Extruder

1.Structure: Cold feed 2.Max. Capacity (without head): 10kg/h 3.Diameter of screw (mm): Ф30 4.L/D: 12 5. Max. revolution. (rpm): 75 6. Motor capacity (KW): 4 7. Revolution of motor (rpm): 0-1500rpm 8. Reduction ratio: 1/19.7 9. No. of pins: no 10. Arrangement: Attached drawing Extruder Head The head design will be discussed. There are cooling water holes in the head and locked by clamp. TCU: 2 Zones Temperature range: 0 ~ 100°C Temperature control accuracy：+/-1.5°C Unit circulating pump：hot water circulating pump Cooling：Indirect cooling Arrangement: See attached drawing Structure Extruder Each extruder consists of screw, barrel, feeder, reducer, coupling and basement Screw A. The screw is right-hand turning, with multiplex thread, equal depth and distance changed in stage. The feeding zone is four-head thread, the fluxing zone and the extruding zone are double thread with different lead. B. The screw is made of high-quality nitrided steel 38crMoALA, with the surface nitrided. The hardness is more than HV900(HS95), and the average nitrided depth is 0.5mm. The surface is polished. C. The screw and the axis of reducer are connected by splined connection for easily centering. It can be installed and uninstalled from the front. D. The screw is hollow for entering and eliciting the temp-controlling water. The inner tube is made of 0Cr18Ni9 E. No leakage under water pressure of 1 Mpa for 1 hour. Feeder Barrel A. It is made of nitrided steel 38CrMoAlA, welded structure and sufficiently annealed. B. The hardness of the surface is more than HV950. C. There is temp-controlling water channel in the inner circumference for heat exchanging. D. The barrel covers 2 zones of TCU, the plasticizing zone and extruding zone; there are entrance and exit in each zone. E. The front flange of pin-barrel is connected with flange of head F, Water pressure resist test for temperature controlled water channel: no leakage under 1 Mpa for 1 hour. Feeder roller: A. Feed barrel is made of 38CrMoAlA with surface nitrided. B. There is a scraper in the feeder to scrap the rubber on the roller. The clearance between scraper and surface of roller can be adjusted. The scraper is fixed on one side of the main body. The feed roller is fixed on the door of feeder. And the position of scraper can be adjusted when open the door. C. The friction gear is driven by the screw gear and the surface is high-frequency hardened. D. There is leak mouth under the feed in case any rubber enters the roller bearing. E. The friction gear is lubricated by grease. Basement: A. The basement welded with shaped steel. The intension and rigidity should allow the motor, reducer, screw and basement to center and fix on the frame. B. The installing surface is processed. And there is a plane for centering on the basement, there also is a lifting hole and spotting plane. Temperature control unit Structure and operating principle: The TCU controls the temperature of each zone separately by adopting media enforced circularity. Each unit consists of circulating pump, electric heater, heat exchanger, temperature control instrument, cooling water switch valve, automatic air valve, platinum hot resistance and electro connecting pressure gauge. The circulating pump forces the media (permute) to flow through the electric heater and heat exchanger, enter the controlling zone and then return to the pump inlet. When the temperatures are set, the media will discharge the heat by cooling of heater and heat exchanger. So the temperature is constant automatically. The temperature accommodation mode is PID. The supplier and type of main parts and components: Circulating pump: Grundfos Thermoregulator: RKC, Japan List of main components and requirements： Groupware of barrel and screw: Adopt 38CrMoAlA nitrogen treatment for the surface Groupware of feeder roller: Collected grease lubrication for the feed roller AC inverter motor and Reducer: SEW 4kw AC inverter: Mitsubishi Rotary joint: Rocky Basement: Welded Technical documents All of the documentaries should be bind up together with operating instruction (2 copies): A. Technical parameter, summarize of part structure, installing, trial running and maintaining. And also include: General assembly of main extruder, basement drawing, operation guide of screw removal tool and feed roll gear; B. General diagram, zone diagram, principle diagram and pipeline installing diagram of TCU C. Foundation plan, D. Inspection report, E. Packing list The trial run and testing Before leaving, deputy of user may come to spot for the loaded test run in our plant; manufacturer will provide the field, power, grease and temporary die plate and so on. The test run shall be performed in accordance with the user’s procedure. Warranty clause Time of warranty: 1.5 year Manufacturer will be responsible for the product liability caused by wrongly designing and manufacture within the freshness date. Manufacturer will provide instructions about assembly, production and maintain., Manufacturer will be responsible for the purchasing parts. Manufacturer will be responsible for packing and derusting. Installation and trial run The manufacturer shall give technical instruction and the user be responsible for installation. The user shall be responsible for all of the materials needed for installation (cable, frame, pipeline and so on) The manufacturer shall be responsible for mechanical inspection and the user shall provide the conditions needed. 2 weeks shall be needed for inspection and loaded trial run. No delay caused by user is included. Acceptance Extruder A. The dimension of barrel meets the requirements of design. B. The material and hardness of barrel meets the technical requirements. C. No leakage in water pressure test. Head A. The dimension of head meets the requirements. B. No rubber leakage at the connection of head and barrel. C. No leakage in water pressure test. Loaded trial run A. No abnormal shake and noise when function. B. No temperature sharp rising in any bearing. And the temperature rising is ≤40°C C. No leakage in the lubricating system. D. The airproof is in good condition E. No rubber leakage between the contact surface Acceptance A. No malfunction for 48 hour 48continuous working. The characteristics meet the requirements of Main Specification and Parameter. The product quality meets the requirement of technological requirements. B. Accept after 48 hours working without malfunction. The trial run should be redone if any interruption caused by equipment itself occurs. The acceptance gauge should be in accordance with the agreement by both sides. Painting Corrosion preventive coating 2 coats Finish coat of designated color 2 coats Others A. The manufacturer should provide the drawings of hydraulic and electric assembly and driven, civil work condition 60 days before delivery. B. The user should provide the drawings of complex tread and the technological acceptance condition within 25 days after the contract executed. It is validated only after both side sign as one of the appendices of the contract. C. The installation condition and technological acceptance condition should be put forward in advance. Or the manufacturer should be responsible for the consequence. D. The user provides the cable, frame and pipeline needed for installation. The other correlating technical parameters shall be acknowledge when design. Time of warranty：1.5 year after delivery. Delivery time: 4 months after execution of contract Supply scope Mechanical parts A. Ø30 pin barrel cold feed extruder: 1set B. Head: 1set C. Speed adjustment cabinet: 1set D. 2-zone TCU: 1set E. Accessories: 1set Electric parts Electric control box Main components and sub- suppliers: AC inverter motor (4kw): SEW AC inverter: Mitsubishi Main low voltage component: Schneider Button, indicator: Schneider Temperature controller: RKC, Japan Pressure sensor: CHINA Circulating pump: Grundfos Rotary joint: China Accessories and spare parts Accessories： Anchor bolt: 1 30 Screw ejector: 1 Spare parts： For extruder Scraper: Φ30 1pcs. Rotary: Φ30 1pcs. For TCU Solid state relay: 1 Electric heater: 1 Hot resistance: 1 Technical documents All of the documentaries should be bind up together with operating instruction (2 copies) Technical parameter, summarize of part structure, installing, trial running and maintaining. And also include: General assembly of main extruder, basement drawing, operation guide of screw removal tool and feed roll gear; General diagram, zone diagram, principle diagram and pipeline installing diagram of TCU Foundation plan; Inspection report Packing list The trial run and testing Before leaving, deputy of user may come to spot for the loaded test run in our plant; manufacturer will provide the field, power, grease and temporary die plate and so on. The test run shall be performed in accordance with the user’s procedure. Warranty clause Time of warranty: 1.5 year Manufacturer will be responsible for the product liability caused by wrongly designing and manufacture within the freshness date. Manufacturer will provide instructions about assembly, production and maintain. Manufacturer will be responsible for the purchasing parts. Manufacturer will be responsible for packing and derusting. Delivery： 4 months after the execution of contract Installing and debugging The user shall be responsible for installing and manufacturer will give instructions on installing and debugging;