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9
Foreword
The steel belt is one of the most versatile tools available to industry and is found
in applications as diverse as baking, chemical processing, materials handling,
wood based panel production and, in recent years, paper manufacturing too.
As far as the wood based panels industry is concerned, the steel belt is the
fundamental machinery element in all continuous presses, be they rotation or
double belt presses. In short, steel belts are essential to the ongoing success of
this technology.
The publication of this handbook has only been possible through the much
appreciated co-operation of companies such as Siempelkamp, Dieffenbacher,
Hymmen, Pagnoni, Held and ,previously, Ksters and Metso Panelboard (Bison),
who have contributed pictures, illustrations and valuable comments.
As a neutral supplier to all these companies, and others, our position is clear.
Whoever we are supplying, we do so with one sole objective to deliver the
best quality steel belt, together with all associated services, and to be a
competent and reliable partner for OEMs and end-users wherever they are in
the world.
We hope you find this book both interesting and informative.
Copyright 2009
by AB Sandvik Process Systems, Sandviken/Sweden
All rights reserved.
Printed in Germany - PS-SB-440 ENG 2.09
I nde x
1.
Historical review
1.1 Pioneering the way to particleboard
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2.
3.
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9.
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10.
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main press
wear plate
idlers
graphite pad
2,500 mm
drive
forming machine
brush
steel belt
support rollers
1,400 mm
tracking tensioning
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Cooling and belt return drum
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Infeed and first pressing drum
3 Press belt return drum, heated,
line pressure 3,500 N/cm
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Press belt drive drum
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Press belt tensioning drums
6 Main press drum, heated, available
in 3, 4 or 5 m diameter
7 + 8 Pressing and calibrating drums
Pressing station
Spreading station
Pressing station
High-frequency
preheater
Spreading station
Cutting station
Bison-Mende system using high-frequency preheating for increased capacity. Forming belt and steel press belt are separate.
Directly before the press infeed, a discharge device can be opened above a pit for faulty batches.
Rawboard density
800 kg/m3 5%
Bending strength
35-50 kg/mm2
750 kg/m3
90 kg/m3
Electricity
300 kWH/m3
2 GJ/m3
0.4 GJ/m3
500 kg/m3
With the Bison-Mende system, the pressed panel continuous ribbon returns above the plant and is sanded inline
(not shown in the picture) and cross-cut. The crosscut saw is designed so that it can operate with short cutting cycles.
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Sandvik
Sandvik Process Systems was the first company to
design and manufacture a continuous Double-Belt
Press System and its design principle is still used for
continuous belt presses today: Multiple rolling bars
guide the steel belt on one side and establish the heat
transfer to the product via the heat plate on the
other side.The process is continuous and the product
is moved by the upper and lower belt. A similar
design is employed in double-belt cooler systems.
The idea of using "rolling bars in a row" for heating
and cooling was progressive and established a long time
before it was used for wood based panel production.
The Sandvik Double-Belt Press can be used at
temperatures of up to 400C and can achieve
tolerances as fine as 0,05 mm. Such a system was
tested for pressing wood based panels and for
laminating finished chipboards.
However, as an outsider in the wood based panel
industry, Sandvik decided against further development
for this industry due to the cost and complexity of
the system. In the early 80s Sandvik backed out of the
business of designing presses for wood based panels
entirely, leaving the market mainly to Siempelkamp
and Dieffenbacher.
Today, all suppliers of press systems for the wood
based panel industry are customers of Sandvik, using
both their steel belts and their service.
Sandvik didn't leave the double-belt press market
entirely though, using its experience to concentrate
on the plastics, composite materials and laminate
industries.
To this day Sandvik remains a supplier of such
spec. pressure
e
pr
l
ss
en
gt
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The roller carpet is composed of a great number of rollers (12.5 mm diameter) connected by the links. The roller carpet elements used at the
outside of the roller carpet are 550 mm wide, allowing a width variation of the product of more than 2 feet.
As a result of the different roller lengths, the fabric shows a special pattern with the characteristic wave-like lines formed by the links; this
arrangement ensures good pressure distribution and leaves no line marks on the panel.
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The first ContiRoll was delivered to LouisianaPacific Corp., USA, for MDF and was hailed as a major
news event in the panel field. Its effective length was
16 m. Suddenly, continuous press technology had
become accepted for both particleboard and MDF.
The ContiRoll was constantly improved and
adapted to the new findings of continuous press
technology. One of the basic features, however,
remained unchanged: the frame construction,
which mirrored that used in cycle-pressing. Heavy
longitudinal girders take up the high counteracting
forces resulting from the high belt tension which is
necessary for continuous pressing; the foundations
thus have to support only the dead weight of the
press, eliminating the need for anchoring rods with
additional foundations to take up horizontal forces
(see page 21).
Both the upper and the lower press platens in
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Siempelkamps ContiRoll Press, 7 x 55,3 m for MDF, Location: Yildiz Kimya, Turkey
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View of ContiRoll infeed end. On the left, the belt infeed drums are directly followed by the return and entrance of the rod carpet. In
the high-pressure zone, the frames are arranged in pairs. On the right can be seen how closely the press cylinders are spaced to enable
precision adjustment of the flexibly supported upper press plate.
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H
igh specific performance based on high
availability
Operator-friendly controls
Transparency in modular setup, remarkable
robustness
Good access and simple maintenance facilities
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Hollow chain
Steel press belt
Connecting rod
The rolling rods of the CPS are connected coaxially with the links of the hollow chain by resilient rods
Infeed of the rolling rods by means of gear wheels and spring leafs at both ends.
Footner OSB production with belt width 4,080 mm, belt thickness 3.0 mm.
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Fibreboards
Cork or rubber flooring
Industrial laminates
Rubber boards
Heavy transport belts
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High-performance DBP for decorative laminate, two formats, 1.30 m and 1.50 m, 80 bars, 30 m/min (CLEAF, Italy)
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Continuous high-gloss laminate, two formats, 1.35 m and 1.55 m, 80 bars, 30 m/min (Westag & Getalit)
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Worlds largest isobaric DBP for decorative laminate. Press platens 5.20 m x 2.30 m, 80 bars, 48 m/min (SIT Gruppo Mauro Saviola, Italy)
Continuous press Pagnoni Easylam for engineered parquet, pressing hot platens 1000 x 4200 mm
The press
The Pagnoni Easylam press is modular in design and
its main elements are the drums, the hot platens, the
rollers, the bearings and the steel belts.
The press structure consists of 2 m long modules.
The upper part moves vertically in relation to
the lower one, while the lower section lays on
base beams which are fixed to the foundation.
The structure is open on one side to allow easy
replacement of the steel belt.
Two motorized drums and two idle ones, 1200
mm diameter, provide the drive and guiding/
tensioning of the steel belts.The in-feed drums
are heated with thermal oil, through axial rotary
joints, and the temperature in each drum can be
independently adjusted.
The sliding platens are placed between the upper/
lower structures and the relevant steel belt.They
are made up of modular elements, positioned side
by side. Each element consists of a canalized platen
(with heating circulation to ensure correct working
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Sandviks range of steel belt grades enables the company to offer the appropriate product for all requirements. Most
common in the WBP industry are grades 1300C, 1320C, 1500SM and 1650SM, for belts from 1.2-3.5 mm thickness,
with the width of the belts between 1,200-4 ,620 mm.
Sandvik 1300C
Sandvik 1320C
Si
Mn
Cr
0.65
0.25
0.65
0.20
Static strength
Standard strength at room temperature, nominal values
Position
Matrix
Transverse weld
(heat treated)
Yield
Tensile
Elongation
strength
strength
A5
MPa
ksi
MPa
ksi
(%)
1200
174
1280
186
11
880
128
990
144
] for more details please ask for our separate data sheet.
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Si
Mn
Al
Nb
0.15
0.50
1.80
0.04
0.03
Static strength
Standard strength at room temperature, nominal values
Position
Yield
Tensile
Elongation
strength
strength
A5
MPa
ksi
MPa
ksi
(%)
Matrix
1250
Transverse weld
(not heat treated) 890
181
1340
194
129
1000
145
] for more details please ask for our separate data sheet.
Si
Mn
Cr
Ni
Cu
Nb & Ta
0.07
1.0
1.0
15.0
3.5
0.3
Static strength
Standard strength at room temperature, nominal values
Position
Yield
Tensile
Elongation
strength
strength
A5
MPa
ksi
MPa
ksi
(%)
Matrix
1420
Transverse weld
(not heat treated) 1100
206
1500
217
160
1150
166
] for more details please ask for our separate data sheet.
Si
Mn
Cr
Ni
Cu
Ti
Mo
0.08
1.5
1.0
14.0
0.7
0.3
0.8
Static strength
Standard strength at room temperature, nominal values
Position
Yield
Tensile
Elongation
strength
strength
A5
MPa ksi
MPa
ksi
(%)
Matrix
1580
Transverse weld
(heat treated)
1250
Transverse weld
(not heat treated) 1100
229
1600
232
181
1300
189
159
1150
167
] for more details please ask for our separate data sheet.
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1
Decoiling station
Double-belt press
Cooling device
Decor paper coiling device
Dimensions
There are approximately 35 double-belt press
systems in use around the world for the production
of coated particle boards and laminates.The belts are
usually 1100-2300 mm wide with an overall length of
9-15 m.The typical thickness varies from 1,2-2 mm.
5.
6.
7.
8.
Grinding machine
Edge cutting station
Coiling system
Cutting station
Material
Due to the stringent requirements previously
mentioned, martensitic stainless steel belts are
generally used for this application.The thermal
conductivity of this material is comparable with
austenitic stainless steel but the thermal expansion is
significantly lower.
Therefore, this kind of steel is not as susceptible
to buckling/bumping under thermal loads caused by
the different temperature zones within the laminating
process.
Fig. 2 and Fig. 3: Double-belt press for the continuous production of decorative and technical laminates
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The 'cross-wise' weld seam is easier to produce the risk of bumping or edge failures is low (Fig. 5). On
the other hand, the shorter weld seam has to
withstand the complete stress of the belt in longitudinal
direction. If there are variations within the welding
process, the weld seam might be visible on the final
belt and product.This risk is avoided by means of
grinding and heat treatment of the weld seam.
The 'spiral' weld seam distributes the longitudinal
belt stress over a much longer weld length, which
gives a better load condition for the weld seam. On
the other hand, the weld seam is much longer and
more difficult to produce.
However, the pros and cons of one method
over the other are mostly theoretical.To date, no
statistically-significant advantage has been proven
for either method in terms of the final life time of
endless press belts. One reason might be statistical
failures such as belt damage caused by accidents in
the production environment. In other words, belts
are generally destroyed in other ways before the belt
weld has any impact on life expectancy.
After the welding process, the belt is ground
coil
cutting
edge preparing
pad grinding
printing
etching
edge cutting
gloss adjustment
packaging
Fig. 4: The typical and most important steps for the production of an endless press belt
welding
Fig. 5: Geometrical failures during the welding process of endless press belts - examples: A) bumping, B) edge failure
Belt maintenance:
- regular cleaning of the belt (Fig. 7)
- regular checks of the surface for damage and
effecting repair, if possible
- regular checks of the belt edges and belt-edge
maintenance
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Fig. 8: Endless press belt on belt carrier unit with "handscraped" texture
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The worlds widest grinding line capable of grinding belts up to 4620 mm wide installed in Sandviken/Sweden
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Service in Brazil
Sandvik QuickDiscTM
The QuickDisc is probably the most widely used
repair tool in the range, and combines proven metalcutting technology from Sandvik Coromant with
the specific belt repair expertise gained by Sandvik
Process Systems in the WBP field.
The tool is clamped to the belt surface by means
of suction pads and a rotating tipped cutter cuts out
a circular area of belt containing the damage. An
identically-sized disc, cut from belt off-cut, is welded
in place and the join ground until virtually invisible.
The cutting system has no limitations in terms of steel
grade or belt thickness. Precision discs from 70-300
mm diameter can easily be cut out and inserted with
help of the QuickClamping tool.
Sandvik's QuickDisc
Sandvik QuickClamper
When inserting a circular blank into a damaged
steel belt, thick copper or aluminum plates are used
to achieve proper cooling to the weld area.These
plates are kept at place with a device equipped with
pneumatic system for pressure and holding.The body
of the QuickDisc is used on the bottom side of the
belt and the QuickClamper is used on the upper
side to provide maximum space for welding and
inspection of the repair.
Steel belt repair kit
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Sandvik QuickGrinder
An air driven belt grinding unit, customized for safe
and efficient removal of material remaining from
repair or installation welding. A 50 mm wide grinding
belt is used to smooth out variations in thickness over
a wide area; a safety guiding system is also provided
to avoid grinding mistakes by digging or slipping.
Sandvik QuickCutter
The use of ever-thicker belts has created a real challenge
in terms of in-house cutting. Sandviks QuickCutter is an
easy-to-use hand machine equipped with a cemented
carbide cutting disc and guided by an accurate linear
unit to achieve a straight direct weldable cut.
Sandvik QuickCutter
Sandvik QuickGrinder, designed for the efficient removal of excess
material or deformations resulting from the welding process, either
in new belt installations or following repair work such as disc inserts.
Sandvik QuickBlaster
The Sandvik QuickBlaster is an innovative remedial
solution for deformed belts. It offers a quick, cost
effective method of flattening out deformed steel
belts without interrupting production. Sandvik
developed the shot peening method of repairing
heavily deformed and troughed belts in the 1980s.
Using the same principle, todays QuickBlaster tool
is used by hundreds of press owners to repair belt
deformation without having to turn the belt.
Sandvik QuickExpert
The reduction of costly downtime has been
the driving force behind the development of
the QuickExpert programme, with efficient and
frequent inspections prolonging belt life and allowing
scheduling of planned repair and maintenance.This
initiative has also seen the development of an on-line
tool enabling users to calculate the actual cost savings
that could be achieved in their own businesses by
reducing downtime.
Belt inspection
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Belt edges
Belt surface (clean inside at regular intervals and
inspect as most fatigue cracks start from inside; oil
on the board product indicates a crack as oil seeps
through)
Belt shape
Belt tracking
Brake parts, dirt and lubrication
4. Running-in of belts
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5. Safety devices
7. General
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Sandvik Group
The Sandvik Group is a high technology engineering group,
with advanced products and world-leading positions in
selected areas. Operations comprise the Tooling, Mining and
Construction, and the Materials Technology business areas.
The group has 50,000 employees and representations in 130
countries.
Sandvik Materials Technology
Sandvik Materials Technology is a business area within the Sandvik
Group and a world-leading manufacturer of high value-added
products in advanced stainless materials, special alloys, metallic and
ceramic resistance materials, as well as process plants. The product
areas comprises Tube, Strip, Wire, Kanthal, Process Systems and
Med Tech.
Sandvik Process Systems itself made up of two product
centres, Belts (incl. Press Plates) and Industrial Processing.
Quality Assurance
Sandvik Materials Technology has a quality management system
approved by internationally recognised organisations. We hold
for example: ASME Quality System Certificate as a Materials
Organisation, approval to ISO 9001 and QS 9000, as well as
approvals from LRQA, JIS and other organisations as a materials
manufacturer.
Environment
Environmental awareness is an integral part of our business and
is at the forefront of all activities within our operation. We hold
approval to ISO 14001.
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Sandviks position in the WBP and laminate industry is virtually unique, with
the company operating in partnership with double-belt press manufacturers
and the panel producers themselves. As well as being one of its major
strengths, this also places the company in a position of responsibility.
The investment that has been put into R&D, the global network of service
teams, the ever-increasing range of belt grades and new repair techniques
that maximize the operational life of steel belts the combination of all of
these factors is a clear demonstration of Sandviks determination to live up to
its leadership responsibility and to continue supporting this industry far into
the third millennium.
www.smt.sandvik.com/sps