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The first critical step in molecular sieve processing is creating precise access points for filler injection—without compromising the structural integrity of the target component (e.g., hollow glass aluminum spacers, adsorption towers, or catalyst reactors). The all-in-one automatic filler’s punching module is engineered to address this challenge through advanced mechanical design and intelligent control systems.Unlike manual punching, which often results in irregular hole sizes, burr formation, or material deformation, the automated punching mechanism leverages servo-driven actuators and precision tooling to deliver consistent, repeatable results. For instance, in hollow glass production, the system targets aluminum spacers (6–24mm in width) with punch diameters calibrated to match molecular sieve particle sizes (0.5–0.8mm), ensuring unobstructed filler flow while minimizing post-processing debris. The punching process is synchronized with component positioning systems, which use optical sensors to align the punch with pre-programmed coordinates—eliminating human error and ensuring hole placement accuracy within ±0.1mm.Notably, the module’s adaptability is a key strength. It accommodates diverse component geometries, from straight aluminum strips to custom-bent frames (square, rectangular,弓形, or rounded-corner designs) and cylindrical adsorption towers, making it suitable for multiple industrial sectors . Advanced models also feature adjustable punch depth and force control, preventing material damage while maintaining structural integrity—a critical consideration for thin-walled components or high-pressure applications like gas separation reactors.

Butyl Coating Machine: Core Equipment for Precision Sealing in Modern Insulating Glass Manufacturing

Abstract

In the global push for energy-efficient buildings and high-performance architectural and automotive glass, insulating glass (IG) has become a cornerstone material, with its thermal insulation, soundproofing, and durability directly dependent on the quality of edge sealing. The butyl coating machine, as a critical piece of automated equipment in the IG production line, is specifically designed for the uniform, continuous application of hot-melt butyl rubber—an essential primary sealant for insulating glass spacers. This article explores the working principle, technical characteristics, core advantages, application scenarios, and development trends of butyl coating machines, demonstrating their indispensable role in ensuring the long-term reliability, production efficiency, and cost-effectiveness of modern insulating glass manufacturing.

1. Introduction

The global demand for energy-saving and environmentally friendly building materials has surged in recent years, driven by stringent carbon neutrality policies and the rapid development of green construction. Insulating glass, composed of two or more glass panes separated by a spacer frame and sealed with dual-layer sealants (primary butyl rubber and secondary polysulfide/silicone sealant), has emerged as the preferred choice for modern commercial and residential buildings, automotive windows, and aerospace components. The primary seal—hot-melt butyl rubber—acts as the first line of defense against moisture penetration, gas leakage, and spacer corrosion, directly determining the service life and performance stability of insulating glass.

Traditional manual or semi-automatic butyl coating methods suffer from inherent flaws such as uneven glue application, inconsistent thickness, low efficiency, and high material waste, which severely compromise the quality of insulating glass and increase production costs. In contrast, modern butyl coating machines integrate advanced PLC control systems, servo-driven precision mechanisms, and intelligent temperature control technology, enabling fully automated, high-precision, and continuous butyl rubber coating. As the "heart" of the insulating glass primary sealing process, butyl coating machines have become an irreplaceable core equipment for manufacturers seeking to upgrade production lines, improve product quality, and enhance market competitiveness.

2. Working Principle and Core Components of Butyl Coating Machine

2.1 Basic Working Principle

Butyl coating machines operate on the principle of hot-melt extrusion and precision coating. Solid or semi-solid hot-melt butyl rubber is first heated to a molten state (typically 110–150°C) in a temperature-controlled heating system, then pressurized and delivered to a precision coating nozzle via a screw or piston extrusion mechanism. The spacer frame (aluminum, warm-edge, or composite spacer) is fed through the machine’s transmission system at a constant speed, and the molten butyl rubber is extruded uniformly onto the two sides of the spacer frame in a continuous, bead-like form. The machine’s control system real-time adjusts extrusion pressure, coating speed, and glue bead thickness to ensure consistent coating quality across different spacer sizes and types. After coating, the spacer is cooled slightly to maintain the shape of the butyl rubber bead, ready for the subsequent glass bonding and secondary sealing processes.

2.2 Core Components and Functions

A high-performance butyl coating machine comprises several key modules, each contributing to its precision and reliability:

2.2.1 Heating and Melting System

This system consists of a heating barrel, temperature sensors, and a digital temperature controller. The heating barrel is equipped with multi-zone electric heating elements and thermal insulation layers to ensure uniform heating of butyl rubber, preventing local overheating (which causes glue degradation) or insufficient melting (which leads to poor fluidity). High-precision temperature sensors (±1°C accuracy) monitor the melting temperature in real time, with the controller automatically adjusting heating power to maintain a stable molten state—critical for consistent extrusion and coating quality.

2.2.2 Extrusion Mechanism

The extrusion mechanism is the core of the butyl coating machine, available in two main types: screw extrusion and piston extrusion.


Screw extrusion: Features a precision-ground screw with a variable pitch design, which pushes molten butyl rubber forward through rotation, ensuring stable and continuous extrusion. It is suitable for high-volume, continuous production lines and can handle a wide range of butyl rubber viscosities.
Piston extrusion: Uses a hydraulic or pneumatic piston to pressurize and extrude molten glue, offering higher extrusion pressure and more precise glue volume control. It is ideal for small-batch, customized production or coating narrow-width spacers, with minimal glue residue and waste.


Modern high-end models often adopt servo-driven screw extrusion, combining the advantages of continuous production and precision control, with extrusion pressure adjustable from 0.5 to 20 MPa to meet diverse coating requirements.

2.2.3 Precision Coating Nozzle

The coating nozzle is designed for uniform glue distribution and adaptability to different spacer specifications. Key features include:


Dual-side coating design: Simultaneously coats butyl rubber on both sides of the spacer frame, improving production efficiency by 50% compared to single-side coating.
Adjustable nozzle gap: The gap between the nozzle and spacer can be finely adjusted (0.1–3 mm) to control glue bead thickness (typically 0.5–2 mm) and width (2–10 mm), compatible with spacers of 6–27 mm width (the most common in insulating glass).
Anti-drip and anti-clogging design: Equipped with a pneumatic or electric glue cutoff valve to prevent glue dripping when the machine stops, and a self-cleaning function to remove residual butyl rubber and avoid nozzle clogging.
Curved surface adaptability: Some models feature a floating nozzle design, which can automatically adjust to the curvature of curved spacers (used in automotive or special-shaped insulating glass), ensuring uniform coating on non-linear surfaces.


2.2.4 Transmission and Positioning System

The transmission system uses a servo motor-driven roller chain or belt conveyor, with a speed range of 0–30 m/min (adjustable via the HMI). High-precision positioning sensors (photoelectric or proximity sensors) detect the position and length of the spacer, automatically starting and stopping the coating process to avoid glue waste on spacer ends. For multi-specification spacers, the system can store up to 50+ sets of parameter presets, enabling one-click switching between different production tasks and reducing setup time by over 80%.

2.2.5 PLC Control and Human-Machine Interface (HMI)

The core control system is based on a Siemens or Mitsubishi PLC, paired with a 7–10 inch touchscreen HMI for intuitive operation. Key functions include:


Real-time display of temperature, extrusion pressure, coating speed, and glue bead thickness.
One-key setting and storage of process parameters for different spacer types and glue formulas.
Fault self-diagnosis and alarm (e.g., over-temperature, low pressure, nozzle clogging), with troubleshooting prompts displayed on the HMI.
Remote monitoring and data export (via Ethernet or USB), supporting production data tracking and quality traceability—critical for compliance with international quality standards (e.g., CE, ASTM, GB/T 11944).


2.2.6 Safety and Auxiliary Systems

To ensure operational safety and equipment durability, butyl coating machines are equipped with:


Safety interlocks: Emergency stop buttons, safety doors, and protective covers that stop the machine immediately when opened, preventing operator contact with high-temperature components and moving parts.
Glue level detection: A sensor monitors the butyl rubber level in the melting barrel, triggering an alarm when the glue is low to avoid empty extrusion.
Cooling system: A forced air cooling or water cooling system cools the coated spacer slightly, maintaining the shape of the butyl rubber bead and preventing deformation during subsequent handling.


3. Technical Advantages of Modern Butyl Coating Machines

3.1 High Precision and Consistent Coating Quality

The most significant advantage of butyl coating machines is their ability to deliver uniform, bubble-free, and consistent butyl rubber coating—a critical requirement for insulating glass primary sealing. Unlike manual coating, which is prone to uneven thickness, gaps, or excess glue, the machine’s servo-driven extrusion and precision nozzle ensure that the glue bead has a consistent cross-section (width and thickness) along the entire length of the spacer (up to 6 m long). This eliminates moisture penetration paths and gas leakage points, significantly improving the insulating glass’s thermal insulation performance and service life (extending it from 5–10 years to 15–20 years or more). For high-value Low-E (low-emissivity) glass and multi-cavity insulating glass, the machine’s non-contact floating nozzle design avoids scratching the sensitive Low-E coating or damaging multi-layer spacers, ensuring product integrity.

3.2 High Production Efficiency and Cost Savings

Automated butyl coating machines drastically improve production efficiency compared to manual or semi-automatic methods. A standard high-speed model can coat spacers at a speed of up to 30 m/min, processing 800–1200 spacer frames per 8-hour shift—a 5–10 times increase in output compared to manual coating. The continuous extrusion design eliminates downtime for glue refilling (large-capacity melting barrels hold 5–20 kg of butyl rubber, reducing refilling frequency), and the one-click parameter switching reduces setup time for different spacer specifications from 30–60 minutes to 2–5 minutes.

In terms of cost savings, the machine’s precise glue volume control reduces butyl rubber waste by 30–50% compared to manual coating (excess glue is minimized, and no dripping or spillage occurs). Additionally, automation reduces labor costs: a single operator can manage 2–3 machines simultaneously, replacing 4–6 manual workers. Over the equipment’s 8–10 year service life, the savings in material and labor costs far outweigh the initial investment, delivering a rapid return on investment (ROI) for manufacturers.

3.3 Wide Compatibility and Versatility

Modern butyl coating machines are highly versatile, compatible with a wide range of spacer types and insulating glass products:


Spacer materials: Aluminum spacers (standard, bent, or welded), warm-edge spacers (stainless steel, composite, or foam), and special-shaped spacers (curved, angled, or multi-cavity).
Spacer specifications: Width 6–27 mm, thickness 0.3–1.2 mm, length up to 6 m, suitable for both small-sized residential glass and large-sized commercial curtain wall glass.
Butyl rubber types: Hot-melt butyl rubber of different viscosities (low, medium, high) and formulations (standard, anti-aging, or low-VOC), compatible with all major butyl rubber brands in the market.
Application scenarios: Flat insulating glass, curved insulating glass, triple-glazing, multi-cavity insulating glass, automotive glass, and solar photovoltaic glass.


Some advanced models also feature a dual-nozzle design for coating multi-cavity spacers (e.g., 3-cavity or 4-cavity spacers used in ultra-high-performance insulating glass), enabling simultaneous coating of multiple glue lines and further expanding their application scope.

3.4 Enhanced Safety and Environmental Compliance

Butyl coating machines prioritize operator safety and environmental protection, addressing the drawbacks of manual coating:


Safety: By automating the high-temperature (110–150°C) coating process, the machine eliminates operator contact with molten butyl rubber and high-temperature components, reducing the risk of burns and repetitive motion injuries. Safety interlocks and emergency stop functions provide additional protection, complying with international safety standards (e.g., OSHA, CE).
Environmental protection: The closed melting and extrusion system minimizes the emission of volatile organic compounds (VOCs) from butyl rubber, improving the workshop air quality. The precise glue control reduces waste, and the self-cleaning nozzle design minimizes residual glue disposal—aligning with global environmental regulations and green manufacturing trends. Many models are also compatible with low-VOC and eco-friendly butyl rubber formulations, further reducing the environmental footprint of production.


3.5 Stable Performance and Low Maintenance

High-quality butyl coating machines are built with durable materials (stainless steel for the melting barrel, hardened alloy for the screw and nozzle, and industrial-grade servo motors) to ensure long-term stable operation under continuous production conditions. The key components have a service life of 50,000+ hours, and the modular design simplifies maintenance: wearing parts (e.g., nozzles, seals) can be replaced quickly, and routine maintenance (e.g., cleaning, lubrication) is minimal. The PLC control system’s fault self-diagnosis function reduces downtime by identifying and resolving issues promptly, ensuring uninterrupted production—critical for large-scale insulating glass manufacturing plants.

4. Application Scenarios of Butyl Coating Machines

4.1 Architectural Insulating Glass Manufacturing

The largest application area of butyl coating machines is the architectural insulating glass industry, covering residential windows, commercial curtain walls, office buildings, shopping malls, and green buildings. In high-rise buildings and energy-saving residential complexes, insulating glass with high-quality butyl rubber primary sealing provides excellent thermal insulation (U-value as low as 1.0 W/(m²·K)) and soundproofing (up to 35–40 dB), reducing heating and cooling costs by 30–50% compared to single-pane glass. Butyl coating machines enable mass production of standard and customized architectural insulating glass, meeting the demand for large-sized glass (up to 3 m × 6 m) used in modern curtain walls and ensuring consistent quality across thousands of units.

4.2 Automotive Glass Production

In the automotive industry, butyl coating machines are used to produce insulating glass for windshields, side windows, sunroofs, and rear windows of passenger cars, commercial vehicles, and new energy vehicles (NEVs). Automotive insulating glass requires not only thermal insulation and soundproofing but also resistance to extreme temperatures (-40°C to 85°C), vibration, and UV radiation. The machine’s precision coating ensures that the butyl rubber seal adheres firmly to the glass and spacer, preventing moisture from entering the glass cavity and causing fogging—critical for driving safety. For curved automotive glass, models with floating nozzles and curved spacer adaptability deliver uniform coating on non-linear surfaces, meeting the strict quality standards of automotive OEMs (e.g., Volkswagen, Toyota, Tesla).

4.3 Solar Photovoltaic (PV) Glass and Special Glass

With the rapid development of the solar energy industry, butyl coating machines are increasingly used in the production of PV insulating glass (used in solar panels and BIPV—building-integrated photovoltaics). PV glass requires a highly durable seal to protect the solar cells from moisture and corrosion, and the machine’s high-precision butyl coating provides a long-lasting primary seal, extending the service life of PV modules to 25+ years. Additionally, butyl coating machines are used in the production of special glass for aerospace, marine, and industrial applications, such as insulated glass for aircraft cabins, ship windows, and industrial furnace observation windows—where sealing reliability under extreme conditions is paramount.

4.4 Small and Medium-Sized Enterprises (SMEs) and Customized Production

Butyl coating machines are not only suitable for large-scale mass production lines but also for SMEs and customized glass manufacturers. Semi-automatic or compact models (with a small footprint and low investment) are ideal for SMEs producing small batches of customized insulating glass (e.g., for villas, specialty buildings, or automotive aftermarket). These models retain the core precision and efficiency advantages of full-automatic machines but with a lower price point and simpler operation, making advanced butyl coating technology accessible to a broader range of manufacturers. Refurbished butyl coating machines (from reputable brands) are also a cost-effective option for SMEs, offering the same performance as new equipment at 50–70% of the cost.

5. Development Trends of Butyl Coating Machines

5.1 Intelligentization and Digitalization

The future of butyl coating machines lies in intelligentization and digital transformation, driven by Industry 4.0 and smart manufacturing. Advanced models will integrate artificial intelligence (AI) and machine learning algorithms to optimize process parameters in real time: for example, automatically adjusting extrusion pressure and temperature based on butyl rubber viscosity changes (caused by temperature or batch differences) to maintain consistent coating quality. IoT (Internet of Things) connectivity will enable remote monitoring, predictive maintenance, and production data analysis—manufacturers can track machine performance, output, and quality from a central control room, and the system will predict component failures (e.g., screw wear, nozzle clogging) and schedule maintenance in advance, reducing unplanned downtime. Digital twin technology will also be applied, allowing manufacturers to simulate coating processes and optimize production lines before physical implementation.

5.2 High-Speed and High-Precision Upgrades

To meet the growing demand for large-scale and high-quality insulating glass, butyl coating machines will continue to evolve toward higher speed and precision. Future models will feature servo-driven systems with faster response times, increasing coating speed to 40–50 m/min while maintaining glue bead precision (±0.05 mm thickness tolerance). The extrusion mechanism will be optimized for higher pressure and more uniform glue distribution, enabling coating of ultra-narrow spacers (3–5 mm width) and ultra-thick glue beads (3–5 mm) for special applications. Additionally, 3D vision sensors will be integrated to detect spacer position and curvature in real time, enabling fully adaptive coating on complex-shaped spacers without manual adjustment.

5.3 Green and Eco-Friendly Design

Sustainability will be a core focus in the development of butyl coating machines, aligning with global carbon neutrality goals. Future models will feature energy-efficient heating systems (e.g., infrared heating or electromagnetic heating) that reduce energy consumption by 20–30% compared to traditional electric heating. The closed-loop glue recycling system will collect and reuse residual butyl rubber, further reducing material waste to less than 5%. Compatibility with bio-based butyl rubber (made from renewable resources) and low-VOC, zero-halogen formulations will be enhanced, making the production process more environmentally friendly. Additionally, the machine’s design will prioritize recyclable materials and modular components, reducing the environmental impact of manufacturing and disposal.

5.4 Integration with Automated Production Lines

Butyl coating machines will be more deeply integrated into fully automated insulating glass production lines, connecting with upstream spacer bending/welding machines, glass washing machines, and downstream glass bonding/secondary sealing robots. The entire production process—from spacer processing to final insulating glass assembly—will be automated, with seamless data exchange between machines via a central control system. This integration will eliminate manual handling, reduce production cycle time by 40–60%, and ensure 100% quality consistency across the entire production line. For example, the spacer bending machine will transmit spacer specifications to the butyl coating machine, which automatically adjusts parameters and starts coating; after coating, the spacer is automatically transferred to the glass bonding station, with no human intervention required.

6. Conclusion

As the core equipment for primary sealing in modern insulating glass manufacturing, the butyl coating machine plays a pivotal role in ensuring product quality, improving production efficiency, and reducing costs. Its technical advantages—high precision, high efficiency, wide compatibility, safety, and environmental protection—address the limitations of traditional coating methods, making it an indispensable tool for manufacturers seeking to meet the demand for energy-efficient, high-performance insulating glass.

With the ongoing development of the global green building and automotive industries, the demand for high-quality insulating glass will continue to grow, driving the continuous innovation of butyl coating machines toward intelligentization, high-speed, green, and integrated production. For insulating glass manufacturers, investing in a high-performance butyl coating machine is not only a practical upgrade for production lines but also a strategic decision to enhance market competitiveness, comply with international quality and environmental standards, and seize opportunities in the rapidly growing energy-saving glass market.

In the future, as technology advances, butyl coating machines will further evolve into smart, connected, and eco-friendly equipment, empowering the insulating glass industry to achieve higher levels of automation, efficiency, and sustainability—contributing to the global transition to a low-carbon, green economy.

References


GB/T 11944-2012, Insulating Glass for Buildings.
ASTM E2190-19, Standard Specification for Insulating Glass Units.
CE Marking Standards for Machinery (2006/42/EC).
International Energy Agency (IEA), Energy Efficiency Trends in Buildings, 2024.
Journal of Glass Technology, Vol. 65, No. 3, 2023: Advances in Insulating Glass Sealing Technology.
Automotive Engineering International, Vol. 28, No. 5, 2024: Sealing Solutions for Automotive Insulating Glass.

Manual: Aluminium Bar Bending Machine

1. Foreword

This manual is compiled to specify the operation specifications, safety precautions, maintenance requirements and troubleshooting methods of the Aluminium Bar Bending Machine, aiming to guide operators to use the equipment correctly, ensure the bending accuracy of aluminium bars, extend the service life of the machine, and eliminate potential safety hazards in the operation process. The Aluminium Bar Bending Machine is a special equipment widely used in insulating glass production, door and window manufacturing, architectural decoration and other industries, which is used for bending and forming various specifications of aluminium spacer bars. All operators must read this manual carefully, receive professional training and pass the assessment before operating the equipment. Any operation in violation of this manual may lead to equipment damage, product quality defects or personal safety accidents. This manual applies to all conventional models of Aluminium Bar Bending Machines, and for special customized models, the supplementary instructions provided by the manufacturer shall be referred to additionally.

2. Scope of Application

This manual is applicable to the operation, daily maintenance, routine inspection and fault handling of vertical and horizontal Aluminium Bar Bending Machines for insulating glass spacer bars, including but not limited to single-head bending machines, double-head bending machines and CNC automatic Aluminium Bar Bending Machines. It covers the whole process from equipment startup preparation, aluminium bar loading, parameter setting, bending operation to shutdown and post-operation treatment. The aluminium bars applicable to this equipment include hollow glass aluminium spacer bars with specifications of 6A, 9A, 12A, 15A, 18A, 20A, etc., and the bending angle ranges from 90° to 180°, which can meet the bending forming requirements of rectangular, square and special-shaped aluminium frames for insulating glass.

3. Equipment Overview

3.1 Basic Structure

The Aluminium Bar Bending Machine is mainly composed of frame system, bending execution system, clamping and positioning system, control system, feeding and discharging system, and safety protection system.


Frame System: It is the main bearing structure of the equipment, made of high-strength steel plate welding or profile assembly, with high rigidity and stability, to ensure that the equipment does not deform during the bending process.
Bending Execution System: The core working part of the equipment, including bending die, bending shaft, driving motor (servo motor or hydraulic motor), transmission mechanism, etc., which completes the bending action of aluminium bars through the rotation of the die and the driving of the power system.
Clamping and Positioning System: Composed of pneumatic clamping cylinder, positioning baffle, pressure plate, etc., it is used to fix the aluminium bar firmly during bending, prevent displacement and deflection, and ensure the bending accuracy.
Control System: Including touch screen, operation button panel, PLC controller, servo driver, etc., which realizes the setting of bending parameters (angle, length, speed), automatic operation control and fault alarm display.
Feeding and Discharging System: Consisting of feeding roller table, discharging bracket, conveying roller, etc., it facilitates the loading of raw aluminium bars and the unloading of formed aluminium frames, improving operation efficiency.
Safety Protection System: Including emergency stop button, safety grating, protective cover, overload protection device, etc., to prevent personal injury and equipment damage caused by misoperation.


3.2 Working Principle

The Aluminium Bar Bending Machine takes electric or hydraulic as the driving power, and the PLC controller sends out control instructions according to the set parameters. The aluminium bar is fixed by the clamping mechanism, and the bending die is driven by the servo/hydraulic system to rotate at a set angle, so as to realize the plastic deformation of the aluminium bar at the specified position and complete the bending forming. The equipment adopts precision positioning and closed-loop control technology, which can automatically compensate for the springback of aluminium bars, ensure the consistency of bending angle and size, and meet the assembly requirements of insulating glass.

3.3 Technical Parameters

The main technical parameters of conventional Aluminium Bar Bending Machines are as follows (for reference only, subject to the actual nameplate of the equipment):


Applicable aluminium bar width: 6mm-20mm
Applicable aluminium bar height: 5mm-30mm
Bending angle range: 0°-180° (stepless adjustment)
Bending accuracy: ±0.5°
Maximum bending length: 6000mm
Driving mode: Servo motor drive / hydraulic drive
Working air pressure: 0.4-0.6MPa
Power supply: 380V 50Hz three-phase four-wire
Overall dimension: (length×width×height) 2500mm×800mm×1500mm (conventional model)
Weight: About 800kg-1200kg


4. Pre-operation Preparation

4.1 Personnel Preparation


Operators must be over 18 years old, in good health, and have received special equipment operation training, familiar with the structure, performance, operating procedures and safety precautions of the Aluminium Bar Bending Machine, and hold a post certificate before taking up their posts.
Operators must wear standard labor protection equipment, including anti-pinch gloves, anti-static work clothes, safety shoes, and protective goggles (when cutting or processing special aluminium bars). It is forbidden to wear loose clothes, scarves, jewelry, or have long hair unbound, so as to avoid being involved in the rotating parts of the equipment.
Non-operators are strictly prohibited from entering the equipment working area, and obvious warning signs such as "No Unauthorized Operation" and "Danger, Keep Away" shall be set up at the operation site.


4.2 Equipment Inspection


Appearance and Structure Inspection: Check the appearance of the equipment for deformation, damage or loose parts, check the welding part of the frame for cracks, and check the fastening bolts of each component (such as die, clamping cylinder, motor base) for looseness, and tighten them in time if any.
Power and Air Supply Inspection: Check whether the power cord, plug and socket of the equipment are intact, whether the wiring is firm, and whether the leakage protector is normal. For pneumatic clamping models, check the air compressor, air pipeline and air filter for air leakage, blockage or water accumulation, and adjust the air pressure to 0.4-0.6MPa. Drain the water in the air storage tank and filter regularly to prevent moisture from entering the pneumatic components.
Mechanical Transmission Inspection: Check the bending die, transmission gear, chain, belt and other transmission parts for wear, deformation or damage, check whether the lubrication is sufficient, and add lubricating oil or grease according to the regulations if necessary. Manually rotate the bending shaft to check whether it rotates smoothly without jamming or abnormal noise.
Control System Inspection: Turn on the power supply of the equipment, check whether the touch screen and operation panel are lighted normally, whether the display data is accurate, and test the functions of start, stop, emergency stop, parameter adjustment and other buttons to ensure that all control functions are sensitive and effective. Check the PLC controller and servo driver for fault alarms, and eliminate the alarms in time if any.
Die and Accessory Inspection: Select the bending die matching the specification of the aluminium bar, check the die for wear, cracks or burrs, and replace it in time if it is damaged. Check the positioning baffle, pressure plate and clamping block for wear or deformation, and adjust or replace them to ensure the positioning accuracy.


4.3 Material and Tool Preparation


Select qualified aluminium spacer bars that meet the production requirements, check the appearance of aluminium bars for scratches, deformation, oxidation or impurities, check the dimensional accuracy (width, height, thickness), and prohibit the use of unqualified aluminium bars that do not meet the bending requirements.
Prepare auxiliary tools, such as hexagon wrench, screwdriver, torque wrench, cleaning cloth, lubricating oil, measuring tools (angle ruler, tape measure, vernier caliper), etc., to ensure that the tools are complete and intact.
Prepare the product drawings or process documents, confirm the bending parameters of aluminium bars (bending angle, side length, quantity, etc.), and input the parameters into the control system in advance for trial bending verification.


5. Standard Operation Procedures

5.1 Equipment Startup


Turn on the main power switch of the equipment, and then turn on the power supply of the control system, PLC and touch screen in sequence. Wait for the system to start and self-check, and confirm that there is no fault alarm before proceeding to the next operation.
For hydraulic drive models, turn on the hydraulic pump motor, run it idly for 3-5 minutes, check the hydraulic system for oil leakage, abnormal noise or overheating, and confirm that the hydraulic pressure is within the normal range.
For pneumatic models, open the air supply valve, check the air pressure gauge to ensure that the air pressure is stable at 0.4-0.6MPa, and test the action of the clamping cylinder to ensure that the clamping and loosening actions are flexible and in place.


5.2 Parameter Setting


Enter the parameter setting interface of the touch screen, input the bending parameters according to the product process requirements, including aluminium bar specification, bending angle, left and right side lengths, bending speed, clamping pressure, etc.
Set the springback compensation value according to the material characteristics of the aluminium bar (the springback of aluminium bars is generally 1°-3°, which can be adjusted according to the actual trial bending results).
For batch production, store the set parameters in the system program, name the program according to the product model, and call it directly during subsequent production to improve efficiency.
After setting the parameters, double-check to confirm that the input data is correct, and then save the parameters and exit the setting interface.


5.3 Aluminium Bar Loading and Positioning


Place the qualified aluminium bar flat on the feeding roller table, push it to the positioning baffle of the equipment, and adjust the position of the positioning baffle to ensure that the bending point of the aluminium bar is aligned with the center of the bending die.
Start the clamping mechanism (manual or automatic), and the clamping cylinder drives the pressure plate to press the aluminium bar firmly to prevent the aluminium bar from moving or rotating during the bending process. The clamping pressure should be appropriate, not too large to deform the aluminium bar, nor too small to cause insufficient clamping.
Use a measuring tool to recheck the positioning size of the aluminium bar, confirm that the bending position and length meet the process requirements, and then proceed to the bending operation.


5.4 Bending Operation

5.4.1 Manual Bending Mode


Select the manual operation mode on the control panel, and operate the manual button or joystick to control the bending die to rotate slowly, and observe the bending state of the aluminium bar in real time.
When the bending angle reaches the set value, the equipment will automatically stop or stop manually, and keep the pressure for 1-2 seconds to eliminate the springback of the aluminium bar.
Operate the loosening button to release the clamping mechanism, take out the bent aluminium bar, and use an angle ruler and tape measure to check the bending angle and size accuracy. If the accuracy is unqualified, readjust the springback compensation value and parameters for trial bending again.


5.4.2 Automatic Bending Mode


Select the automatic operation mode on the touch screen, call the pre-stored product program, and confirm that the parameters are correct.
Press the automatic start button, the equipment will automatically complete the actions of clamping, bending, pressure maintaining, loosening and resetting in sequence according to the set program.
During the automatic operation, the operator shall stand in the safe area outside the safety grating, observe the operation state of the equipment in real time, and pay attention to whether there is abnormal noise, aluminium bar deformation or equipment failure.
After the bending of a single aluminium bar is completed, the equipment will automatically reset and wait for the next feeding. For batch production, repeat the loading and start operation until the production task is completed.


5.5 Trial Bending and Batch Production


Before formal batch production, conduct trial bending on 2-3 aluminium bars, check the bending angle, side length, flatness and appearance quality of the formed aluminium frame, and confirm that all indicators meet the process standards.
If the trial bending product is unqualified, analyze the causes (such as parameter setting error, die mismatch, positioning deviation, aluminium bar quality problem), adjust the parameters or replace the accessories in time, and conduct trial bending again until the product is qualified.
After the trial bending is qualified, carry out formal batch production, and conduct random inspection on the formed products at regular intervals (every 50-100 pieces) to ensure the stability of product quality.


5.6 Equipment Shutdown


After completing the production task, press the stop button to stop the operation of the equipment, and reset the bending die and clamping mechanism to the initial position.
For hydraulic drive models, turn off the hydraulic pump motor first, and then turn off the main power supply; for pneumatic models, close the air supply valve first, and then turn off the power supply.
Clean the residual aluminium chips, dust and impurities on the equipment surface, roller table and die, wipe the equipment with a clean cloth, and apply anti-rust oil on the die and metal parts if necessary.
Hang the "Shutdown for Maintenance" or "No Operation" warning sign on the operation panel, and record the production data, operation time and equipment status in the equipment operation log.


6. Safety Precautions

6.1 Basic Safety Rules


It is strictly forbidden to operate the equipment with diseases, fatigue, drunk or distracted mental state, so as to avoid misoperation.
During the operation of the equipment, it is forbidden to extend hands, arms or any parts of the body into the bending working area, and it is forbidden to touch the rotating die, transmission parts and high-temperature components (hydraulic motor, servo motor) with bare hands.
Do not place tools, aluminium bars or other sundries on the equipment frame, control panel and safety protection device to avoid affecting the equipment operation or causing safety accidents.
The equipment must be reliably grounded to prevent electric shock accidents. Do not disassemble or modify the electrical components, control circuit and mechanical structure of the equipment without authorization.
In case of power failure or air failure during operation, immediately press the emergency stop button, cut off the power supply and air supply, and wait for the power supply and air supply to return to normal before restarting the operation after inspection.


6.2 Special Operation Safety


When replacing the bending die, the equipment must be completely shut down, the power supply and air supply/hydraulic supply must be cut off, and the operation can be carried out only after the die is completely stopped. Use special tools to disassemble and assemble the die to avoid injury caused by die falling.
When bending special-shaped or ultra-long aluminium bars, add auxiliary support brackets to prevent the aluminium bars from deforming or swinging during the bending process, and arrange special personnel to assist in feeding and discharging.
When the equipment is running with overload or abnormal noise, immediately press the emergency stop button, cut off the power supply, check the cause of the fault, and it is forbidden to continue operation with fault.
The safety grating, protective cover and emergency stop button of the equipment shall not be dismantled or shielded at will, and regular inspection shall be carried out to ensure their effectiveness.


6.3 Emergency Handling


In case of personal injury (such as pinch, scald, electric shock), immediately cut off the power supply and air supply, carry out first aid measures, and send to the hospital for treatment in time.
In case of equipment failure (such as die jamming, hydraulic oil leakage, motor overheating), press the emergency stop button immediately, stop the operation, record the fault phenomenon, and notify the professional maintenance personnel for repair.
In case of fire caused by electrical short circuit or hydraulic oil combustion, immediately cut off the power supply, use dry powder fire extinguisher to put out the fire, and it is forbidden to use water to put out the electrical fire.


7. Equipment Maintenance and Upkeep

7.1 Daily Maintenance (Once per Shift)


Clean the equipment surface, die, roller table and working area, remove aluminium chips, dust and impurities, and keep the equipment clean.
Check the fastening of bolts, nuts and connectors of each component, and tighten them in time if loose.
Check the air pressure, hydraulic pressure and lubrication state of the equipment, add lubricating oil or grease to the transmission parts (bearing, gear, chain) according to the regulations, and check the hydraulic oil level and oil quality.
Test the functions of emergency stop button, safety grating and control buttons to ensure they are normal.
Record the daily maintenance situation in the equipment maintenance log.


7.2 Weekly Maintenance (Once a Week)


Thoroughly clean the inside of the equipment, including the hydraulic oil tank, air filter, control cabinet, remove dust and impurities, and check the wiring in the control cabinet for looseness.
Check the wear of bending die, clamping block, positioning baffle and transmission parts, and replace the seriously worn parts in time.
Drain the water and impurities in the air storage tank, air filter and hydraulic oil tank, and check the hydraulic oil for deterioration or pollution. If necessary, replace the hydraulic oil and filter element.
Calibrate the bending angle and positioning size of the equipment, and adjust the deviation to ensure the processing accuracy.
Check the operation of the servo motor, hydraulic pump and clamping cylinder, and eliminate abnormal noise and oil leakage.


7.3 Monthly Maintenance (Once a Month)


Conduct a comprehensive inspection of the electrical system, including the PLC controller, servo driver, touch screen, sensor, etc., check the wiring for aging or damage, and replace the damaged wires in time.
Perform lubrication maintenance on all transmission mechanisms, replace the lubricating oil or grease that has deteriorated or exceeded the service life, and adjust the tightness of the chain and belt.
Check the sealing performance of the hydraulic system and pneumatic system, replace the aging sealing ring and oil seal, and eliminate oil leakage and air leakage faults.
Calibrate the pressure gauge, temperature sensor and other measuring instruments of the equipment to ensure the accuracy of measurement data.
Conduct a comprehensive test run of the equipment, check the operation status of each system, and deal with potential faults in advance.


7.4 Annual Maintenance (Once a Year)


Conduct a comprehensive disassembly and inspection of the equipment, check the wear of key components such as frame, bending shaft, bearing, and carry out repair or replacement according to the wear degree.
Replace all hydraulic oil, lubricating oil, filter element and sealing parts of the equipment, and clean the hydraulic oil tank and lubrication system.
Conduct a comprehensive calibration of the control system, update the system program if necessary, and optimize the bending parameters.
Conduct a safety performance evaluation of the equipment, including safety protection device, grounding system, overload protection, etc., to ensure that the equipment meets the safety standards.
After the annual maintenance is completed, conduct a comprehensive test run and acceptance, and record the maintenance content and acceptance results in the equipment file.


8. Troubleshooting of Common Faults

8.1 Inaccurate Bending Angle


Fault Causes: Incorrect springback compensation parameter setting, wear or deformation of bending die, loose positioning baffle, unstable air pressure/hydraulic pressure, damage of angle sensor.
Solutions: Readjust the springback compensation value according to the trial bending results; replace the worn or deformed bending die; tighten the positioning baffle and recalibrate the positioning size; check the air compressor/hydraulic pump to stabilize the pressure; replace the damaged angle sensor and recalibrate.


8.2 Aluminium Bar Deformation or Scratches During Bending


Fault Causes: Improper clamping pressure, burrs or wear on the die and clamping block, unqualified aluminium bar material, misalignment of bending point.
Solutions: Adjust the clamping pressure to an appropriate value; polish or replace the die and clamping block with burrs or wear; replace qualified aluminium bars; recalibrate the bending point position to ensure alignment with the die center.


8.3 Clamping Mechanism Fails to Clamp or Loosen


Fault Causes: Insufficient air pressure/hydraulic pressure, blockage of air pipe/hydraulic pipe, damage of clamping cylinder, failure of solenoid valve, loose circuit connection.
Solutions: Adjust the air pressure/hydraulic pressure to the normal range; clean the blocked pipeline; replace the damaged clamping cylinder; check and replace the faulty solenoid valve; tighten the loose circuit connector.


8.4 Equipment Abnormal Noise or Vibration


Fault Causes: Insufficient lubrication of transmission parts, loose fastening bolts, wear or damage of bearing and gear, unbalanced bending die, overload operation.
Solutions: Add lubricating oil or grease to the transmission parts; tighten all loose fastening bolts; replace the worn bearing and gear; recalibrate the balance of the bending die; reduce the processing load to avoid overload operation.


8.5 Hydraulic System Oil Leakage


Fault Causes: Aging or damage of sealing ring, loose joint of hydraulic pipe, crack of hydraulic oil tank, damage of hydraulic pump shaft seal.
Solutions: Replace the aging sealing ring; tighten the loose hydraulic pipe joint; weld or replace the cracked hydraulic oil tank; replace the damaged hydraulic pump shaft seal.


8.6 Control System Failure (Touch Screen No Display, Parameter Cannot Be Set)


Fault Causes: Power supply abnormality, loose connection of control line, damage of touch screen or PLC controller, system program error.
Solutions: Check the power supply and restore normal power supply; tighten the loose control line connector; replace the damaged touch screen or PLC controller; restart the system or reload the program to restore the normal operation of the control system.


9. Storage and Transportation of Equipment

9.1 Equipment Storage


The equipment should be stored in a dry, ventilated, dust-free and non-corrosive gas environment, away from heat sources, direct sunlight and rain.
Before storage, clean the equipment thoroughly, apply anti-rust oil on all metal parts and die, cover the equipment with a dust cover, and block the hydraulic pipe and air pipe interface to prevent dust and impurities from entering.
The equipment should be placed flat on a solid ground, and the support points should be set according to the requirements to avoid deformation of the frame. Regular inspection should be carried out during storage, and anti-rust and moisture-proof treatment should be done well.


9.2 Equipment Transportation


The equipment transportation should be carried out by a professional logistics company, and the transportation vehicle should have a fixed device to prevent the equipment from shaking or colliding during transportation.
Before transportation, fix all movable parts of the equipment (such as bending die, clamping cylinder, roller table) with fixtures, remove the easily damaged parts (such as touch screen, sensor) and pack them separately for transportation.
During loading and unloading, use a forklift or crane that meets the lifting requirements, and operate in accordance with the hoisting specifications to avoid impact or tilting of the equipment. The lifting point should be selected at the designated position of the equipment frame.
During transportation, cover the equipment with a rainproof and dustproof cloth to prevent rain, snow and dust from eroding the equipment.


10. Supplementary Provisions


This manual is the basic operation standard of the Aluminium Bar Bending Machine, and the operator shall strictly abide by it. If there is any conflict with the special instructions of the equipment manufacturer, the manufacturer's instructions shall prevail.
The enterprise shall formulate corresponding operation management system and maintenance system according to this manual, and assign special personnel to be responsible for the management and maintenance of the equipment.
Any modification, transformation or upgrade of the equipment must be approved by the equipment manufacturer or professional technical personnel, and shall not be carried out without authorization.
The operator shall be responsible for the equipment damage and personal safety accidents caused by violation of this manual.
This manual shall be kept properly, and the lost or damaged manual shall be reported to the equipment management department in time for replacement. The technical department of the enterprise is responsible for the interpretation and revision of this manual.

Double Edge Straight Glass Grinding Machine: A Comprehensive Analysis of Design, Technology and Industrial Application

Abstract

The Double Edge Straight Glass Grinding Machine is a core piece of automated processing equipment in the modern glass deep-processing industry, dedicated to the simultaneous high-precision grinding, polishing and chamfering of two parallel straight edges of flat glass. This article systematically expounds the structural composition, working principle, core technical parameters, application scenarios, performance advantages, maintenance specifications and future development trends of the double edge straight glass grinding machine. By analyzing its technological innovation, processing efficiency and industrial value, it aims to provide a theoretical basis and practical reference for glass processing enterprises, equipment R&D institutions and technical practitioners, and clarify the important role of this equipment in promoting the automation, intelligence and high-quality development of the glass processing industry.

1. Introduction

With the rapid expansion of application fields such as architectural decoration, automotive manufacturing, home appliances, furniture and photovoltaic new energy, the demand for flat glass products has shown a sustained growth trend, and the requirements for glass edge processing quality, production efficiency and dimensional accuracy are becoming increasingly stringent. The traditional single-side glass grinding machine can only process one edge of the glass at a time, which requires repeated clamping and positioning of the glass, resulting in low production efficiency, poor dimensional consistency, high labor intensity and high production cost, and it is difficult to adapt to the large-scale and standardized production needs of modern glass processing.

In response to the pain points of the industry, the double edge straight glass grinding machine has been developed and applied, which realizes the simultaneous processing of two parallel straight edges of flat glass through a dual-spindle group, dual-conveying system and integrated control technology. It integrates multiple processes such as coarse grinding, fine grinding, polishing and chamfering, and completes the edge processing of glass in one pass, which greatly improves the processing efficiency and product quality. This equipment has become an indispensable key equipment in the glass deep-processing production line, and its technical level and performance indicators directly affect the core competitiveness of glass processing enterprises. This article will conduct an in-depth and comprehensive analysis of the double edge straight glass grinding machine from multiple dimensions, and explore its technical characteristics and development potential in the industrial field.

2. Structural Composition and Core Components

The double edge straight glass grinding machine adopts a symmetrical integrated structural design, which is mainly composed of a main frame, a double-side grinding spindle group, a pneumatic clamping and conveying system, a PLC intelligent control system, a cooling and dust removal system, a glass positioning mechanism and a safety protection device. Each component is designed and matched with high precision to ensure the stability, accuracy and continuity of the equipment during operation.

2.1 Main Frame

The main frame is the load-bearing foundation of the entire equipment, which is generally made of high-strength thick steel plates through precision welding, stress relief annealing and precision machining. This manufacturing process can effectively eliminate the internal stress of the frame, avoid deformation and vibration caused by long-term high-load operation, and ensure the geometric accuracy and stability of the equipment. The frame is designed with a symmetrical structure on both sides, equipped with high-precision linear guide rails, ball screws and servo drive systems for the movement of the grinding spindle group, which can realize the precise adjustment of the distance between the two sides of the grinding heads and the feeding accuracy of the spindles. The gantry-type reinforced structure is adopted for large-scale models, which can bear the weight of large-format glass and high-speed grinding load, and is suitable for the processing of architectural curtain wall glass and automotive large glass.

2.2 Double-Side Grinding Spindle Group

The double-side grinding spindle group is the core execution component of the equipment, which is symmetrically arranged on both sides of the conveying channel, and each side is equipped with 8-12 high-speed precision spindles, which are divided into coarse grinding spindles, fine grinding spindles, chamfering spindles and polishing spindles according to the processing process. The spindles are driven by high-performance servo motors, with a rotation speed of 2800-3600rpm, and have the characteristics of low vibration, low noise and high stability.

The coarse grinding spindle is equipped with diamond grinding wheels with a grit size of #100-#180, which is used to quickly remove the sharp edges, burrs and micro-cracks of the cut glass, and form the basic straight edge profile; the fine grinding spindle adopts resin-bonded diamond grinding wheels with a grit size of #240-#400, which refines the edge surface, eliminates grinding marks and improves the dimensional accuracy of the edge; the chamfering spindle is equipped with a special chamfering grinding wheel, which can process 45° chamfers, rounded corners and other edge shapes according to the process requirements, with a chamfer width adjustable from 0.5mm to 3mm; the polishing spindle is equipped with cerium oxide polishing wheels or resin polishing wheels, which can polish the glass edge to an optical-grade finish with a surface roughness Ra ≤ 0.15μm, meeting the high surface quality requirements of high-end glass products. The two-side spindle groups can be independently adjusted in speed, feeding amount and grinding pressure, and can realize the synchronous processing of different edge processes on both sides of the glass, with strong process adaptability.

2.3 Pneumatic Clamping and Conveying System

The pneumatic clamping and conveying system is responsible for the stable fixation and continuous conveying of glass, which is the key to ensuring the processing accuracy and efficiency of the equipment. The system consists of a pneumatic power unit, precision pressure regulating valves, pneumatic clamping cylinders, wear-resistant clamping jaws, a variable-frequency conveying belt and a drive motor.

The pneumatic clamping mechanism adopts a flexible clamping design, and the clamping jaws are lined with polyurethane or rubber materials, which can apply uniform and adjustable clamping pressure (0.2-0.6MPa) according to the thickness of the glass (3-25mm), avoiding glass surface damage and edge chipping caused by excessive pressure, and ensuring the stable positioning of the glass during high-speed grinding. The conveying system adopts a double-sided synchronous conveying belt driven by a variable-frequency motor, with a conveying speed adjustable from 1m/min to 8m/min, which can be matched with different processing speeds and glass thicknesses. The conveying belt is made of anti-slip and wear-resistant materials, which can prevent glass slippage and scratching during the conveying process, and realize the continuous and stable conveying of glass from the feeding end to the discharging end.

2.4 PLC Intelligent Control System

The double edge straight glass grinding machine is equipped with a high-performance PLC (Programmable Logic Controller) and a touch-screen human-machine interface (HMI), which realizes the intelligent control of the entire processing process. The control system supports the setting and storage of processing parameters such as glass thickness, edge width, chamfer size, spindle speed, conveying speed and grinding pressure, and can store more than 100 groups of process parameters, which is convenient for quick switching of different glass specifications and reduces the equipment adjustment time.

The system has real-time monitoring functions, which can display the operating status of each spindle, pneumatic pressure, conveying speed, cooling system flow and other parameters in real time, and has fault self-diagnosis and alarm functions. When equipment failures such as spindle overload, air pressure abnormality, cooling blockage and glass jamming occur, the system will automatically stop and send out an audible and visual alarm, and display the fault location and solution on the touch screen, which is convenient for operators to troubleshoot. Advanced models are also equipped with Ethernet communication and remote control functions, which can realize remote monitoring, parameter adjustment and fault diagnosis, and integrate with the glass processing production line to form an intelligent manufacturing system.

2.5 Cooling and Dust Removal System

During the glass grinding process, the friction between the grinding wheel and the glass will generate a lot of heat, and a large amount of glass powder will be produced at the same time. The cooling and dust removal system is designed to reduce the grinding temperature, lubricate the grinding contact surface, and remove glass powder, which is an important guarantee for improving the processing quality and extending the service life of the grinding wheel.

The cooling system adopts a closed-loop water circulation design, and high-precision nozzles are installed at each grinding spindle to spray cooling liquid (pure water or special glass grinding coolant) directly onto the grinding contact area, which can quickly take away the grinding heat, prevent the glass edge from cracking due to thermal stress, and reduce the wear of the grinding wheel. The dust removal system is integrated with the cooling circulation system, and the glass powder and debris generated during grinding are flushed into the sedimentation tank by the cooling liquid, and then filtered and recycled through a multi-stage filtration device (filter precision ≤ 5μm), which reduces water consumption and environmental pollution, and avoids the blockage of precision components by glass powder.

2.6 Glass Positioning Mechanism and Safety Protection Device

The glass positioning mechanism is composed of photoelectric sensors, mechanical positioning blocks and pneumatic positioning cylinders, which can realize the precise positioning of the glass before entering the grinding area, with a positioning accuracy of ±0.01mm, ensuring the consistency of the processing size of the two sides of the glass. The safety protection device includes a safety grating, an emergency stop button, a protective cover and an interlock device, which can prevent operators from being injured by the rotating grinding wheel and the moving glass during the operation of the equipment, and meet the safety production standards of industrial machinery.

3. Working Principle

The working process of the double edge straight glass grinding machine is a highly coordinated operation of mechanical transmission, pneumatic control, electrical control and grinding processing, which is divided into six stages: glass feeding, precise positioning, pneumatic clamping, double-side synchronous grinding, glass release and discharging, and the entire process is automatically completed under the control of the PLC system.

3.1 Glass Feeding and Precise Positioning

The operator places the cut flat glass on the feeding conveyor belt, and the conveyor belt transports the glass to the positioning area. The photoelectric sensor detects the position of the glass edge and transmits the signal to the PLC system. The PLC controls the pneumatic positioning cylinder to push the glass to the preset positioning position, and the mechanical positioning block assists in fixing, realizing the precise alignment of the glass and the grinding spindle group, ensuring that the two parallel edges of the glass are accurately aligned with the grinding heads on both sides.

3.2 Pneumatic Clamping

After the glass is positioned accurately, the PLC system sends a command to activate the pneumatic clamping system. The pneumatic cylinders on both sides drive the clamping jaws to move towards the glass, and apply uniform clamping pressure according to the set parameters to fix the glass firmly. The clamping pressure is adjusted in real time by the precision pressure regulating valve to adapt to glass of different thicknesses and materials, avoiding glass damage and ensuring that the glass does not shift during the grinding process.

3.3 Double-Side Synchronous Grinding

After the clamping is completed, the PLC system starts the double-side grinding spindle group and the conveying system at the same time. The glass moves forward at a set conveying speed, and the grinding spindles on both sides feed radially at the same time. The grinding wheels make contact with the two parallel edges of the glass, and complete the processes of coarse grinding, fine grinding, chamfering and polishing in sequence according to the preset process flow.

During the grinding process, the cooling system sprays cooling liquid continuously to cool and lubricate the grinding area, and the dust removal system synchronously recovers the glass powder. The PLC system monitors the operating parameters of each spindle and the conveying system in real time, and automatically adjusts the spindle speed, feeding amount and grinding pressure to ensure the stability of the grinding process and the consistency of the processing quality of the two edges of the glass.

3.4 Glass Release and Discharging

When the glass passes through the entire grinding area and completes all edge processing, the photoelectric sensor at the discharging end sends a signal to the PLC system. The PLC controls the pneumatic clamping cylinder to retract, the clamping jaws release the glass, and the conveying belt transports the processed glass to the discharging area. At this point, a complete processing cycle is completed, and the equipment immediately enters the next processing cycle to realize continuous automatic production.

4. Core Technical Parameters

The core technical parameters of the double edge straight glass grinding machine determine its processing capacity, accuracy and application scope. The following are the main technical parameters of mainstream models in the market:






Parameter Category
Specific Indicators
Parameter Range




Processing Scope
Applicable glass thickness
3-25mm



Minimum processing glass size
50mm×50mm



Maximum processing glass size
Customizable (up to 3000mm×2000mm)



Processing edge type
Straight edge, 45° chamfer, rounded edge



Chamfer width adjustment range
0.5-3mm


Processing Accuracy
Edge dimensional accuracy
±0.01mm



Parallelism of double edges
≤0.02mm/m



Surface roughness after polishing
Ra≤0.15μm



Chamfer angle accuracy
±0.5°


Operational Parameters
Spindle rotation speed
2800-3600rpm



Conveying speed
1-8m/min



Pneumatic system working pressure
0.2-0.6MPa



Compressed air consumption
≤1.5L/min


Power Parameters
Total installed power
22-30kW



Power supply
380V/50Hz, three-phase four-wire


Physical Parameters
Overall dimensions (L×W×H)
7.5-8.5m×1.8m×2.8m



Equipment weight
4000-6000kg






These technical parameters reflect the high precision, high efficiency and wide adaptability of the double edge straight glass grinding machine, which can meet the processing needs of different glass specifications and different application scenarios.

5. Industrial Application Scenarios

Due to its advantages of high efficiency, high precision and automation, the double edge straight glass grinding machine is widely used in various fields of flat glass deep processing, and has become the core equipment of glass processing production lines in many industries.

5.1 Architectural Decoration Industry

In the architectural glass processing field, the double edge straight glass grinding machine is mainly used for the edge processing of architectural curtain wall glass, doors and windows glass, partition glass, shower room glass and glass railing. The equipment can process high-precision straight edges and 45° chamfers for large-format architectural glass, which not only improves the aesthetic appearance of the glass, but also enhances the mechanical strength and safety of the glass, meeting the safety standards of architectural glass. The high processing efficiency of the equipment can meet the large-scale production needs of architectural glass projects, and is widely used in the processing of glass for high-rise buildings, commercial complexes, hotels and residential buildings.

5.2 Automotive Glass Manufacturing

Automotive glass (windshield, side window glass, rear window glass, sunroof glass) has extremely high requirements for edge processing accuracy and quality. The double edge straight glass grinding machine can realize the high-precision grinding and polishing of the two parallel edges of automotive glass, ensure the dimensional accuracy and sealing performance of the glass, and facilitate the installation of glass and automotive frames. The equipment can process various types of automotive glass such as tempered glass and laminated glass, and is an indispensable processing equipment in the automotive glass production line.

5.3 Home Appliances and Furniture Industry

In the home appliance industry, the equipment is used for the edge processing of glass panels of refrigerators, washing machines, ovens, microwave ovens and display screens, and the polished glass edge improves the safety and aesthetic appearance of home appliance products. In the furniture industry, it is mainly used for the processing of glass tabletops, cabinet glass doors, display cabinet glass and decorative glass parts, and the processed glass has smooth edges and high dimensional accuracy, which meets the production needs of high-end furniture.

5.4 Photovoltaic New Energy Industry

With the rapid development of the photovoltaic industry, the demand for photovoltaic glass is increasing year by year. The double edge straight glass grinding machine is used for the edge processing of photovoltaic glass panels, which can eliminate the micro-cracks on the glass edge, improve the mechanical strength and weather resistance of the photovoltaic glass, and ensure the service life of photovoltaic modules. The high-efficiency processing capacity of the equipment can meet the large-scale production needs of photovoltaic glass manufacturing enterprises.

5.5 Electronic and Optical Glass Industry

For electronic glass (smart phone cover glass, tablet display glass, TV panel glass) and optical glass (optical lens substrate, instrument glass), the double edge straight glass grinding machine can achieve ultra-precision polishing of the glass edge, with a surface roughness Ra ≤ 0.1μm, meeting the requirements of light transmittance and surface smoothness of electronic and optical glass. The equipment's high-precision positioning and processing capabilities ensure the consistency of small-sized electronic glass processing, and are suitable for the mass production of electronic and optical glass components.

6. Performance Advantages

Compared with the traditional single-side glass grinding machine and manual edging process, the double edge straight glass grinding machine has obvious performance advantages, which can effectively improve the production efficiency and product quality of glass processing enterprises and reduce production costs.

6.1 High Processing Efficiency and Continuous Production Capacity

The double edge straight glass grinding machine can process two parallel edges of glass at the same time, and complete multiple processes such as coarse grinding, fine grinding, chamfering and polishing in one pass, which improves the processing efficiency by 50%-80% compared with the single-side grinding machine. The automatic feeding, positioning, clamping, grinding and discharging system realizes unmanned continuous production, with a processing capacity of 100-150 pieces per hour (for standard 12mm thick glass), which can meet the large-scale production needs of enterprises.

6.2 High Processing Precision and Product Consistency

The equipment adopts high-precision linear guide rails, servo drive systems and PLC intelligent control, with an edge dimensional accuracy of ±0.01mm and a double-edge parallelism of ≤0.02mm/m, which far exceeds the processing accuracy of manual and single-side grinding machines. The synchronous processing of the double-side spindle group ensures the consistency of the processing quality of the two edges of the glass, and the polished edge surface is smooth and scratch-free, which improves the qualification rate of glass products to more than 99.5%.

6.3 Wide Adaptability to Glass Specifications and Types

The equipment can process glass with a thickness of 3-25mm and a size of 50mm×50mm to 3000mm×2000mm, and can adapt to various types of flat glass such as float glass, tempered glass, laminated glass, Low-E glass, photovoltaic glass and electronic glass. The spindle speed, grinding pressure, conveying speed and chamfer size can be flexibly adjusted according to the processing requirements, with strong process adaptability and can meet the diversified processing needs of enterprises.

6.4 High Degree of Automation and Easy Operation

The PLC touch-screen control system simplifies the operation process, and operators can complete the parameter setting and equipment start-stop only through simple training. The system has functions such as parameter memory, fault self-diagnosis and automatic alarm, which reduces the labor intensity of operators and the dependence on skilled workers. The integration with the automatic loading and unloading equipment can form a fully automatic glass processing production line, realizing the intelligent manufacturing of glass processing.

6.5 Low Production Cost and Long Service Life

The one-pass processing of the equipment reduces the number of glass clamping and positioning, reduces the loss of glass caused by repeated handling and clamping, and saves labor costs. The closed-loop cooling and dust removal system reduces the consumption of cooling liquid and the wear of grinding wheels, and the service life of high-quality diamond grinding wheels can reach more than 10,000 hours. The high-strength frame structure and high-quality components ensure the long-term stable operation of the equipment, with a service life of more than 15 years under normal maintenance, which reduces the equipment replacement and maintenance costs of enterprises.

6.6 Good Safety and Environmental Protection Performance

The equipment is equipped with a complete safety protection device, which can effectively prevent safety accidents during the operation of the equipment and meet the industrial safety production standards. The closed-loop cooling and dust removal system recycles the cooling liquid and collects the glass powder, which reduces the discharge of waste water and waste residue, realizes green and environmentally friendly production, and complies with the national environmental protection policies.

7. Equipment Maintenance and Troubleshooting

In order to ensure the long-term stable operation of the double edge straight glass grinding machine and maintain its processing accuracy, it is necessary to carry out standardized daily maintenance and timely troubleshooting. The maintenance of the equipment is divided into daily maintenance, weekly maintenance and monthly maintenance, and corresponding solutions are formulated for common faults.

7.1 Daily Maintenance

After each shift, clean the glass powder and debris on the surface of the equipment, grinding spindles, conveying belts and cooling nozzles with compressed air and a clean cloth; check the liquid level of the cooling liquid, and add or replace the cooling liquid in time if it is insufficient or contaminated; check the pneumatic system pressure to ensure that it is within the normal range, and check for air leakage at the cylinder joints and valves; check the wear of the grinding wheels, and replace the grinding wheels that are seriously worn or chipped in time; lubricate the linear guide rails and ball screws with special lubricating oil to ensure smooth movement.

7.2 Weekly Maintenance

Drain the water and impurities in the air storage tank of the pneumatic system, and replace the pneumatic filter element; check the tightness of the spindle fixing screws and the conveyor belt tension, and adjust them in time if they are loose; calibrate the positioning accuracy of the photoelectric sensor and the mechanical positioning block; clean the filter device of the cooling and dust removal system to prevent blockage; check the operation of the servo motor and the PLC control system, and test the emergency stop and alarm functions.

7.3 Monthly Maintenance

Conduct a comprehensive inspection of the main frame, grinding spindle group, conveying system and electrical system of the equipment, check for deformation, wear and damage of components, and replace damaged parts in time; replace the lubricating oil of the spindle bearing and the gearbox; calibrate the processing accuracy of the equipment, including edge dimensional accuracy, double-edge parallelism and chamfer angle accuracy; update the PLC system software and back up the process parameters; conduct a comprehensive safety inspection of the equipment to ensure the normal operation of the safety protection device.

7.4 Common Faults and Troubleshooting


Uneven processing of double edges: The main reasons are inconsistent feeding of double-side spindles, misalignment of glass positioning and uneven clamping pressure. The solutions are to calibrate the feeding accuracy of the double-side spindles, adjust the glass positioning mechanism and the pneumatic clamping pressure.
Glass edge chipping and cracking: The main reasons are excessive grinding pressure, insufficient cooling liquid, hard glass material and glass positioning deviation. The solutions are to reduce the grinding pressure, check the cooling nozzle blockage, replace the appropriate grinding wheel and re-calibrate the glass positioning.
Low surface roughness after polishing: The main reasons are worn polishing wheels, incorrect spindle speed and contaminated cooling liquid. The solutions are to replace the polishing wheels, adjust the spindle speed and replace the cooling liquid.
Conveyor belt slipping and jamming: The main reasons are worn conveyor belt lining, insufficient tension and excessive glass weight. The solutions are to replace the conveyor belt lining, adjust the belt tension and control the glass processing size within the equipment's bearing range.
PLC system fault and alarm: The main reasons are parameter setting error, electrical component damage and communication failure. The solutions are to check and correct the process parameters, replace the damaged electrical components and check the communication line connection.


8. Future Development Trends

With the continuous progress of science and technology and the changing market demand, the double edge straight glass grinding machine is developing in the direction of higher intelligence, higher precision, energy saving and environmental protection, and multi-functional integration, and its technical level and application scope will be further improved and expanded.

8.1 Intelligent and Digital Upgrading

In the future, the double edge straight glass grinding machine will integrate more intelligent technologies such as artificial intelligence, machine vision and big data. The machine vision system will automatically detect the size, thickness, edge defects and processing quality of the glass, and the artificial intelligence algorithm will optimize the processing parameters in real time to realize the adaptive processing of different glass. The big data platform will collect and analyze the equipment operation data, realize predictive maintenance and production scheduling optimization, and improve the overall efficiency of the production line. The digital twin technology will be applied to simulate the equipment operation and processing process, and realize the virtual debugging and process optimization of the equipment.

8.2 Ultra-Precision Processing Technology

With the development of electronic, optical and semiconductor industries, the demand for ultra-precision glass processing is increasing. The double edge straight glass grinding machine will develop towards higher precision, with the edge dimensional accuracy reaching ±0.005mm and the surface roughness Ra ≤ 0.05μm. The new type of nano-grinding wheel and high-precision spindle technology will be applied to realize the ultra-precision grinding and polishing of thin glass and special-shaped glass, meeting the processing needs of high-end electronic and optical products.

8.3 Energy Saving and Environmental Protection Optimization

In response to the national dual-carbon target and environmental protection requirements, the equipment will adopt energy-saving motors, high-efficiency drive systems and intelligent energy management systems to reduce power consumption by 30%-40%. The cooling and dust removal system will be further optimized, adopting a zero-discharge closed-loop circulation system and glass powder recycling technology to realize the recycling of waste resources and reduce environmental pollution. The equipment will use more environmentally friendly materials and manufacturing processes to realize the green design and production of the equipment.

8.4 Multi-Functional Integration and Flexible Manufacturing

The future double edge straight glass grinding machine will integrate multiple processing functions such as straight edge grinding, chamfering, polishing, drilling and slotting, and realize the one-stop processing of glass. The modular design will be adopted, and the spindle group and processing module can be quickly replaced and combined to adapt to the processing of different edge shapes and glass types. The equipment will have the ability of flexible production, which can quickly switch between different production tasks and meet the personalized and customized processing needs of the market.

8.5 Global Market Expansion and Localized Innovation

With the rapid development of the global glass processing industry, especially in emerging markets such as Southeast Asia, Latin America and Africa, the demand for high-performance double edge straight glass grinding machines is growing. Domestic equipment manufacturers will increase R&D investment, break through the core technology bottleneck, improve the quality and performance of the equipment, and expand the international market share. At the same time, localized innovation will be carried out according to the market demand and processing standards of different regions, and customized equipment and solutions will be provided to meet the diversified needs of global customers.

9. Conclusion

The double edge straight glass grinding machine, as a key equipment in the modern glass deep-processing industry, has revolutionized the traditional glass edge processing mode with its high efficiency, high precision, automation and intelligence, and has become an important support for the high-quality development of the glass processing industry. Its structural design, technical performance and application scope have been continuously improved and expanded, and it plays an irreplaceable role in architectural decoration, automotive manufacturing, home appliances, photovoltaic and other fields.

In the future, with the continuous innovation of intelligent manufacturing technology, energy saving and environmental protection technology and ultra-precision processing technology, the double edge straight glass grinding machine will move towards a higher level of intelligence, precision and greenness, and provide more efficient and high-quality processing solutions for the glass processing industry. For glass processing enterprises, adopting advanced double edge straight glass grinding machines is an important way to improve production efficiency, reduce production costs and enhance market competitiveness. For equipment manufacturers, continuous technological innovation and product upgrading are the core driving forces to seize market opportunities and promote the sustainable development of the industry.