The distributed block cutting section in the aerated block production line serves as a pivotal link, primarily responsible for precisely cutting the aerated block embryos after initial curing and a certain degree of strength development, ultimately forming aerated blocks that meet specifications. The core equipment in this section comprises the longitudinal cutting machine and the transverse cutting machine, each fulfilling distinct roles.
Role of Longitudinal Cutting Machine:
Precise Cutting: It achieves precise longitudinal cutting of the embryo by driving the cutting device (such as cutting wires or blades) along the length of the embryo through a motor. This ensures dimensional accuracy and consistency of the final products.
Enhanced Production Efficiency: Equipped with an automated control system, the longitudinal cutting machine enables continuous and efficient cutting operations, thereby boosting overall production line efficiency.
Adaptability to Different Sizes: It can adjust cutting dimensions to cater to the production of aerated blocks of varying specifications.
Role of Transverse Cutting Machine:
Auxiliary Cutting: Following the longitudinal cutting by the longitudinal cutting machine, the transverse cutting machine further slices the embryo in the width direction, shaping the final aerated block products.
Quality Assurance: It employs precise cutting methods to ensure the flatness and dimensional accuracy of the cut surfaces, thereby enhancing the overall product quality.
Flexibility: Similar to the longitudinal cutting machine, the transverse cutting machine can also adjust cutting sizes to meet the production needs of different specifications.
Cutting Process Flow:
The cutting process in the distributed block cutting section typically encompasses the following steps:
Flipping and Demolding: Initially, a flipping hoist is used to rotate the embryo 90 degrees in the air and remove the mold frame. This step facilitates the stable placement of the embryo on the cutting table.
Longitudinal Cutting: Subsequently, the longitudinal cutting machine is activated to cut the embryo along its length. The cutting device moves along the embryo's length, completing the longitudinal cut.
Transverse Cutting: After longitudinal cutting, the transverse cutting machine initiates to slice the embryo in the width direction. Driven by a motor, the cutting device moves across the embryo's width, completing the transverse cut.
Product Sorting: Once cutting is complete, the aerated block products are removed from the cutting table for subsequent sorting and stacking.
I. Preliminary Preparation
Embryo Initial Curing: Prior to cutting, the aerated block embryos undergo initial curing to attain sufficient strength and stability, facilitating subsequent cutting operations. During this process, the embryos are naturally cured under specific temperature and humidity conditions to promote internal hydration reactions and strength development.
Equipment Inspection: Before starting the cutting machines (longitudinal and transverse), a comprehensive inspection is conducted to ensure the sharpness and integrity of cutting devices (e.g., cutting wires, blades), as well as the proper functioning of transmission systems, control systems, and other components.
II. Cutting Operations
Flipping and Demolding:
The embryo is smoothly lifted out of the mold using a flipping hoist and placed on the cutting table. This operation ensures the embryo's stability and safety, preventing damage or tipping during flipping.
After demolding, the embryo's surface is inspected for flatness, cracks, or defects to guarantee cutting quality.
Longitudinal Cutting:
The longitudinal cutting machine is activated, and the cutting device's position is adjusted according to the preset cutting dimensions.
The cutting device (e.g., cutting wire) moves along the embryo's length under motor power, achieving longitudinal cutting. During this process, stable cutting speed and flat cutting surfaces are maintained.
Transverse Cutting:
Following longitudinal cutting, the transverse cutting machine is activated to slice the embryo in the width direction.
Similar to longitudinal cutting, the transverse cutting machine adjusts based on preset dimensions and moves across the embryo's width, dividing it into multiple aerated block products that meet specifications.
III. Product Sorting and Inspection
Product Sorting:
After cutting, the aerated block products are removed from the cutting table using handling tools and undergo preliminary sorting and stacking. Stacking should consider product stability and safety, avoiding mutual compression or collision that could cause damage.
Quality Inspection:
The cut aerated block products undergo quality inspection to verify compliance with standards in terms of dimensional accuracy, appearance quality, and physical-mechanical properties. Non-conforming products are rejected or reprocessed.
IV. Post-Processing
Scrap Recycling: Waste materials generated during cutting (e.g., cut-off scraps) are recycled to reduce resource waste and environmental pollution.
Equipment Maintenance: After cutting, the cutting machines are cleaned and maintained to extend their lifespan and ensure smooth cutting operations for future use.
V. Precautions
Throughout the cutting process, strict adherence to safety operating procedures and equipment operation norms is crucial to ensure operators' safety and equipment's proper functioning.
Maintain a clean and organized production environment to prevent debris and dust from affecting cutting quality.
Adjust cutting parameters and processes based on different aerated block types and production requirements to optimize product quality and production efficiency.
Additional Precautions:
Ensure the sharpness and stability of cutting devices to prevent unnecessary damage to the embryo.
Promptly clear waste generated during cutting to maintain a tidy and organized production environment.
Regularly maintain and service cutting equipment to prolong its lifespan and ensure cutting precision.
In summary, the distributed block cutting section in the aerated block production line, through the collaborative efforts of the longitudinal and transverse cutting machines, achieves precise cutting and efficient production of embryos. This section is instrumental in enhancing product quality and production efficiency.
