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ZYM2436(4-19mm) flat tempered glass machine

1.brief introduction
This machine composed of loading section, heating section, flat tempering and cooling section, unloading section, blower system and control system.
It is used to temper low-E flat glasses for architectural, interior decoration, furniture appliances etc.

1.1 Loading section
The loading table is composed of rubber-covered rollers. When the glass is put onto the rollers, the glass will be conveyed automatically to the entrance of the furnace where it will be in ready-to-enter-furnace position and the rollers stop moving. It will send the glass into the furnace once the computer control system gives enter instruction. The drive system uses the chain. With lifting table and side roller.

1.2 Heating Section
The structure of the heating section is of a double-layer box type covered with thermo-insulating material. Inside the section there is a conveyor system with high temperature resistant ceramic rollers, which are imported from well-known manufacturers, i.e. Vesuvius, China. Heating elements are installed on the upper layer and lower layer of this section. The heating element is of an integrated part with spiral type resistance erected on ceramic part, it's easy to replace. When the glass is going to enter the furnace, the front door of the heating section opens, the rollers of the loading table and heating section move at the same time. When the glass is in the furnace, the front door will close and the glass on the rollers will be moved back and forth at the distance calculated by the controlling system automatically, so that the glass will be heated evenly. The upper section can be lifted up by remote control for maintenance. The heating elements are in matrix layout. The upper side has many heating elements, and lower side has many also. Each has one independent control loop.

CONVECTION FUNCTION

Top Convection System
On the top of the furnace, there are three convection blowers. Convection blowers pump the hot air which is inside the furnace, then the hot air go through the stainless steel pipe which on the top of the furnace, through the ceramic duct ,the hot air is near to the glass surface, in this way, the heating speed of top glass surface is increased ,so the LOW-E glass can be produced.

1.3 Flat Quenching/Cooling Section
The blast heads are divided into upper and lower parts. The nozzles are made of aluminum alloy, and the distance between glass and upper/lower nozzles can be adjusted according to the quenching demand for different kinds of glass. In among the blast heads, there are a lot of rollers conveying the glass sheets forwarding. When the glass sheet comes out the furnace, the rollers here will move synchronously with the rollers in the furnace, to transit the glass sheet into quenching section. Meanwhile, the huge blower will immediately blow the high pressure air on the surface of the glass through air ducts. The air pressure and flux is decided by the blower inverter, which is controlled automatically by the control system. And the rollers are covered by one kind of special heat-resistant material.

1.4 Unloading Table

The unloading table is the same as the loading table. When the glass is transported to the end of the conveyor, the rollers will stop, and the glass can be taken away by hand, or by robot, if there is available at the customer’s factory. Same the loading table drives system. With lifting table and side roller.

1.5 Air Box
The upper and lower part is separate. The air pressure can be adjusted separately. It also displays on the computer separately. The air pressure and its value difference can be shown on the computer.

1.6 Control System
The control system includes the followings:
1.Process parameters storage and re-call, such as glass thickness, size, color, glass type and maybe different sources of float glass and etc. Whenever you produce a new order for different thickness, size, color, type, source and etc., you just enter the process parameters, and the system will memorize these process data. Next time, when you have the re-order, or the same order, you can re-call the data, and the machine will automatically use the stored processing data to produce.
2.Controller for roller driving system.
3.Controller for the temperature control.
4.Controller for quenching control.
5.The abnormity alarming system would warn while trouble happens to indicate how to solve this trouble.
6.The furnace has auto pre-heating function. After the shift of a day, the furnace will be in the stand-by status; only less than 25% of heating power will be consumed, while the ceramic rollers will be still running. And ahead of working time on the next morning, the system will start up to heat up to the working temperature until the operator begins the production.
7.The main industrial control computer is installed with the terminals at the control desk. Display screen can provide users with analog process status: main screen, process parameter screen, operation and maintenance screen and system parameter screen. The system has reading and writing function for process parameters, automatic control, unit equipment operation and test as well as self-diagnosis, as well as display alarming function.

NOTES:
a) Main drive control system is accomplished by the inverter system which is controlled by computer. On-line of every part is controlled by computer.
b) The main screen is the page displayed on the monitor during normal production. The contents displayed directly in English are the statuses of glass in the furnace, driving system, temperature at each zone, time of heating, quench and cooling, actual pressure, set point of fans and length sum of pieces of glass in the furnace. This screen is for the operator's notice. The process parameter screen records the designed moving distance of loading table when the pedal switch is actuated by the operator, temperature set point of upper and lower furnace, pressure set point of fans, quench time and cooling time set point. These screens are frequently used for normal operation. Maintenance screen is used by maintenance people to test every part of the system. System parameter screen is used by the manufacturer, in order to test the machine.

. Technical parameters

2.1 Flat Glass:
Glass thickness range: 4-19 mm
 
Glass size:

Max glass size: 2440mm (width) ×3660mm (5-19mm)
2440mm (width) ×1500mm (4mm half quench)
Min glass size:  100×300mm

Standard                  : EN12150-1:2000
Finished product rate: 4mm not less than 95%;
Over 5mm not less than 97%.
Productivity cycle time: 16 Loads per hour for 5 mm (max.)

2.2 Technical Qualification

2.2.1 Installed power:

Heating: 580 kW
Drives: 16 kW
Quenching: 220 kw (with ONE Siemens MM430 inverter)
Convection blower: 3*4kw

Total installed power: 828kW x 80%=662.4KW
The Buyer need prepare the transformer power is: 800 KVA.

2.2.2 Compressed air (One air tank should be supplied with 1M3 at least by the Buyer):
Volume: 0.5-0.8 m3 /min
Pressure: > 0.7 MPa

2.3 Suitable glass sorts:
1.Clear float glass
2.Coated glasses (Including most kinds of hard coated glass, parts of special soft coated glass, which withstands about temperature 700 ℃)
3.Patterned glass
4.Tinted glass
5.Low-E glass (E valve≥0.02)
2.4 Supply Scope
1. Loading table (With lifting table and side roller.)
2.Heating section (furnace)
3. Flat quenching section
4. Unloading table (With lifting table and side roller.)
5. Associated electrical and control equipment
6. Blower System (mounted on steel frame with big motor and vibration pad)
7. Modem with long distance diagnosis system
8. Inverter (Siemens Germany)
9. Blower brackets
10. Driving motors and Blower motors (Made in China)

11. forced convection system

2.5 Controlling System
1) The whole control procedure, software of industrial computer and PLC are whole one special module is developed by one industrial control company
2) PLC is OMRON product.
3) Industrial computer is one product from Taiwan.
4) Inverters are Siemens products only.
5) Optical, Sensor Beam Switch is of OMRON product.
6) Monitor is from PHILIPS.
2.6 Terms Relating Commissioning and Installation

Responsibilities of Both Parties

2.6.1 The Seller
1) Manufacture and deliver of equipment according to the contract.
2) Packaging, loading, delivery to the shipping port and sea transportation according to the contract and the acceptance of the buyer, the products will be packed after the buyer’s inspection and confirmation.
3) Provide 60 person-day (3-4 technicians x 25-30 days) for free installation guidance, commissioning and training. If it is over 80 person-day and it is for the Buyer’ reason, the Buyer has to pay USD 100.00 per person-to the Seller’s technician; if it is for Seller’s reason, the technicians will stay until installation, commissioning, and training are completed.
4) Provide the design of the plant layout of equipment and consultations needed by the Buyer. (All the designs and layouts for the plant and equipment will be sent to buyer immediately after the down payment has been done by the buyer).
5) Provide full sets of operation manuals in English, including electric diagram, guidance of operation and maintenance, and setting the main process parameters.
6) The Guarantee period is twelve months from the date on which a successful acceptance test or fourteen months calculated from the delivery time, which is shorter provided the furnace is used and maintained properly without any man-made damages and/or wrong operation.
Provide guarantee for the equipment except the following consumables:
1. Solid relay

2. Fuse

3. Kevlar rope
4. Fiber Glass Rope

5. Timing belt for furnace driving

6. Castor ball
After the guarantee, the buyer shall pay for the cost of engineers’ traveling between China and buyer’s country, labor costs and accommodations in Buyer’s country. At the same time, Gangxin glass shall provide spare parts to the buyer without profit.
7) Long term technical support and spare parts supply as well as guiding the buyer to settle of the eventual new problem happened in the production.
8) Give Technical Training to the Buyer’ personnel:
All the machine installation time, after that, there will be additional 7 days training in Buyer’s factory.

2.6.2 The Buyer
1) Payment in time to the bank pointed by the Seller according to the contract.
2) Supply of electrical power and compressed air to the positions set by the Seller. Confirm, in a written form, electric power supply data in the buyer’s plant site: e.g. electric voltage, electric frequency and etc; Confirm, in a written form, altitude above the sea level and atmospheric temperature as per Annex 2 of the contract within three days after the contract is signed.

3) Provide Air tickets, board and lodging, catering, local transportation, communication, medical care, health and accident insurance for the Seller’s technicians while they are working in the Buyer’s site for the installation guidance and commissioning.

4) Supply the relevant materials and manpower needed for the installation and the acceptance test of the machinery.

5) When the furnace arrives in the Buyer’s site, the Buyer should guarantee that all the conditions are fulfilled and supplies are available so that the installation and commissioning will be possible to carry out within 2 months. This need send to the seller’s company by photo and in a written form. If causing a delay from this time limit, the Buyer has to pay USD100.00 per working day with each person for exceeding day or days.

6) The Buyer should supply free materials, glass substrates, testing and measuring apparatus and instruments for tempered glass, two forklift trucks of 5 Ton and one mobile crane or bridge crane of 16Ton, and manpower (at least four skilled technical assistants free of charge) needed for the installation and acceptance test of the equipment. Workers to be working on this tempering unit are supposed to have mechanical and electrical engineering background so that effect of the training shall be ensured

7)During the period of installation and test,  the Buyer should be responsible for the translator to the Seller’s technicians in Buyer’s factory.

Configurations
1. Main parts of tempering furnace (refer to Appendix1)
2. Environmental Data
The environmental data is very important for designing. The Buyer is requested to fill in the data sheet, after signing the contract (refer to Appendix 2)
3. Acceptance Test (refer to Appendix 3)

Annex 1

Specification of Main Parts

Main mechanical elements for Tempering Furnace

Note: The products in this form without specification are high-quality product in domestic market. Manufacturer reserves the right to amend the products according to the requirement of technology, the quality of displacement should not be less than the original one, and the imported one can not be replaced by a domestic one.
Annex2
A. Power Supply System
1) Wire System: wires
2) Number of Phases: ____
3) Neutral: Yes/No
4) Protective Earth: Yes/No
5) Line Voltage Supply: VAC
6) Phase to Neutral: VAC
7) Voltage Variations: +/- %
8) Voltage frequency: Hz.
B. Environmental Condition
1) Humidity: %
2) Air Density: KG/M3
3) Average Temperature:
Summer: ℃
Winter: ℃
4) Atmospheric
Pressure: Pa.
5) Altitude Above the Sea Level: Meters
C. Color of Electric Cables
1) Color of A phase
2) Color of B phase
3) Color of C phase
4) Color of Neutral
5) Color of Protective Ground
D. Certificate (of electrical safety) requested by the Buyer:
Charges of the certification are not included in the total quoted price.
Attention: These data must be given by the buyer and are strictly binding! A deviation of these data relieves the seller of his obligations concerning performance and guarantee!

Payment terms:
1.LC at sight;
2.TT(30% in advance,the balance before delivery)

Trade terms:
EXW or FOB or others by request.

Package:
Wooden box

Delivery:
Regular standard items delivery will be 10 days after deposit;
Customized items delivery will be depended on negotiation.

After-service:
7*24 hotline:+8615866605088;
Video solutions;
Technicians provided.

Guarantee:
12 months guarantee after items recieved,damaged parts changed for free within one year;
Service provided for whole servcie life,just pay the parts cost;