块根据工艺速度 和所述距离数据计算出启动第二辊涂机组的特定时间， 并按照所述特定时间 启动第二辊涂机组 , 完成第二辊涂机组的辊涂转印。 在所述步骤 c的 S4步骤后，通过暗码识别模块釆集印刷后的花纹，并通 过电脑识别确定花色错位距离， 从而对对应辊涂机组的工艺速度进行修正。 在所述步骤 a中， 所述金属板的生产过程依次为： 热轧钢卷、 对热轧后 的所述钢卷进行酸洗、 对酸洗后的所述钢卷进行冷轧以及对经过冷轧后的所 述钢卷进行连续热浸镀锌处理以形成金属板。
在所述步骤 b中， 对所述金属板进行印刷花纹前的处理过程为： 脱脂处 理、 清洗处理、 前烘干处理、 钝化处理、 后烘干处理初涂底漆处理、 烘烤固 化处理以及冷却处理。 在所述步骤 e中， 在精涂光亮漆之后进行再次烘干处理， 在再次烘干处 理之后进行再次冷却处理。 所述步骤 B中的具体生产过程为： 首先对所述金属饰面板以及所述衬底 分别进行覆膜处理、压型处理以及涂胶处理，并对所述保温层进行涂胶处理， 然后将所述保温层加装在所述金属饰面层与所述衬底之间并进行压合处理以 形成图码保温板。 在所述步骤 B中， 所述保温层釆用密度为 120kg/m3的岩棉， 且所述岩棉 的纤维走向垂直于所述金属饰面层以及所述衬底。 在所述步骤 c和所述步骤 d中釆用的辊涂转印机组包括供料设备， 用于 提供涂料； 吸料辊， 其圓周面与所述供料设备连接， 所述圓周面上具有在用 所述涂料填充时形成图像区域的多个凹陷； 橡胶涂覆辊， 其圓周面与所述吸 料辊连接， 用于承接所述涂料在所述涂覆辊上形成的图像区域， 并将所述图 像区域转印到钢板上； 第一刮刀， 安装在第一刮刀支架上， 以特定角度与所 述吸料辊接触， 用于刮除所述吸料辊的所述图像区域之外的涂料； 以及第二 刮刀， 安装在第二刮刀支架上， 以特定角度与所述涂覆辊接触， 用于刮除所 述橡胶涂覆辊上的所述图像区域之外的涂料。 所述第一刮刀以小于 30度的角度与所述吸料辊接触； 所述第二刮刀以 大于 30度的角度与所述涂覆辊接触。 本发明提供的适用于建筑物外墙的图码保温板的生产方法具有以下优 点：
1. 本发明提供的适用于建筑物外墙的图码保温板的辊涂生产方法， 先 生产金属饰面板、 衬底并在所述金属饰面板上印刷花纹然后将保温层加装在 所述金属饰面板以及所述衬底之间以形成图码保温板， 最后将生产出的图码 缺陷 （饰面层安装时不便于利用辊涂生产线直接在已经安装在墙体的保温板 上辊涂花纹， 从而现有保温板一般装饰效果较差， 不美观）， 实现了保温与装 饰的一体化。 并且， 对于一次转印来说， 一方面， 伺服控制系统中的 PLC控 制模块通过釆集工艺速度以及辊涂机组中各辊子的转速， 计算出辊涂机组中 各辊子的理论辊面线速度， 并使得理论辊面线速度与工艺转速一致； 另一方 面 , 通过具有编码器的伺服控制模块釆集辊涂机组中各辊子的实际辊面线速 度， 并将实际辊面线速度信号输入到 PLC控制系统， 从而使得 PLC控制系统 能够与实际辊面线速度和理论辊面线速度进行比较， 并调整电流频率， 直至 实际辊面线速度与理论辊面线速度相一致。 上述控制方法将实际辊面线速度 调整为与理论辊面线速度相一致， 而理论辊面线速度与工艺速度一致， 从而 确保了实际辊面线速度与工艺转速一致，进而在生产过程中不需要停线调整， 提高了生产效率。
2. 本发明提供的适用于建筑物外墙的图码保温板的辊涂生产方法， 所述 PLC控制模块中还输入有第一辊涂转印机组和第二辊涂转印机组之间的距离 数据，并能够根据工艺速度和所述距离数据计算出启动第二辊涂机组的时间。 由于生产线一旦确定， 相邻机组之间的距离就确定， 事先将所述数据数据输 入到 PLC控制模块中， 所述 PLC控制模块根据工艺速度以及距离数据计算出 下一辊涂转印机组启动的时间， 从而将时间进行事先设定， 从而使得下一辊 涂生产线在特定时间内启动， 进而实现了相邻辊涂机组的连续作业， 进一步 提高了生产效率。
3. 本发明提供的适用于建筑物外墙的图码保温板的辊涂生产方法，还包 括暗码识别模块， 所述暗码识别模块釆集印刷后的花纹， 并通过电脑识别确 定花色错位距离， 从而对对应辊涂机组的工艺速度进行修正。 在下一辊涂生 产线启动并完成二次转印后， 通过暗码识别模块釆集印刷后的花纹， 并通过 电脑识别确定花色错位距离，从而根据花色错位距离对各辊的转速进行修正， 使得花色错位情况得到修正， 上述过程可以循环进行， 从而保证了印制出的 花纹完整而逼真， 另外， 暗码识别模块的加入使得印刷出的花纹的长度大大 增大。
4. 本发明提供的适用于建筑物外墙的图码保温板的辊涂生产方法， 在 所述步骤 a中， 所述金属板的生产过程依次为： 热轧钢卷、 对热轧后的所述 钢卷进行酸洗、 对酸洗后的所述钢卷进行冷轧以及对经过冷轧后的所述钢卷 进行连续热浸镀锌处理以形成金属板， 热轧处理有利于金属板的成型， 酸洗 处理有利于除锈且便于裁边， 热轧后进行冷轧有利于消除气孔， 而冷轧后进 行连续热镀锌处理既能实现退火效果还能提高金属板的抗氧化性能。
5. 本发明提供的适用于建筑物外墙的图码保温板的辊涂生产方法，在所 述步骤 b中， 对所述金属板进行印刷花纹前的处理过程为： 脱脂处理、 清洗 处理、 前烘干处理、 钝化处理、 后烘干处理初涂底漆处理、 烘烤固化处理以 及冷却处理。 上述前处理步骤有效的增加了辊涂过程中涂料与待印金属板之 间的附着力， 并提高了金属饰面板后期的成型性能。
6. 本发明提供的适用于建筑物外墙的图码保温板的辊涂生产方法，在所 述步骤 B中， 所述保温层釆用密度为 120kg/m3的岩棉， 且所述岩棉的纤维走 向垂直于所述金属饰面层以及所述衬底。 密度的合理选择有利于提高保温层 本身的强度， 而将所述岩棉的纤维走向设置为垂直于所述金属饰面层以及所 述衬底则保证了岩棉与金属饰面层以及衬底之间不容易滑动错位， 从而提高 了刚度。 附图说明 为了使本发明的内容更容易被清楚的理解， 下面根据本发明的具体实施 例并结合附图， 对本发明作进一步详细的说明， 其中 图 1是本发明釆用的辊涂机组的结构示意图；
图中附图标记表示为：
1-供料设备； 2-吸料辊； 3-橡胶涂覆辊； 4-第一刮刀； 5-第二刮刀； 6- 清洗装置； 61-供液箱； 62-传送泵； 63-传送管道； 64-喷淋管； 65-喷淋孔； 67-回收槽； 68-过滤器； 7-支撑辊。 实施例 1
本实施例提供一种适用于建筑物外墙的图码保温板的生产方法， 依次包 括如下步骤： A. 生产金属饰面板、 衬底并在所述金属饰面板上印刷花纹的步 骤； 以及 B.将保温层加装在所述金属饰面板以及所述衬底之间以形成图码保 温板的步骤； 所述步骤 A中生产金属饰面板时依次包括如下步骤： a.生产金 属板的步骤； b.对所述金属板进行印刷花纹前的处理； c.釆用第一辊涂机组 对所述金属板进行一次辊涂转印； d.特定时间后釆用第二辊涂机组对所述金 属板进行二次辊涂转印，在所述金属板上形成花纹， 以生产出金属饰面板； e. 对所述金属饰面板进行喷涂光亮漆的后处理。
在所述步骤 a中， 所述金属板的生产过程具体为： 热轧钢卷、 对热轧后 的所述钢卷釆用盐酸进行酸洗、 对酸洗后的所述钢卷进行冷轧以及对经过冷 轧后的所述钢卷在 650 °C (也可以在 650 °C -850 °C之间选择其他温度值进行连 续热浸镀锌处理以形成金属板，在此， 650°C下进行连续热镀锌处理相当于先 进行了退火处理而后再进行热镀锌处理， 不但提高了力学性能， 而且提高了 抗氧化性。
在所述步骤 b中， 对所述金属板进行印刷花纹前的处理的具体过程为： 脱脂处理、 清洗处理、 前烘干处理、 钝化处理、 后烘干处理初涂底漆处理、 烘烤固化处理以及冷却处理。具体为：脱脂处理，釆用浓度为 1%,温度 50-65 度的碱液进行脱脂， 以去除带钢表面的油污及粉尘， 碱液总碱与游离碱的比 例小于 2. 5; 清洗处理， 釆用 50-65度的脱盐水对脱脂后的带钢表面进行冲 洗， 以去除带钢表面的残余碱液， 冲洗水的 PH值小于 7. 8; 前烘干处理， 釆 用 75-85度的热风对清洗后的带钢表面残余的水分进行干燥， 热风通过蒸汽 换热器进行加热； 钝化处理， 釆用铬点为 22-32之间的处理液对清洁后的带 钢表面进行钝化处理， 以增加带钢与底漆的附着力及防腐性能；后烘干处理， 釆用电加热烘箱对钝化处理后的表面进行干燥处理， 以强化钝化效果， 板面 烘烤温度 72-85度； 初涂底漆处理， 釆用第一辊涂机组对带钢表面涂覆背漆 及底漆， 底漆的颜色及性能根据所印花色来确定； 烘烤固化处理以及冷却处 理， 对涂覆底漆和背漆的带钢进行烘烤， 使底漆及背漆充分固化， 固化温度 214-232 度， 然后通过水雾及水流对烘烤固化后的带钢进行冷却， 进一步稳 在本实施例中， 为了提高花纹的亮度及保护， 在所述步骤 e中对金属板 进行后处理， 所述后处理包括在金属板表面精涂光亮漆， 在精涂光亮漆之后 进行再次烘干处理， 在再次烘干处理之后进行再次冷却处理。
本实施例中， 在所述步骤 c和 d中釆用伺服控制系统对所述第一辊涂机 组进行控制， 以在金属板上形成两色花纹， 具体的控制过程为：
51 ,将第一辊涂机组中各辊的辊径以及工艺速度输入到 PLC控制模块中 , 所述 PLC控制模块根据工艺速度以及各辊的辊径计算出各辊的理论辊面线速 度（理论转速 =工艺速度 / (兀 *各辊直径，理论辊面线速度=理论转速 *辊直径 * 兀），使得各辊的理论辊面线速度与所述工艺速度一致，并将计算出的各辊的 理论辊面线速度信号分别输出到具有编码器的伺服控制模块；
52 , 所述伺服控制模块接收来自所述 PLC控制模块的各辊的理论辊面线 速度信号， 并根据所述理论辊面线速度信号驱动各辊；
53,所述编码器釆集各辊的实际辊面线速度，并向所述 PLC控制模块输出 各辊的实际辊面线速度信号；
S4，所述 PLC控制模块根据接收到的各辊的实际辊面线速度信号和理论 辊面线速度信号调整驱动各辊的电机的电流频率， 进而将各辊的实际辊面线 速度修正至与所述理论辊面线速度一致时， 完成第一辊涂机组的辊涂转印。
在本实施例中， 为了实现相邻辊涂机组的线上连续作业， 在所述步骤 S 1 中， 所述 PLC控制模块中还输入有第一辊涂机组和第二辊涂机组之间的距离 数据， 所述 PLC控制模块根据工艺速度和所述距离数据计算出启动第二辊涂 机组的时间，并按照启动时间启动第二辊涂机组， 完成第二辊涂机组的印刷。 在本实施例中， 为了印制不规则的长幅花纹的需要， 在完成第二辊涂机 组的印刷后， 即在 S4步骤后， 通过暗码识别模块釆集印刷后的花纹， 并通过 电脑识别系统确定花色错位距离，从而对对应辊涂机组的工艺速度进行修正。 具体的修正过程为： 如果通过暗码识别模块釆集到的花纹中后辊涂的颜色相 对于先辊涂上的颜色与预定辊涂位置产生一个错位距离， 例如， 相对于预定 辊涂位置靠前了 10匪， 这说明运送金属板的辊子的实际工艺速度（用 VI表 示）相对于应该运行的工艺速度（用 V2表示）在单位时间内快了 10mm, 此时， V2=V1-1 0 ,计算出 V2之后，将 V2转化为应该运行的辊子的转速（用 N表示）， N= V2/兀 *辊直径径， 从而根据转速 N调整对应电机的电流频率， 从而对对应 辊子的转速进行调整， 进而调整工艺速度， 最终将花色的错位精度控制在士 0. 6 毫米以内， 这是一个动态反复的调节过程。 在此， 通过暗码识别模块中 的数码摄像机釆集印刷后的花纹。 需要说明的是， 对于本发明的上述生产方法来说， 所述步骤 c和所述步 骤 d需要釆用辊涂机组来实现， 但是对于具体的辊涂机组的结构不做限制。 值得注意的是， 本实施例提供的是两色花纹的金属饰面板的生产方法， 所需要的辊涂转印机组为两组， 而本领域技术人员可以按照本实施例公开的 生产方法， 尤其是伺服控制系统中的调整转速、 第二辊涂机组启动时间以及 暗码识别技术在本实施例基础上进行改造， 进行三色、 四色、 五色或者更多 色花纹的金属饰面板的生产。
本实施例中， 所述步骤 B的具体生产过程为： 首先对所述金属饰面板以 及所述衬底分别进行覆膜处理、 压型处理以及涂胶处理， 并对所述保温层进 行涂胶处理， 然后将所述保温层加装在所述金属饰面层与所述衬底之间并进 行压合处理以形成图码保温板。 所述保温层釆用密度为 120kg/m3的岩棉， 且 所述岩棉的纤维走向垂直于所述金属饰面层以及所述衬底。 涂胶处理中釆用 的是聚氨酯发泡剂。 为了提高防水性能， 将所述保温层加装在所述金属饰面 层与所述衬底之间并进行压合处理且形成图码保温板之后， 釆用聚氨酯发泡 剂对所述图码保温板进行封边处理。
实施例 2 本实施例中提供一种用于实施例 1中的步骤 c和步骤 d的辊涂转印机组 的结构， 具体结构见图 1 , 所述辊涂机组包括供料设备 1 , 用于提供涂料； 吸 料辊 2 , 其圓周面与所述供料设备 1连接， 所述圓周面上具有在用所述涂料 填充时形成图像区域的多个凹陷； 橡胶涂覆辊 3 , 其圓周面与所述吸料辊 1 连接， 用于承接所述涂料在所述涂覆辊 3上形成的图像区域， 并将所述图像 区域转印到钢板上； 还包括第一刮刀 4 , 安装在第一刮刀支架上， 以特定角 度与所述吸料辊 2接触，用于刮除所述吸料辊 2的所述图像区域之外的涂料； 第二刮刀 5 , 安装在第二刮刀支架上， 以特定角度与所述涂覆辊 2接触， 用 于刮除所述橡胶涂覆辊 3上的所述图像区域之外的涂料。 本实施例提供的辊涂机组的工作过程为： 所述吸料辊 2运动， 所述供料 设备 1向吸料辊 1上供应涂料，所述涂料一部分进入所述吸料辊 2上的用于 形成图像区域的凹陷内，一部分位于所述吸料辊 2上的凹陷以外的区域； 用 第一刮刀 4刮除所述吸料辊 2的凹陷以外的区域上的涂料后， 所述吸料辊 2 转动将所述凹陷内的涂料转印上所述橡胶涂覆辊 3上， 形成图像区域， 用第 二刮刀刮除所述橡胶涂覆辊 3上的图像区域以外的涂料； 所述橡胶涂覆辊 3 转动时进一步将所述图像区域转印到待印金属板上形成花纹，支撑辊 7用于 支撑所述待印金属板， 为所述橡胶涂覆辊的涂覆提供支撑力。 釆用本实施提供的辊涂机组在金属板上印刷花纹的具体控制过程为：
S1,将第一辊涂机组中的吸料辊 1、涂覆辊 3的辊径以及工艺速度输入到 PLC控制模块中， 所述 PLC控制模块根据工艺速度以及所述吸料辊 2和所述 涂覆辊 3的辊径计算出所述吸料辊 1和所述涂覆辊 3的理论辊面线速度， 使 得所述吸料辊 1和所述涂覆辊 3的理论辊面线速度与所述工艺速度一致， 并 将计算出的所述吸料辊 1和所述涂覆辊 3的理论辊面线速度信号分别输出到 具有第一编码器的第一伺服控制模块， 和具有第二编码器的第二伺服控制模 块；
S2，所述第一伺服控制模块接收来自所述 PLC 控制模块的所述吸料辊 2 的理论辊面线速度信号，并根据所述理论辊面线速度信号驱动所述吸料辊 2 , 所述第二伺服控制模块接收来自所述 PLC控制模块的所述涂覆辊 3的理论辊 面线速度信号， 并根据所述理论辊面线速度信号驱动所述涂覆辊 3; S3，所述第一编码器釆集所述吸料辊 2的实际辊面线速度，并向所述 PLC 控制模块输出吸料辊 2的实际辊面线速度信号， 所述第二编码器釆集所述涂 覆辊 3的实际辊面线速度， 并向所述 PLC控制模块输出涂覆辊 3的实际辊面 线速度信号；
S4,所述 PLC控制模块将接收到的所述吸料辊 2和所述涂覆辊 3的实际辊 面线速度信号和理论辊面线速度信号调整驱动各辊的电机的电流频率， 进而 将所述吸料辊 1和所述涂覆辊 3的实际辊面线速度修正至与所述理论辊面线 速度一致时， 完成第一辊涂机组的印刷。 本实施例提供的辊涂机组的涂敷辊 3釆用橡胶制成，这样的结构设计使 得涂敷辊分别与吸料辊 1以及待印钢板之间进行柔性接触，从而保证了接触 的 "严丝合缝"， 不但能够将吸料辊 2上的图案区域完整的转印到橡胶涂覆 辊 3上， 也能够将橡胶涂覆辊 3上的图像区域完整的转印到待印钢板上，从 而形成完整的图案区域； 另外， 本实施例提供的凹版印刷机包括第一刮刀 4 和第二刮刀 5 (图 1中是第一刮刀 4和第二刮刀 5分别与吸料辊 2和橡胶涂 覆辊 3接触时的示意）， 所述第一刮刀 4用于将所述吸料辊 2上的用于形成 图像区域的凹陷以外的涂料刮除， 所述第二刮刀 5用于将所述橡胶涂覆辊 3 上图像区域以外的涂料去除，避免了人工清楚上述涂料造成了劳动效率较低 的缺陷， 从而提高了劳动生产率； 另外， 所述第一刮刀 4和所述第二刮刀 4 分别以特定角度与所述吸料辊 2和所述橡胶涂覆辊 3接触，能够保证较好的 刮除效果， 并有利于提高刮刀的使用寿命。 在本实施例中，所述第一刮刀 4和所述第二刮刀 5分别与可调高度和角 度的支架固定连接， 在此， 进一步地， 所示高度和角度可调的实现方式为： 刮刀两端各固定有一套能够上下移动的滑轨副，滑轨的上下移动通过与之连 接在一起的涡轮蜗杆装置来进行调节，两端的涡轮蜗杆由一刚性连杆连接在 一起， 通过调节手轮来带动蜗杆的旋转， 从而实现刮刀的上下移动； 刮刀的 两端设有显示高度的标尺， 以显示调节量。 所述角度可调的实现方式为： 刮 刀两端的滑轨副的下端各有一个铰接机构， 滑轨副可沿着铰接机构旋转， 滑 轨副的旋转通过调节丝杆来调节，调节丝杆的转动由人工利用调节扳手进行 操作， 滑轨副的旁边设有显示角度的标尺， 以显示转动的角度。
需要说明的是， 本实施例提供的涂覆辊的材料除了釆用橡胶之外， 还可 以釆用能够保证正常涂覆且能与吸料辊和待印钢板柔性接触的其他材料，例 如， 能够同时满足弹性、 硬度以及涂覆时转印性能的硅胶制品。
在本实施例中， 所述第一刮刀 4以小于 30度的角度与所述吸料辊 2接 触； 所述第二刮刀 5以大于 30度的角度与所述涂覆辊 3接触。 在凹版印刷 过程中， 同一时刻对于涂料的刮除位置不同， 所述第一刮刀 4和所述第二刮 刀 5设置为不同的角度， 可以同时保证对吸料辊 2和涂覆辊 3的刮除。 在本实施例中， 所述第一刮刀 4为钛钢板； 所述第二刮刀 5为钛钢板。 所述第一刮刀 4 的刀刃的厚度为 0. 3mm, 所述第二刮刀 5 的刀刃的厚度为 0. 3mm。 在本实施例中， 为了改进辊涂机组的性能， 加装了清洗装置 6 , 用于对 所述第二刮刀 5以及所述橡胶涂覆辊 3上的涂料进行清洗。 所述清洗装置 6 包括供液箱 61、 用于泵送所述供液箱 61内的清洗液传送泵 62、 与所述清洗 液传送泵 62连通的清洗液传送管道 63以及与所述清洗液传送管道连通的喷 淋管 64 , 所述喷淋管 64设置在所述橡胶涂覆辊 3的轴向上方， 所述喷淋管 64上具有若干个喷淋孔 65 ;所述清洗装置 6还包括设置在所述涂覆辊 3下方 的清洗液回收槽 66 ; 所述清洗液回收槽 66连接一个回收管道 67 , 所述回收 管道 67通向所述供液箱 61 ; 所述回收管道 67和所述供液箱 61之间设置一 个过滤器 68。 本实施例提供的清洗装置 6的工作过程为：
在工作时， 通过传送泵 62将供液箱 61内的清洗液泵送到喷淋管 64内 通过喷淋孔 65进行喷淋， 之后清洗液从所述橡胶涂覆辊 3回流到清洗液回 收槽 66内，并通过回收管道 67以及过滤器 68过滤后最后回到供液箱 61内， 供循环使用。 在本实施例中， 所述供料设备 1为一个具有凹槽的料盘。 显然， 上述实施例仅仅是为清楚地说明所作的举例， 而并非对实施方式 的限定。对于所属领域的普通技术人员来说， 在上述说明的基础上还可以做 出其它不同形式的变化或变动。 这里无需也无法对所有的实施方式予以穷 举。 而由此所引伸出的显而易见的变化或变动仍处于本发明的保护范围之 内。

Claims

权 利 要 求 书
1.一种适用于建筑物外墙的图码保温板的辊涂生产方法， 依次包括如下 步骤：
A. 生产金属饰面板、 衬底并在所述金属饰面板上印刷花纹的步骤； 以及
B.将保温层加装在所述金属饰面板以及所述衬底之间以形成图码保温板 的步骤；
所述步骤 A中生产金属饰面板时依次包括如下步骤：
a.生产金属板的步骤；
b.对所述金属板进行印刷花纹前的处理；
c釆用第一辊涂机组对所述金属板进行一次辊涂转印；
d.特定时间后釆用第二辊涂机组对所述金属板进行二次辊涂转印，在所 述金属板上形成花纹， 以生产出金属饰面板；
e.对所述金属饰面板进行喷涂光亮漆的后处理；
其特征在于： 在所述步骤 c中釆用伺服控制系统对所述第一辊涂机组进行控制， 所述 伺服控制系统的控制过程为：
51 ,将第一辊涂机组中各辊的辊径以及工艺速度输入到 PLC控制模块中 , 所述 PLC控制模块根据工艺速度以及各辊的辊径计算出各辊的理论辊面线速 度， 使得各辊的理论辊面线速度与所述工艺速度一致， 并将计算出的各辊的 理论辊面线速度信号分别输出到带有编码器的伺服控制模块；
52 , 所述伺服控制模块接收来自所述 PLC控制模块的各辊的理论辊面线 速度信号， 并根据所述理论辊面线速度信号驱动各辊；
53,所述编码器釆集各辊的实际辊面线速度，并向所述 PLC控制模块输出 各辊的实际辊面线速度信号；
S4，所述 PLC控制模块根据接收到的各辊的实际辊面线速度信号和理论 辊面线速度信号调整驱动各辊的电机的电流频率， 进而将各辊的实际辊面线 速度修正至与所述理论辊面线速度一致时， 完成第一辊涂机组的辊涂转印。
2.根据权利要求 1所述的适用于建筑物外墙的图码保温板的辊涂生产方 法， 其特征在于： 在所述步骤 c的 S 1步骤中， 所述 PLC控制模块中还输入有 所述第一辊涂机组和所述第二辊涂机组之间的距离数据， 所述 PLC控制模块 根据工艺速度和所述距离数据计算出启动第二辊涂机组的特定时间， 并按照 所述特定时间启动第二辊涂机组， 完成第二辊涂机组的辊涂转印。
3.根据权利要求 2所述的适用于建筑物外墙的图码保温板的辊涂生产方 法， 其特征在于： 在所述步骤 c的 S4步骤后， 通过暗码识别模块釆集印刷后 的花纹， 并通过电脑识别确定花色错位距离， 从而对对应辊涂机组的工艺速 度进行修正。
4.根据权利要求 1- 3中任一项所述的适用于建筑物外墙的图码保温板的 辊涂生产方法， 其特征在于： 在所述步骤 a中， 所述金属板的生产过程依次 为： 热轧钢卷、 对热轧后的所述钢卷进行酸洗、 对酸洗后的所述钢卷进行冷 轧以及对经过冷轧后的所述钢卷进行连续热浸镀锌处理以形成金属板。
5.根据权利要求 4所述的适用于建筑物外墙的图码保温板的辊涂生产方 法， 其特征在于： 在所述步骤 b中， 对所述金属板进行印刷花纹前的处理过 程为： 脱脂处理、 清洗处理、 前烘干处理、 钝化处理、 后烘干处理初涂底漆 处理、 烘烤固化处理以及冷却处理。
6.根据权利要求 1-5中任一项所述的适用于建筑物外墙的图码保温板的 辊涂生产方法， 其特征在于： 在所述步骤 e中， 在精涂光亮漆之后进行再次 烘干处理， 在再次烘干处理之后进行再次冷却处理。
7.根据权利要求 1-6中任一项所述的适用于建筑物外墙的图码保温板的 辊涂生产方法， 其特征在于： 所述步骤 B中的具体生产过程为： 首先对所述 金属饰面板以及所述衬底分别进行覆膜处理、 压型处理以及涂胶处理， 并对 所述保温层进行涂胶处理， 然后将所述保温层加装在所述金属饰面层与所述 衬底之间并进行压合处理以形成图码保温板。
8.根据权利要求 7所述的适用于建筑物外墙的图码保温板的辊涂生产方 法，其特征在于： 在所述步骤 B中， 所述保温层釆用密度为 120kg/m3的岩棉， 且所述岩棉的纤维走向垂直于所述金属饰面层以及所述衬底。
9.根据权利要求 8所述的适用于建筑物外墙的图码保温板的辊涂生产方 法， 其特征在于： 在所述步骤 B中， 涂胶处理中釆用的是聚氨酯发泡剂。
1 0.根据权利要求 9 所述的适用于建筑物外墙的图码保温板的辊涂生产 方法， 其特征在于： 在所述步骤 B中， 将所述保温层加装在所述金属饰面层 与所述衬底之间并进行压合处理且形成图码保温板之后， 釆用聚氨酯发泡剂 对所述图码保温板进行封边处理。
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