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More than 80% of reworked wood-based panels (panels) are caused by abnormal Edge banding ,quality control and inspection

More than 80% of reworked wood-based panels (panels) are caused by abnormal Edge banding

Edge banding is the process involving the most tools, parameters and materials in the intelligent workshop. According to statistics, in the production line of the intelligent workshop, more than 60% of the downtime is caused by the edge banding process, more than 80% of the reworked plates are caused by abnormal edge banding, and more than 25% of the complaints are related to edge banding. Therefore, edge banding is the most complicated process in the production of customized furniture.

Therefore, analyzing the current situation of the edge banding process and discussing its development trend can point out the development direction for enterprises that have established intelligent manufacturing workshops, reduce unnecessary downtime and rework in production, and reduce the customer complaint rate.

01 current edge banding technology and equipment

At present, hot melt adhesive edge sealing technology is the most commonly used technology in panel furniture enterprises. The following is an analysis of the equipment involved in hot melt adhesive edge sealing technology.

The edge banding machine is divided into manual edge banding machine, automatic edge banding machine and intelligent edge banding machine according to the degree of automation. The edge banding process is divided into single machine, two machine connection and four machine connection according to the number of edge banding machines.

The process of edge sealing can be regarded as five steps: transportation (feeding, feeding and unloading), pretreatment (pre milling, preheating and spraying of separating agent), gluing and edge sealing, trimming (trimming and chamfering) and inspection.

More than 80% of the reworked plates are caused by abnormal edge banding. How can we re understand the edge banding?

With the improvement of automation, the number of operations that can be completed by the equipment increases, which reduces the manual labor of workers, reduces the requirements for the operation proficiency of workers, and also improves the quality of plate edge sealing.

More than 80% of the reworked plates are caused by abnormal edge banding. How can we re understand the edge banding?

▲ function comparison of edge banding machine at different stages

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01-1 manual edge banding machine

The manual edge banding machine can complete the operation of glue melting and gluing. It relies on manual feeding, rotating and moving the plates, and manually controls the conveying and cutting of the edge banding belt. After the edge banding belt and the plates are firmly combined, the plates are trimmed and chamfered. Finally, the quality of the edge banding is observed visually to see whether it meets the requirements.

More than 80% of the reworked plates are caused by abnormal edge banding. How can we re understand the edge banding?

▲ manual edge banding machine

01-2 automatic edge banding machine

The automatic edge banding machine is operated by two operators in cooperation with the rotary table. The main hand needs to strictly feed along the abutment to ensure that the plates are regular rectangular after the edge banding is completed. The auxiliary hand discharges the plates at the outlet, places the plates on the rotary table, and transfers the plates to the upper outlet through the rotary table.

The operator also needs to add hot melt glue and supplement the edge banding belt in the glue pot, and complete the operations such as selecting hot melt glue, replacing the edge banding belt, adjusting the gear position, and selecting the edge banding machine function according to the processing requirements. In addition, it is also necessary to consider the turnover of plates between processes.

More than 80% of the reworked plates are caused by abnormal edge banding. How can we re understand the edge banding?

▲ automatic edge banding machine

01-3 intelligent edge banding machine

The intelligent edge banding machine has an independent controller, which can upload data, automatically identify the code of the plate through the code scanner, read the processing information of the plate, and realize the operation of square, automatic switching of hot melt adhesive, switching of edge banding belt, chamfering, slotting, etc. according to the requirements.

The system includes feeding system, gauge system, gluing system, side belt system, processing system and inspection system. It can be directly connected with the manufacturing execution system for data transmission, and form a full-automatic production line with other intelligent equipment through rollers and belts.

More than 80% of the reworked plates are caused by abnormal edge banding. How can we re understand the edge banding?

▲ intelligent edge banding machine

02 application of edge banding machine in customized household enterprises

A complete cabinet is composed of several different plates (see the table below), mainly including: door plate, side plate, partition, shelf, back plate and other rectangular plates with a thickness of 18 mm, which are collectively referred to as cabinet body plates;

The drawer surface, drawer side, back plate, storage compartment and other plates with a thickness of 10 mm and 12 mm and a small size are collectively referred to as small plates; Non rectangular tabletop plate with thickness exceeding 18mm and super high door plate with height exceeding 2400mm are collectively referred to as special-shaped plate;

More than 80% of the reworked plates are caused by abnormal edge banding. How can we re understand the edge banding?

More than 80% of the reworked plates are caused by abnormal edge banding. How can we re understand the edge banding?

▲ panel composition of customized wardrobe

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02-1 application of manual and automatic edge banding machine

The manual edge banding machine has a low degree of automation, the edge banding quality depends on the operator’s proficiency, and the production efficiency is low. Therefore, the manual edge banding machine is not used for large-scale production in enterprises.

However, the manual edge banding machine has high flexibility, relative safety and low cost, so it is often used to complete the edge banding of curves and small-sized plates, making up for the defects that the automatic edge banding machine and the intelligent edge banding machine cannot complete.

More than 80% of the reworked plates are caused by abnormal edge banding. How can we re understand the edge banding?

The automatic edge banding machine has perfect functions and can perform edge banding of multiple plates at the same time. Its production efficiency and product quality are much higher than that of the manual edge banding machine.

Different from mass production, customized household enterprises produce different panel sizes and colors, and the processing requirements for edge banding are also different. Therefore, during the production process, it is necessary to frequently replace the edge banding belt and hot melt adhesive, switch the processing unit, and interrupt the production rhythm, which will affect the production efficiency.

More than 80% of the reworked plates are caused by abnormal edge banding. How can we re understand the edge banding?

02-2 application of intelligent edge banding machine

Intelligent edge banding machine is the edge banding machine with the most perfect functions, the best equipment stability, the highest production efficiency and the least labor demand among the three types of edge banding machines. It is generally used in production in the form of two machine connection or four machine connection.

(1) Two machine connection

The connection of two machines is to connect two edge banding machines (left mobile phone and right mobile phone) in opposite directions through the roller conveyor. Thanks to the code scanner and the square system, the operator only needs to lay the plate in the specified direction when feeding, and the edge banding operation on opposite sides can be completed at one time.

More than 80% of the reworked plates are caused by abnormal edge banding. How can we re understand the edge banding?

(2) Four machine connection

The edge banding process of the four machine connection can meet the production requirements of the intelligent workshop. It is used in the full-automatic production line with high production rate, stable beat and good product quality. However, the full-automatic production line has its limitations, mainly including the following two points:

① There are strict requirements for plate size:

In the whole production process of material opening, edge sealing, drilling, sorting and packaging, the plates are transported by rollers and conveyor belts, which are collectively referred to as the line system, which can reduce the demand for manpower. At the same time, the transportation of plates in the workshop is very orderly, which is conducive to the analysis and management of site conditions.

② Affected by the previous and subsequent processes,

At the same time, it has an impact on the previous and subsequent processes.

In the fully automatic production line, all processes are connected in series. If the equipment of one process fails, the whole production line may be shut down, especially the edge banding process. This is because the four edge banding machines in the edge banding process are connected in series. When one of the edge banding machines is shut down, the whole edge banding process will stop working, which will affect the operation of the whole production line.

The three kinds of edge banding machines have their own advantages. The intelligent edge banding machine has high production efficiency and high product quality, but the processing plate is relatively single and has great limitations; The efficiency and quality of the automatic edge banding machine are second, but it is relatively flexible and can complete the straight-line edge banding of special-shaped parts; The manual edge banding machine has the lowest efficiency and quality, and is also the most flexible. It can complete curve edge banding and produce small-sized plates with operational risks with automatic edge banding machine.

03 future development trend of edge banding process

The development of edge banding machine can be seen as a process in which manual work is constantly replaced by equipment, improving production efficiency, improving edge banding quality and improving machine stability. At present, the edge banding process in the custom home industry has the following development trends:

(1) Increase the proportion of intelligent edge banding machine

The intelligent edge banding machine has good product quality, high production efficiency and low requirements for the operator’s technical proficiency. Therefore, at present, customized household enterprises are using the intelligent edge banding machine to produce as many plates as possible. The automatic edge banding machine and the manual edge banding machine are used to assist the production of the intelligent edge banding machine and maximize the production capacity.

However, the current full-automatic production line has great limitations, so the structure of the production line needs to be considered and improved to reduce the inevitable correlation between the previous and subsequent processes.

More than 80% of the reworked plates are caused by abnormal edge banding. How can we re understand the edge banding?

(2) Strengthen the control of materials

There are many kinds and quantities of materials involved in the edge banding process, including edge banding belt, hot melt adhesive, Tianna water, polishing wheel and various tools. Therefore, it is necessary to carry out more systematic control over the materials on site and in the warehouse, so as to reduce the confusion on site and reduce the time and energy spent by operators on the replenishment and replacement of materials.

(3) Improve the control of quality inspection information

At present, the main quality control means is to inspect the products after the edge sealing is completed. Once the quality problem occurs, it is necessary to stop the machine unplanned and trace the produced products, which has a great impact on the production efficiency.

The occurrence of problems is often traceable. It is possible to control the quality inspection information, find the rules, apply statistical process control and other technologies, gradually change the post inspection to pre prevention, so as to prevent problems before they occur, and improve the quality and efficiency of production.

More than 80% of the reworked plates are caused by abnormal edge banding. How can we re understand the edge banding?

(4) Improve equipment stability

In the fully automatic production line, equipment failure will bring sudden shutdown, which not only affects the production progress, but also accompanies the production of bad plates. Therefore, reducing the loss of production efficiency and improving the stability of equipment have become an important issue for enterprises. At present, some enterprises are introducing TPM into production and management to improve the stability of equipment through the training of talents and the improvement of the quality of all employees.

More than 80% of the reworked plates are caused by abnormal edge banding. How can we re understand the edge banding?

04 at the end

The production efficiency and quality of the edge banding process have a direct impact on the production of panel furniture. Only by ensuring the orderly and normal edge banding and promoting the steady development of the edge banding process can the production efficiency of panel furniture be steadily improved. By analyzing the common edge banding machines and edge banding production forms at present, the future development of edge banding process is expected to help enterprises make more reasonable production planning and layout.

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