Model HN200-PL HOT MICRO PERFORATION plant for holes from 100µm to 2mm with Ø200mm motorized needle roller
Description
This equipment is designed to make "hot" micro holes on moving films of rubber, faux leather, wood veneer and various thicker and more puncture-resistant materials, and is to be inserted as a host unit in film transport lines, such as cutters, extruders, printing presses, welding machines. The HN200-PL is a motorized unit designed for greater penetration with a synchronization system that ensures perfect micro holes on a variety of materials; ideal for delicate work on heat-shrinkable material, for works that require holes with a very high density of needles per cm2 and to process mono or bi-oriented materials.
Operation
The HN200-PL is an electrically heated micro hot needle perforator. Running film arrives at the device and passes between the motorized needle shaft and the contrast roller, which as they approach each other perforate the material. The micro perforation is achieved by melting and perforating the material, caused by the needles infixed on the interchangeable sleeves that are mounted on the needle shaft placed inside an insulated chamber and brought to a suitable temperature by the infrared lamp unit.
OPERATION is entrusted to our software ready for 4.0 from the electrical control panel. The operator via touch screen manages all operations inherent to the device such as temperature control, heating element operation, emergency activation and needle roller rotation.
When the device is paused, the needle shaft rotates slowly to maintain a uniform heating or cooling temperature to avoid any damage.
In "automatic function," the approach of the counter roller to the needle shaft is enabled only at optimum film running speed and temperature, to ensure perfect holes and to prevent, due to wrong temperature or slow film running, material melting on the needles.
When the operator activates the perforation "stop" function or the film is running at an unsuitable speed, the perforation is disabled: the counter roller with the running material moves away, the shutter separating the hot chamber drops, and the unit goes into "pause" mode, with the needle shaft continuing rotation at reduced speed. A "manual function" is still available, however, allowing the operator to activate perforation at any speed the film is running.
It is possible to equip the device with a photocell reading the material presence, so that when no material is detected it disables perforation and closes the shutter.
When the machine is turned off, it enters the "pause" mode before stopping, continuing the rotation of the needle shaft until it cools down, to prevent needle damage and roller twisting.
Components
1: Needle shaft; 2: Contrast roller; 3: Heating; 4: Shutter; 5: Idler rollers; 6: Penetration adjustment;
1 Needle shaft
It consists of a STEEL ROLLER with mechanical parts SUITABLE FOR WORKING AT HIGH TEMPERATURES to prevent damage from thermal expansion.
2 Counter roller
It has a PERFECTLY UNIFORM SURFACE for obtaining homogeneous holes. It can be supplied in ground natural bristles or rubberized.
It is pneumatically driven, and enables and disables perforation by approaching or moving away from the needle shaft. In order to adjust the penetration into the material, the roller is moved by 2 actuators positioned at the extremities.
3 Electric heating system
For optimum results even on difficult-to-process materials, the needle roller is heated by an electric heating system, consisting of a group of lamps (4 kW infrared ceramic radiators for a material width of 240 mm) with PID control, to ensure a constant temperature along the entire surface of the needle rollers.
The PLC independently manages the three heating lines, ensuring uniform heat output.
4 Shutter
Moved by two pneumatic pistons, it is part of the safety systems: it separates the insulated chamber from the contrast roller and the film to be processed.
5 Idle rollers
They guarantee optimal film tension, and their position can be regulated using the two dedicated screws.
6 Penetration adjustment
The PENETRATION ADJUSTMENT SYSTEM (motorized, touch screen controlled) consists of 2 actuators that raise and lower the contrast roller to adjust the distance between the contrast roller and the needle roller.
By adjusting this distance, it is possible to control the penetration of the needles into the material and thus determine the diameter of the hole to be made. This adjustment can be made both while the machine is stopped and while the machine is running, ensuring maximum precision.
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RUBBER - FAUX LEATHER - WOOD VENEER - LAMINATES - PVC
| TECHNICAL DATA SHEET | |
|---|---|
| Needle shaft Ø | 200mm |
| Hole Ø | Ø min. 100µm / Ø max. 2mm* |
| Movement and power | Asynchronous motor / 400 V+N+T - 50Hz |
| Penetration adjustment | Motorized, controlled by touch screen |
| Maximum Speed | 100 mt/minute* |
| Heating power | 16Kw / mt |
| Maximum temperature | 240° C |
| Air pressure | 6 Bar |
| Counter roller movement | Motorized - 2 actuators |
| Control System | Electrical control panel with integrated touch screen |
| * | Value affected by the type of material |
| OPTIONALS |
|---|
| Safety system: a blade cutting on the fly the material rolled on the needle shaft |
| Calender roller |
| Material Tension Adjustment System |
| Material breakage sensor |
| Filter system for extraction hood |
| Trolley |
| Fume extraction hood |
| Table for easy roller changing |
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