CPU Mining Screen Casting Line Upgrade in China

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A leading East Asian mining equipment manufacturer partnered with Haifeng to upgrade its polyurethane vibrating screen panel manufacturing workshop. The project involved replacing labor-intensive manual batch casting with a fully automated, vacuum-assisted three-component cast polyurethane elastomer (CPU) production unit.

Before the upgrade, the facility struggled with inconsistent flow filling across intricate aperture ribbing (down to 0.5 mm slot widths), resulting in excessive micro-bubble entrapment and a first-pass defect rate near 12.8%. These structural voids severely impaired screen wear life during severe abrasive slurry operations, leading to frequent field warranty claims.

Haifeng designed and integrated an automated casting cell featuring precise closed-loop stoichiometric tracking, vacuum mold evacuation, and multi-axis trajectory dispensing. The upgraded line achieves continuous bubble-free mold filling, elevating the customer's manufacturing capability to meet stringent export quality standards.

Haifeng engineered an integrated casting cell tailored for complex elastomeric screen geometries. The raw materials—PTMEG prepolymer, liquid curative, and specialty wear additives—are conditioned in continuous thin-film vacuum vessels to strip dissolved air and residual moisture prior to metering.

The metering unit utilizes servo-driven high-precision gear pumps paired with Coriolis mass flow meters to ensure consistent output across variable line speeds. Material enters a dynamic mixing head with continuous thermal oil tracing to prevent local solidification.

Before dispensing, the multi-cavity screen molds are locked in a hydraulic clamping station and evacuated to -0.09 MPa. The mixing head then executes a programmed stepped-flow dispensing cycle, filling deep fine-mesh ribs under negative pressure before applying a secondary leveling seal. Following automated in-mold curing, hydraulic pin ejection transfers parts to the post-curing tunnel conveyor.