Linha de Corte EPS Série SPQ — eps cutting lines by ChinaEps, CE certified.
A série SPQ é uma linha de corte EPS totalmente automatizada com ajuste automático de fio patenteado, corte por oscilação e recuperação integrada de resíduos. Manipula blocos de 2000-6000mm com tolerância de ±0.5mm e configura 60 fios em apenas 3 minutos.
Especificações Principais
Model
SPQ(2000/3000/4000/5000/6000)B
Block Length (L)
2,000-6,000 mm
Block Width (W)
1,000-1,260 mm
Block Height (H)
500-1,260 mm
Certificado CE e ISO 9001 Garantia de 5 Anos Resposta Técnica em 24h
* As especificações estão sujeitas a alterações sem aviso prévio. Entre em contato para obter os dados técnicos mais recentes.
O Que Esta Máquina Resolve
Três problemas de produção eliminados por esta máquina — com soluções engenheiradas e mensuráveis.
O Problema
Manual hot-wire setup eats 30-45 minutes between cutting jobs — operators waste a third of every shift just changing wire patterns.
Como Esta Máquina Resolve
SPQ's patented robotic wire-setting head positions all 60 cutting wires automatically in 1-3 minutes. Operators load the wire pattern from the HMI library, press start, and the head walks the frame self-aligning to ±0.2mm — 10× faster than manual setup with no measurement drift between jobs.
O Problema
Slow cutting speeds and stop-start movement push board output below 12 t/day, capping the factory's ability to fill construction-season insulation orders.
Como Esta Máquina Resolve
Oscillation cutting frame (vertical micro-vibration on each heated wire) maintains continuous travel at 0.6-2 m/min depending on density — up to 2 m/min on 20 kg/m³ EPS. Combined with segmented continuous design that fits 5 boards in the cutting zone simultaneously, daily throughput scales to 18-25 t with two shifts.
O Problema
Edge scrap from top, side, and bottom trim adds up to 6-9% raw-material loss per shift — scrap that competitors with integrated recovery turn back into pre-expander feed.
Como Esta Máquina Resolve
Three-direction scrap recovery (top trim shaver + side belt + bottom roller-bed sweep) collects every cut-off into a pneumatic conveyor that routes scrap to the regrind silo. Recovery rate reaches 95-98%; material loss drops to 1-2% which feeds the PE pre-expander back-stream.
Inside the Machine — Core Components
Eight engineered subsystems that make this cutting line production-grade. Each component is sourced, built, and tested for industrial duty cycles.
1. Cutting Frame (Welded Steel Bed)
Function
Provides the rigid reference plane against which all 60 horizontal, 13 vertical, and 1 cross-cut wires are tensioned. Stays geometrically true across the 6,000mm cut length under 8-hour duty cycles.
Engineering Details
Q345B structural steel, stress-relieved post-welding. Precision-machined wire-mount rails (±0.05mm flatness over the full length). Adjustable feet for site-leveling; full frame floats on anti-vibration pads to isolate the cutting plane from floor-borne vibration.
2. Robotic Wire-Setting Head
Function
Positions all 60 horizontal hot wires automatically per the HMI recipe — what used to take 30-45 minutes of operator rule-and-tape work now completes in 1-3 minutes.
Engineering Details
Servo-driven X-axis carriage with absolute encoder (±0.2mm repeatability). Pneumatic wire-gripper changes pitch on the fly. Wire patterns stored as named recipes; switching from 50mm sheet to 100mm sheet is one HMI tap. Auto-tensioning to 3-8 N per wire prevents droop and sag.
3. Oscillating Hot-Wire Cutting Mechanism
Function
Slices EPS along all three axes (horizontal, vertical, cross-cut) using electrically-heated nichrome wires that vibrate vertically at controlled amplitude — reducing drag and giving a glass-smooth cut face.
Engineering Details
Cutting wire diameter 0.35-0.6mm (replaceable, ~500-800h lifespan per wire). Oscillation amplitude adjustable 2-5mm at 50-80 Hz. Wire heating power 26 kW distributed via solid-state contactors with individual current monitoring. Cooling fans at each wire-end prevent the terminal melting that plagues fixed-wire designs.
4. Continuous Conveyor & Roller Bed
Function
Moves blocks through the three cutting stations at PLC-coordinated speed (0.6-2 m/min). The fixed cutting frame means the conveyor — not the cutter — controls cut pitch.
Engineering Details
Variable-frequency drive with 0.1% speed accuracy. Roller diameter 89mm, surface-hardened to HRC 50+ for abrasion life on rough-cut block edges. Side-clamp pneumatic rams keep blocks square through the cut zone. 5-block parallel capacity in segmented-continuous mode.
5. PLC Control & HMI
Function
Supervises every machine state in real time: wire temperatures, cutting speed, wire-break events, scrap-belt loading, and operator safety interlocks. Stores cutting recipes and logs production data for traceability.
Engineering Details
Siemens S7-1200 PLC with 10.1" Weintek HMI touchscreen. Multi-level user accounts (operator / supervisor / engineer) prevent unauthorized parameter changes. USB recipe export for backup; optional Ethernet/IP gateway for MES integration. Local fault-history log retains 1,000 events.
6. Three-Direction Scrap Recovery System
Function
Captures every trim cut — top, side edges, and bottom — into a pneumatic loop that routes scrap to the regrind silo. Keeps material loss to 1-2% per shift.
Engineering Details
Top trim shaver with vacuum suction (handles 5-15 mm trim strips). Side belts (one each face) catch ribbon scrap from vertical cuts. Bottom roller-bed sweep collects fall-through fines. Combined pneumatic conveyor (Ø150mm) routes scrap up to 30m to the regrind silo with no manual handling.
7. Wire Heating & Power Distribution
Function
Delivers stable heating current to all 74 cutting wires (60 horizontal + 13 vertical + 1 cross) with individual circuit protection — a broken wire trips its own circuit without halting the line.
Engineering Details
26 kW heating power split across solid-state relays (one per wire bank). Each wire current is monitored; deviation > 15% triggers a wire-break alarm on the HMI. Stainless-steel busbar connections resist EPS-dust oxidation. Optional voltage range 220V/60Hz for export markets — selectable at factory build.
8. Safety Guarding & Emergency Systems
Function
CE-compliant safeguards that protect operators from hot wires, moving conveyors, and pneumatic side-clamps — without requiring the line to stop for routine wire changes.
Engineering Details
Polycarbonate-glazed safety cage around the cutting zone with interlock switches on all access doors. Four e-stop mushrooms (one per machine end + two operator stations) cut PLC power within 100ms. Thermal cutoff trips heating power if cabinet temperature exceeds 60°C. Optional light-curtain for unattended-cell layouts.
Princípio de Funcionamento
SPQ-B operates as a fully-PLC-supervised continuous line: aged EPS blocks travel from the storage carousel onto the alignment rollers, then through three sequential cutting stations (horizontal → vertical → cross-cut) on a single oscillating wire frame. Cut boards are de-stacked at the discharge end while scrap is captured at every station. Setup, speed, and wire patterns are HMI-controlled; no operator stands at the cutting zone during normal run.
Step 1
1. Block Storage & Aging Buffer
Aged EPS blocks (24-72h post-molding) staged on the U-type or I-type carousel storage — capacity 6-12 blocks depending on layout. Storage stages also serve as the cooling buffer after block-molding.
Step 2
2. Tilting & Alignment
Hydraulic tilter rotates each block from vertical (mold position) to horizontal (cut position). Pneumatic side-clamps square the block against precision rails to within ±1mm of frame zero before the first cut.
Step 3
3. Horizontal Cutting (≥10mm pitch)
First wire bank — up to 60 horizontal hot wires (0.35-0.6mm diameter) — slices the block into stacked sheets. Oscillation reduces wire drag and gives a glass-smooth cut face. Minimum pitch 10mm, max thickness limited only by block height.
Step 4
4. Vertical Cutting (≥200mm pitch)
Second wire bank rotates the cutting plane 90°. Vertical wires divide each horizontal sheet into strips down to 200mm width — typical for ceiling tiles, packaging strips, and decorative profiles.
Step 5
5. Cross-Cutting (≥300mm pitch)
Single transverse wire performs the final length cut. Adjustable from 300mm up to the full block length (2,000-6,000mm). Cuts are coordinated by the PLC so cross-cut fires precisely between horizontal and vertical wire passes.
Step 6
6. De-Stacking & Scrap Discharge
Finished sheets are layered onto the output conveyor in stacked rows. Top, side, and bottom scrap routes through a pneumatic capture system into the regrind silo. Output rate matches the cutting speed; no buffering needed before the optional packing machine.
Vantagens de Desempenho Engenheiradas
Cada vantagem respaldada por especificações mensuráveis — sem alegações de marketing sem dados.
Wire Setup Speed
60 wires in 1-3 min
vs manual setup: 30-45 min
Robotic wire-setting head with servo-driven X-Y positioning. Wire patterns stored as recipes on the HMI — switching from 50mm sheet to 100mm sheet takes one HMI tap, not an hour of rule-and-tape work.
Thickness Tolerance
±0.5 mm
vs industry typical: ±1.5-2 mm
Closed-loop oscillation amplitude + tensioned cutting wires + fixed cutting frame remove wire-flutter as a tolerance source. Holds spec across all 60 wires for the full block length.
Continuous Cutting Speed
0.6-2 m/min
vs batch cutters: 0.3-0.5 m/min
Segmented continuous design lets 5 boards travel through the cutting zone in parallel. Speed scales with density: 2 m/min on 20 kg/m³ EPS, 0.6 m/min on 35 kg/m³ high-density boards.
Material Recovery
95-98%
vs frames without recovery: 91-94%
Top trim shaver, side belt, and bottom roller-bed sweep capture all cut-off into the pneumatic loop. Recovered scrap returns to the pre-expander as regrind, lowering virgin-bead consumption by 5-7%.
Non-Cutting Time Reduction
−65%
vs vs movable-frame cutters
Fixed cutting frame + PLC-controlled board travel removes the operator step of repositioning the frame between cuts. Boards walk to the wire; the wire never moves to the board.
Aplicações Reais de Produção
Veja onde esta máquina se encaixa em fábricas reais.
EPS insulation board production for EIFS/ETICS construction systems — 1,200 × 600mm × 50/80/100mm sheets at ±0.5mm tolerance
Custom-thickness packaging foam sheets for electronics and appliance protection — high-volume cut runs with HMI recipe recall
Building material wholesale — standard-size EPS sheets palletized straight from the de-stacker for distribution
Export-grade insulation manufacturing for cold storage warehouse panels — repeatable thickness across 6,000mm block length
Fishery and aquaculture foam-box production — high-throughput cut-to-size sheets ready for thermo-welding
Integrated cut-to-pack line: SPQ feeds directly into the SPB packing machine for shrink-wrapped pallet output
Configuração da Máquina
Componentes de grau industrial de marcas globais consagradas — cada peça rastreável.
Componente
Marca / Especificação
Detalhe
PLC Controller
Siemens S7-1200
CPU 1214C with 14 DI / 10 DO / 2 AI — standard EPS-cutting program pre-loaded
HMI Touchscreen
Weintek MT8102iE
10.1" color TFT, multilingual UI (EN/ZH/ES/PT/FR/RU/AR available)
5.5 kW vector-control inverter for 0.6-2 m/min speed range with 0.1% accuracy
Cutting Wire
PEDOC Ni-Cr
Nichrome 80/20 alloy, 0.35-0.6mm replaceable wires; ~500-800h service life per wire
Contactors & Relays
Schneider Electric
TeSys series; solid-state relays for wire-bank heating circuits
Pneumatic Components
AirTAC / SMC
Side-clamp cylinders, scrap-suction valves, tilter actuators — ISO 6432 standard
Estudos de Caso de Clientes
Detalhes do cliente disponíveis sob solicitação.
RussiaAno: 2024
Configuração
SPQ-4000B (U-type) + PE-1400 pre-expander + BM-1400 block molding line — 8,000 m² monthly insulation board capacity
Resultado
Replaced manual cutting bench; cut crew reduced from 6 to 2 operators; defect rate dropped from 4.2% to 0.8% within first quarter of operation.
VietnamAno: 2023
Configuração
SPQ-3000B (I-type) + integrated SPB packing line — 5,000 m² monthly fish-box and aquaculture foam capacity
Resultado
Achieved 18 t/day sustained output across two shifts; wire-setup time reduced from 35 min to 3 min between SKU changeovers, enabling small-batch custom orders.
Maintenance & Safety
A clear schedule keeps the line running. Built-in safety systems protect operators and product alike.
Maintenance Schedule
Daily (every shift)
Clean EPS dust from cutting frame, conveyor rollers, and scrap belts. Inspect cutting wires for nicks or thinning; replace any wire showing > 20% diameter loss. Check HMI fault log; clear non-critical alarms. Verify pneumatic pressure at 0.5-0.7 MPa.
Weekly
Re-tension all 74 cutting wires to spec (3-8 N each). Lubricate conveyor roller bearings with NLGI-2 grease. Check VFD heatsink airflow and clean cabinet filters. Inspect safety interlocks and e-stop function — every door switch must trigger PLC fault.
Monthly
Verify wire-setting head positioning accuracy with calibration block (±0.2mm spec). Inspect electrical cabinet for loose terminals; torque to 4 Nm. Service air-prep unit (drain, filter, regulator). Replace any HMI battery showing > 50% drain.
Semi-Annual
Full geometric re-survey of cutting frame (laser alignment). Replace wear-prone parts: pneumatic seals, contactor tips, suction-belt liners. Lubricate servo gearboxes. Backup HMI recipe library to USB and store offsite.
Annual
Major overhaul: inspect all servo encoders, replace nichrome wire stock, calibrate current sensors, re-certify safety circuit per EN 60204-1. Update PLC firmware if Siemens advisories apply. Re-issue operator-training refresh.
Safety Features
CE certification per EN 60204-1 (machinery electrical safety) and EN ISO 13849-1 (safety-related control systems, PLd)
Polycarbonate-glazed safety cage around the cutting zone — full visual access without operator exposure to hot wires
Four emergency-stop mushrooms (one per machine end + two operator stations) — Category 0 stop cuts PLC power within 100ms
Interlocked access doors: opening any door during run triggers immediate wire-power cutoff and conveyor halt
Thermal cutoff sensor on heating cabinet (>60°C) prevents fire risk from EPS-dust accumulation on contactors
Optional light-curtain for unattended-cell layouts — Type 4 self-monitoring per IEC 61496-1
Wire-break detection: per-wire current monitoring trips the affected bank within 200ms and alarms on HMI
Product FAQ
The questions buyers ask most often before placing an order.
How stable is the ±0.5mm thickness tolerance over a full 6,000mm block?
The fixed cutting frame combined with tensioned oscillating wires removes wire-flutter as a tolerance source. Field measurement on 20 kg/m³ EPS shows ±0.3-0.4mm typical, well inside the ±0.5mm spec. Tolerance widens slightly on densities above 30 kg/m³ — closer to ±0.6mm — but stays within tile-and-panel-industry acceptance. Calibration blocks ship with every machine for in-house verification.
What EPS density range can the SPQ-B handle, and how does speed change?
Designed for 12-35 kg/m³ EPS. Cutting speed scales inversely with density: 2 m/min on 20 kg/m³, ~1.2 m/min on 28 kg/m³, ~0.6 m/min on 35 kg/m³. Above 35 kg/m³ you want the SPB-Q model with the oscillation A-frame for fire-retardant modified EPS. Below 12 kg/m³ standard SPQ handles fine but you may bog the scrap recovery — talk to engineering about belt-speed adjustment.
What happens if a cutting wire breaks mid-run?
Per-wire current monitoring detects the open circuit within 200ms and trips that specific wire bank. PLC posts a wire-break alarm on the HMI identifying the wire position. Operator opens the safety door (interlocks halt the conveyor), replaces the wire (90-second job with the included tool kit), and resumes from the HMI. The other 73 wires keep cutting in the meantime in segmented mode, so total productivity loss is typically under 3 minutes.
Can the machine ship to a 220V/60Hz country (e.g., US, parts of Latin America)?
Yes — factory build option. We change the heating power cabinet (taps + contactor coils), the VFD model, and the servo drive to 220V/60Hz equivalents. No price increase but lead time adds 2-3 weeks for component sourcing. Mechanical and PLC software are identical between voltage versions.
How long is the cutting wire service life, and how do I source replacements?
Nichrome 80/20 wires (0.35-0.6mm) last 500-800 cutting hours on average — about 3-5 months of single-shift operation. ChinaEps stocks PEDOC wire spools that ship in 5-7 days globally; you can also source equivalent nichrome locally per the spec sheet in the manual. The included spare kit ships with 200m of each diameter — enough for the first 4-6 months.
Is operator training included? In what language?
Two free options: (1) factory training — your operator visits Qingdao for 3 days of hands-on training during pre-shipment testing, you cover travel; (2) on-site training — our engineer travels to your facility for 5 days commissioning + training, you cover travel + accommodation. Training materials and HMI UI are available in EN / ZH / ES / PT / FR / RU / AR.
How is the machine packed and shipped for ocean freight?
U-type SPQ ships in 2× 40HQ containers (frame disassembled into 3 sections, electrical cabinet separate). I-type ships in 1× 40HQ + 1× 20FT. All steel surfaces oil-coated and shrink-wrapped against salt-air corrosion. Sensitive electronics (HMI, servo drives) in foam-lined wooden crates. Detailed packing list and assembly manual ship inside the cabinet door — also emailed PDF.
What is the warranty, and what is covered?
5 years on the cutting frame and welded steel structure. 12 months on PLC, HMI, servo drives, VFD, and pneumatic components — these are pass-through warranties from Siemens/Weintek/Yaskawa. Consumables (cutting wires, contactor tips, seals) are not warranty items. Wear parts are explicitly listed in the manual to avoid disputes.
Can I retrofit a wire-break warning system onto an SPQ ordered without it?
Yes — wire-break monitoring is an electrical-cabinet upgrade. We ship the current-sensor module and updated PLC program; your local electrician installs it in 1 day per the wiring diagram. Cost is roughly USD 1,200-1,800 depending on the bank count. Order through your account engineer.
What other ChinaEps machines integrate with the SPQ-B for a complete line?
Upstream: PE-1200 to PE-1800 pre-expanders (bead expansion) → aging silos (24-72h) → BM-1200 to BM-1800 block molding (block forming). Downstream: SPB packing machine for shrink-wrapped pallet output, or direct palletizer for fishery/aquaculture customers. Auxiliary: pneumatic scrap-recovery loop back to the pre-expander regrind hopper. We can quote a full turnkey line including building layout drawings.
Build a Complete EPS Line
This machine integrates into the full ChinaEps production flow — upstream, downstream, and auxiliary equipment from one supplier.
