Reliable bonding in filter production can maintain product integrity and performance. Still, filter viscosity problems are often encountered in regular production, which is caused by various issues in the glue injection process. To better solve this problem, Dahe Intelligent provides a comprehensive glue injection production line solution for filter production, with four main glue injection functions: continuous glue injection, staggered glue injection, breakpoint glue injection, and point glue injection. Each function is carefully calibrated to solve specific bonding challenges, ensuring that each filter meets the highest quality standards. Manufacturers can eliminate human errors and variations by automating the glue injection process to achieve consistent, high-quality bonding.
Glue injection production line: four key glue injection functions
The key factor distinguishing Dahe Intelligent’s glue injection production line is its ability to perform four different glue injection functions: continuous glue injection, staggered glue injection, breakpoint glue injection, and point glue injection. Together, they form a holistic approach to bonding challenges, ensuring each product receives the precise amount of glue required for optimal performance.
Continuous glue injection suits applications requiring a steady and even glue flow along the filter’s surface. This feature is ideal for long, continuous glue lines and ensures a strong bond under operating pressure. Offset glue injection is ideal for situations where the application requires a slightly offset glue pattern. It can automatically correct the glue path ±1.5mm to accommodate material offsets during high-speed production. This method is beneficial for solving areas where the glue line may break or be misaligned.
Breakpoint glue injection allows the production line to intelligently manage glue application at specific breakpoints, quickly interrupting or weakening the glue line due to material movement or other factors. It can restore glue flow within 0.3 seconds after interruption to prevent incomplete bonding. The system can enhance adhesion and avoid product failure by injecting additional glue at these critical points. Finally, point glue injection applies glue at discrete points, ensuring additional reinforcement in high-stress areas.
Eliminate glue line breaks with unpowered roller innovation.
Traditional conveyor rollers often cause adhesive separation due to inconsistent tension or misalignment. Dahe’s intelligent glue injection production lines use an unpowered roller with a hinged connection to the wave material output to solve the problems of glue line breakage and viscosity. The hinge joint provides 15° lateral flexibility to absorb material warping, and the servo-connected actuator synchronizes the waveform, ensuring the roller mirrors the movement of the glue nozzle. It also has an infrared sensor to adjust the glue temperature (±0.5°C) to maintain optimal flow. The hinge mechanism allows the roller to dynamically adapt to changes in material output and ensure uniform glue application. This design effectively solves the long-standing problems of glue line disconnection and irregular viscosity.
Intelligent viscosity control in glue injection production lines
Fluctuations in glue viscosity caused by temperature changes or batch changes can damage the integrity of the filter. Dahe’s glue injection production line determines this through a real-time viscometer, in which a laser sensor measures the viscosity every 0.5 seconds. In addition, the system’s closed-loop feedback mechanism ensures that the viscosity remains within ±2% of the target value, even in fast production cycles. This level of control is critical for high-precision applications such as medical filters, where even minor defects can have serious consequences.
Materials and design for optimal bonding
A key design feature of our production line includes an unpowered roller with a hinge that connects to the wavy material output. This innovative design is essential to maintaining a steady flow of glue, as it dynamically allows the drum to adapt to changes in the material production. In addition, we select adhesives for our systems based on their compatibility with various filter substrates, resistance to environmental factors, and ability to maintain a consistent viscosity during application. These adhesives are carefully designed to perform under multiple conditions, ensuring the glue line remains intact even when temperature and humidity fluctuate.
At the same time, the modular design principles in the glue injection line allow for rapid adjustments and upgrades, ensuring that the system can adapt to changing production needs. The user-friendly interface and comprehensive monitoring system enable operators to track real-time performance, making identifying and resolving problems before they escalate easier.
How does the glue injection line improve the operating costs of the workshop?
Although automated systems require an upfront investment, Dahe’s glue injection lines can quickly pay off. They can reduce glue overuse by 40-60% overall and decrease labor needs, allowing one operator to manage two lines instead of requiring three operators per line. At the same time, reducing scrap by 90% is possible. The system’s predictive maintenance capabilities can save costs by preventing unexpected downtime. For example, vibration sensors detect early signs of pump wear, allowing maintenance teams to schedule repairs during planned production pauses. This proactive approach minimizes disruptions and extends the life of critical components.
Make filter production run more smoothly
From its core functions and automation benefits to material selection, design considerations, and the operational advantages it brings. Every aspect of the fully automatic injection production line has been carefully designed to provide customized high-performance solutions to meet the complex needs of modern filter production. Dahe Intelligent has created a solution that improves product quality and production efficiency by combining state-of-the-art technology with a user-friendly interface and robust mechanical design.
