When using a batch foam machine for polyurethane soft foam foaming, have you encountered the following situations?

1.Uneven and numerous foam pores,

2. Rough foam texture.

3. Chaotic pore sizes across the entire foam surface, with slight signs of large pores.

Issues like these are quite common. The main reason for the first issue is that the distance between the mixing impeller of the foam machine and the bottom of the mixing barrel is too great; the second issue is that the mixing blades are too short and narrow: the third issue is that the angle of the mixing blades is too large.

Many manufacturers who design and produce foam machines only understand the principles during the design process, without understanding the significant relationship between a different design in foam production and product quality. A reasonable and perfect mechanical design can only be gradually improved in actual work, and only experienced foamers can achieve this.

Here are some experiences we have had with machine modifications and upgrades, hoping they will be helpful:

First, the installation position of the mixing wheel should be as low as possible, closer to the bottom of the mixing barrel is better. In general, the distance between the lowest point of the mixing blade and the bottom of the mixing barrel should be around two centimeters

Second, the shape of the mixing blade should be fan-shaped, with a moderately wide edge. The advantage of being wide is that it increases the contact area with the liquid material, providing sufficient power and also balances the liquid material.

Third, the length of the mixing blade should also be as long as possible, leaving about three to four centimeters from the baffle inside the mixing barrel.

Fourth, the two edges of the mixing blade should be sloped, with the angle of inclination based on the width of one end and two centimeters difference on both sides. After the mixing blade is modified, proper operation is also crucial, especially the mixing speed. Most batch foam machines nowadays are equipped with high-speed timing frequency conversion devices. However, in actual production, this device is often unnecessary. The operating speed mainly depends on the amount of material in the mixing barrel. If there is a lot of material, the speed should be appropriately faster, and if there is less material, then the speed should be lower.

What to do when the chain stitch quilting machine fails to pick up the thread?

First, check whether the upper and lower threads are correctly threaded and if the thread tension is appropriate. Then, push up the light axis and check if the needle and hook are in the correct position, approximately two millimeters apart.

If the pattern jumping stitch is not picking up the thread, you can adjust the parameters on the computerized control interface to increase the thread length parameter, but be careful not to increase it too much.

What to do when the quilting machine produces imperfect circles?

First, reduce the stitch length appropriately, ideally between 4.8 and 5.2. Then, set the backstitch to 4 and slow down the speed. This should result in a nicely formed small circle.

How to quilt a standard and even pattern?

First, identify the root cause of the problem. Uneven patterns can be related to the thickness of the sponge. If the base material is too thin, it can also cause pattern distortion, uneven sizes, and disproportion. Adjust parameters according to different patterns and material thicknesses.

For continuous patterns, if there is horizontal overlapping, reduce the x-axis parameter; if there is vertical overlapping, reduce the y-axis parameter. Conversely, if horizontal and vertical lines are separated, increase the x and y parameters accordingly.

For jumping patterns, adjust the GX and GY parameters. When quilting diamonds, if the diagonal separation is too wide, increase the diagonal pull parameter; if the diamond diagonals intersect, reduce the diagonal pull parameter.

How to properly control the tension of the upper thread?

When removing the thread, be sure to pass through the thread clamp on the upper thread clamp. The thread clamp cannot be adjusted too tight. When you need to adjust the tightness of the upper thread, you cannot pull the upper thread directly. You must control the tightness of the upper thread through the thread clamp on the control device; when adjusting, it should not be too tight or too loose, and there should be no jamming, otherwise it will cause jumpers. Or disconnected.

How to draw a pattern?

When drawing a pattern for a quilting machine, we can use professional pattern drawing software, but the exported format must be HFP. How to enlarge or reduce the size when drawing a floral pattern? In "Edit Pattern", open "Scale Entire Pattern", and based on our needs, click on the pop-up box's "millimeters" or "inches" option, then add the X and Y parameters according to our needs, and click "OK" after entering.

How to troubleshoot the cause of abnormal noise in a quilting machine?

First, check whether the frequently worn parts are lacking oil, and add some machine oil or grease to the dryer areas; then check whether there is any clearance in the bearings of various components; also carefully observe whether the accessories and wear parts are excessively worn, and replace them timely if discovered.