Automatic Net Reinforcement Line Design
● Safe and reliable: slab with net reinforcement will not fall down when damage.
● High capacity: according to the different slab dimensions, the daily capacity can reach 4,600m², which can fully meet high capacity of sintered slab.
● Enhance crack resistance of slab: slab with net reinforcement can effectively improve the crack resistance.
● Good chemical characteristics: the saturated resin can be directly bonded to the connecting material without reaction.
The process for producing resin must be fine-tuned according to some key parameters, such as material being processed (e.g. specific type of marble, granite, etc.), slab conditions (e.g. cracks and hole size, humidity) and desired finish (e.g. enhancement or preservation of natural color). In general, the basic properties for the initial selection of the Epoxy System (A+B) are“Gel Time”and “Viscosity”. Then, the specific product must be chosen in order to optimize resin penetration in the cracks, mechanically strengthen the slab to the greatest possible level, and achieve the desired surface finishing and gloss. Particularly in the case of white and light colored materials, it is highly recommended to select products specifically designed to minimize UV-induced yellowing.
Epoxy consumption is greatly affected by material density and, in general, it can range from 50-100 g/m2 (in the case of some very compact granites) to 300-350 g/m2 (typical of many low density marbles and other materials). The specific resin amount also depends on many other variables, including the quality of the block, slab surface finishing, resin application technique, and the kind of resin itself.
(by Dr . Matteo Pietrini)
The production line can continuously put the back net according to the output, and the tray for the slab in the hardening oven can be circulated automatically. In the way of hardening, the characteristics of the glue can be fully improved: the adhesion between the back net and the slab can be fully improved, and the stress . can be eliminated. The thickness of the glue can be set according to the strength requirements.
This is the“entry level" configuration.
Back-netting is performed off line, that is, before sending the slab to the resin line. The same oven is used for both drying (20 layers) and hardening (25 layers). Loading and unloading modules are efficient and cost-effective at the same time. Productivity ranges from 15 to 20 slabs per hour depending on slab conditions. It can be achieved in batches with online or offline back-necking.
Back-netting is also done ofline in this configuration. A robot is used for loading. Unloading is made by using unloading machine. The first oven (30layers) is dedicated to drying, the second one (45 layers), to hardening. The material flow is very simple and productivity can range from 25-45 slabs per hour depending on slab conditions. It can be achieved in batches with online or offline back-necking.
In this configuration, back-netting is performed in line. Two different robot are is used for loading and unloading.
After loading， the slab is sent to drying， then to back-netting and hardening. Upon exiting the hardening oven, the slab is rotated upside down and then sent to resin filling， vacuum, retouching, hardening and unloading. Productivity is up to 30-45 slabs/hour (Bookmatch or Slab edge aligning: 25- 30 slabs/hour), the material flow is very simple and the layout optimized to reduce space occupancy.
Rotary Stacker
Rotary stackers are obtained assembling 2 one-side stackers together and placing them on a rotating platform. The advantage of the rotary stacker is the possibility to load/unload on one side, while the other side is serving the resin line. This clearly reduces time.
Loading with Suckers
The machine can be used for resin line and polishing line, which can replace the robot to meet the simple loading demand.
The machine has ultrasonic positioning function, which can load slabs automatically or semi- automatically.
Heavy Load Robot Machine plus Turn-Over table
It is a fixed “comb”type structure utilized, in combination with the robot, to rotate the slab 180°. After having taken the slab from the stacker, the robot places it on the turn-over table, then moves to the bottom side, takes the slab again and positions it on the conveyor or on the roller table.
The heavy load robot machine can take cracked slabs and automatically adapt to taking slabs on the rough block trucks.
Turn-Over Machine
After back-netting, the slab must be rotated. From the main line the slab is sent to the turn-over station, a "sandwich-type structure"。where it is clamped, rotated and then sent back to the main line.
Net Laying Machine
The back net is accurately laid on the slab according to the length. The net can be sent accurately, smoothly and quickly, with automatic cutting off device. Two net rolls, one for use and one for standby, to ensure the continuity of the net laying.
Vacuum Chamber
Resin penetration is enhanced by means of vacuum. This cycle lasts from 5" to 15" at 2-0.08 MPa.
The chamber is robust and the vacuum circuit, efficient and reliable.
Hardening Oven
This equipment is applicable to the "Two-oven resin line" or the "Three-oven resin line".
Place stone slabs in the hardening oven, where the temperature and airflow inside facilitate hardening. The hardenin g temperature ranges from 45*C to 50°C allowing the glue to fully penetrate the cracks in the slabs, this enables full glue penetration into slab cracks. This enhances the slabs' gloss and adhesion, improving material yield during cutting. The hardening time varies with the product type and temperature, typically lasting up to 90 minutes, after which the slabs are fully hardened and ready for removal.
Automatic Unloading
As an alternative to the robot, this module can be used to take the slab at the exit of the hardening oven and transfer it to the stacker. Oven dozens of projects, stainless steel rolls, sensors and hydraulic systems have proved to be efficient, reliable and cost effective.
The system consists of devices for mixing resin, applying resin, conveying, and cleaning. First, the mixing ratio of A and B resins and the amount ofresin per square meter are preset. After the scanner reads the area of the slab, the resin mixer automatically calculates the required amount of resin. The pump mixes the precisely proportioned A and B resins, which are evenly applied to the back of the slab through the curtain applicator. This process eliminates manual labor and significantly reduces resin waste.
Domestic first, solving the problem of limited factory height, ensuring uniform curing temperature, and providing good stability
Compared to traditional hardening ovens, the height of the cyclic oven has been reduced. This optimized design effectively addresses the issue of limited factory height. Under the premise of the same production efficiency, the storage time of the slabs inside the cyclic oven is extended, thereby achieving a more ideal hardening effect
Drying and Hardening Oven
It can be installed in different sections of the line and can really be considered the "heart" of any resin line. It has 30/45 layers and, depending on the resin line configuration, it can perform both drying (20 layers) and hardening (25 layers) tasks, or only drying (30/45 layers).The concept design is simple and efficient: a lift takes the slab from the conveyor, places it on the assigned layer and ,after catalysis, retrieves it in order to send it to the next phase. The . fully automatic operations are managed by the PLC.
Air Circulation System
It is designed to assure uniform temperatures on the slab surface. Sensors detect humidity and temperature, in order to properly control the air flow in the chamber. This is to guarantee proper conditions for the correct catalysis of the resin. Drying and hardening tasks are performed at 45°C to 60*C and can take from 60 to 90 min.
Cyclic Oven
Through heating and circulating movement, the hardening oven can make the slab from normal temperature to hardening temperature and then to normal temperature, so that the glue on the back net can be fully hardened. The stress can be eliminated by adjusting the temperature gradient. Each . hardening oven can store 80 slabs, and the heating source can be electricity or natural gas.
Working Principle
The machine can solve the factory height limitation problem, improve efficiency, increase oven time. .
Microwave Resin Line
The resin line based on microwave drying ovens and catalytic ovens represents the third-generation product, offering a superior alternative to traditional resin lines with more extensive functionality. The system includes two types of ovens:
● Microwave Drying Oven: The microwave drying oven generates high temperatures through internal molecular vibration, causing water molecules to vaporize and escape, including the removal of structurally bound water molecules. This achieves rapid drying and is therefore used for immediate drying and delhydration
● Microwave Catalytic Oven: The microwave catalytic oven uses the high-frequency electromagnetic field of microwaves to induce polarization of resin molecules, enhancing the intermolecular forces and thus promoting the hardening reaction. It also reduces the activation energy of the hardening reaction, accelerating the cross-linking reaction of thermosetting materials such as epoxy resins. This results in shorter hardening times and improved mechanical properties of the hardening slabs
Both types of ovens feature modular structures, which can be easily integrated into existing traditional resin application lines to achieve cost savings. They can also serve as key components of new production lines.
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Good dehydration effect
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Save the drying and curing time
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Climate - adaptive design
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Enhanced space utilization
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It is applicable to the glue - filling of luxury stones.
The acquisition system is to collect slab information at the factory end, store the slab photo, pattern, size, batch, material and other information collected in the cloud end for remote online call for inventory management, production planning organization, CAM programming.
Higher profitability
Veegoo intelligent slab storage system：
● Optimization of space, reduce storage area
● Reduction of breakages
● Reduction of shorter slab identification times
● Reduction of labor work to achieve higher profitability.
Expandability
The intelligent storage system is composed of multiple groups of movable storage racks, which can be extended later or increased sideways according to demand to meet production requirements.
More available space
● Veegoo intelligent slab storage system allows optimization of the occupied surface area by eliminating the space required for conventional slab handling.
● The length of slab storage rack is divided into 400mm and 100mm, meeting the needs of large-scale slabs and single slab storage.
Waste material management
The Veegoo Intelligent Slab Storage System can be integrated with Warehouse Management System (WMS) software, making the identification and retrieval of slabs from the warehouse intuitive and convenient. A photo database can be created to display slab dimensions and characteristics, track materials, and identify available remnants of specific slabs for storage and tracking
Cantilever Robot is a robot whose job is to load and unload slabs on virtually any stone processing line or machine (including resin lines, quartz plants, polishing lines, and CNC machines).
It can communicate in any language and receive orders through a user-friendly touch screen (Schneider Electric PLC). Its four axes (X, Y, B, C) are controlled by encoders and inverters in order to ensure precise, smooth and fast movements (cycle time for 8-meter long X rails is around 1 minute).
It can handle a wide range of materials (including marble, granite, and quartz slabs) even if they are cracked or contain holes. This is possible thanks to the use of safety, non-return valves, and sensors for reading minimum vacuum levels. In other words, the robot can handle situations in which up to five suction cups fail due to face cracks or holes in the slabs.
It is smart. By means of weighing cells, it can detect if there are two or more wet slabs stuck together in order to avoid slab dropping. Additionally, in the event of a power failure, it can implement a safety system to maintain effective vacuum levels. With the help of a turn-over table, it can also perform "book-matching" operations.
The cantilever design and various other manufacturing details make it a reliable and flexible assistant that can be installed in many different configurations so as to optimize operations and material flow. Compared to traditional human-handling by means of cranes, it has proved to be safer and more efficient, ergonomic and cost effective.
It payback period varies depending on the country where it operates, but considering its outstanding performance/price ratio, it is always a good investment.
Gantry structure, supported by several columns, which is more stable.
Two beams structure, which has more bearing capacity, mechanical synchronous transmission which enables beams movement fast and stable.
Used for the environment of lots of dust, which has long life time and is easy to maintenance.
All kinds of suckers combination which can be used for all slabs.
Use stable vacuum components with short air system which is quick to reaction, and. has power-off protection.
References
Since its establishment, in 2011, Veegoo has installed 100+ engineered stone plants and around 100 Resin Line. Besides China mainland, we have installed 73 complete lines and some machines in Europe, USA, Russia, Turkey, South Korea, India, Oman, Vietnam, Cambodia, Namibia, Lebanon and Taiwan.
