Equipment Specifications
Version 6.0
2.00 SINGLE PULLER – DC Motor
2.11 SINGLE PULLER OUTLINE
This is an established designed single track puller with the puller cycle integrated with a manually adjustable auto cycle hot saw. The hot saw with a presenter is mounted on the initial table to enable a “one length parting” in between extrudate
The puller head is mounted on a single base carriage with firm grip rollers to provide stable smooth operations. On the puller head body itself is mounted a sufficient sized hydraulic power pack to provide hydraulic power for the grabber arms and pinching fingers operations. At the side of the puller rail is strung a self tension cable assembly connected to a floor mounted drive motor which provide the traction power to the puller head
The puller head, made from high strength steel machined plates have its own “on-board” electrical control board to sequence the grabber arm and pinching fingers to drop, grab and grip the extrudate head in accordance to puller sequence cycle
The entire operating sequence is supervised by the puller PLC to ensure “intelligent” programmable cycle sequencing. The PLC supervised drive motor is coupled to an “electric brake” to ensure smooth and sure footed declaration & stopping
MAIN SPECIFICATIONS
Pull tension & Speed
Pull head tension tension set 0 – 400 kg
Pull forward speed step less >100 meters/min
Return speed PLC set > 4 meters/sec
Puller position Digital display in Meters or Feet
Puller Pull Speed Digital display in Meters/min or Feet/min
Puller apparent tension Digital display
2.32 Puller rails
Initial table section 8 meters
Run out table section 50 meters
Total rail length 61 meters
2.33 Puller Grip Area
Width 350 mm
Height 300 mm
• Hot Saw – motorized
Diameter 550 mm 22 ins.
No of teeth 80
• Motors
Main Drive
DC Motor 15 HP 1 unit
On puller head
AC hydraulic pump motor 1.0 HP 1 unit
Hot saw drive AC motor 7.5 HP 1 unit
2.36 STANDARD ACCESSORIES
The Single puller comes with the following standard accessories & spares
Puller main control panel
• Operation pulpit control
• 1 set power rail copper contacts
• 2 piece “force control PCB cards”
• 1 lot spare HS fuse
• 4 spare grip rollers
• 1 spare tension pulley
• 1 spare encoder
• INITIAL FIXED HEIGHT KEVLAR ROLLER TABLE – Single Puller
2.51 INITIAL TABLE OUTLINE – single puller
The initial table is a simple sturdy steel frame welded table set between the press platen and initial head of the run out table. The top of this table is mounted with free rolling Kevlar sleeve rollers of the “impregnated” type for the first 4 meters and rest 3 meters with the “Red” type. The rollers are adequately pitched. This type of rollers is the current industry best for wear and high temperature operations. Above this table can be set with an air/water quench system or forced air fans or “through water quench” system to Buyers option (these options are not included here)
• OUTLINE SPECIFICATION INITIAL TABLE – single puller
a) Size
Length 8.0 meters
Effective Width 500 mm
Height FL + 840 mm
b) Rollers
Drive Non-driven free roller
Diameter 86 mm
Effective Width 450 mm
Pitched distance 400 mm
Full length Marathon Gold sleeves
• Entry end graphite guide device
Lead screw assembly device to lift and side guide extrudate into centre line of initial table
e) The initial table is hinged on one end and height adjustable on the end adjacent to the
Platen. Height adjustment is manual via a traverse gear box
2.53 STANDARD ACCESSORIES INITIAL TABLE – single puller
The initial table puller comes with the following standard accessories & spares
1) 2 spare Gold roller
2) 2 spare Green roller
3) 1 lot graphite slats
4) 45 units 18 INS fans
3.00 5 BELT CONVEYOR HANDLING TABLE SYSTEM
Take off Cooling X stretcher Aft stretcher Saw Batch
run out table Saw feed table
The offered Handling table offered is a reliable heavy gauge 5 Kevlar felt type conveyor belt design able to rapidly handle traffic mark free with the options of automated full batching ability upgrading in the future. The up down run out table and saw feed table eliminate traditional pick off arms damaging effects
3.10 STRUCTURE
The Handling table consists of;
• Up/Down & full powered rollers Run-Out table
• Take-off Belt
• Cooling Belts
• X-Stretcher belt
• Aft Stretcher belt
• Saw batching belt
• UP/Down & full powered Saw-Feed table
3.11 UP/Down & full powered Run-Out table
This is a full length purpose built long table to continue to convey the extrudate after the Initial table. This table is set after the initial table in line to the line of extrudate and is adjacent to the puller rail structure. The table is hydraulic powered in the Up/Down movement and the assembly is of welded steel structure with a single chain running the full length of the table to fully power all the Kevlar sleeve drive rollers mounted on the top of this table. The compensated chain tension single chain design enables for the ability for easy maintenance and repair of the Kevlar rollers (simply unfasten the pillow block bearings and remove affected roller without affecting the entire line) and also this design ensures a constant speed delivery or reverse ability independent of chain slack The high powered hydraulic cylinders enables the table to smoothly drop down or move up at a controllable speed to effectively transfer the long bar extrudate to the Take-off Belts and return to operation height with total reliability
3.12 Up/Down & full powered Run-out table specification
Height of table 950 mm
Length of table 50 meters
Width 500 mm
Kevlar rollers width 450 mm
Kevlar roller Diameter 86 mm Marathon Green high temperature type
Kevlar roller pitched 330 mm
Rollers driven by sprockets
Sprocket driven by spring tension link chain
Driven speed 0 – 100M/min
Drive power hydraulic motor
Full table Up/Down Hydraulic cylinder
Mechanism Rollers on taper cam bottom mount chassis
Control Auto/manual over ride forward reverse
• No 1 à Take off belts
The take off belts is designed for the high speed movement for adjacent transfer of extrudate from the lowered run-out table. This belt system is mounted adjacent to the Run-Out table and the belt booms are made of aluminum for sturdy guiding of the Kevlar belts
3.21 Height 950 mm
Length of Belt 50 meters
Pitch of booms 1000mm
Booms Extruded aluminum
Belts Marathon green high temperature type
Belt width 100 mm
Belt effective work length 1000 mm
Belt speed 16 M/min
Drive 2 Hp
Control Manual forward & 1 cycle/Auto
3.30 No 2 à Cooling belts
The cooling belts are designed with maximum belt tension This will ensure full table movement of the extrudate. The cooling belts on auto cycle will synchronize with the take off belts – a delay after initial belt stop to straighten and close gap of the extrudate, then followed by a fixed time batching movement to make a “one” extrudate batch on the cooling table
3.31
Height 950 mm
Length of Belt 50 meters
Pitch of booms 1000mm
Booms Extruded aluminum
Belts Marathon green high temperature type
Belt width 100 mm
Belt effective work length 4000 mm
Belt speed 7.6 M/min
Drive 2 Hp
Control Manual – forward reverse/Auto batching forward
3.40 No 3 à X Stretcher belts
The X stretcher belts comb into sections of the cooling belts and are independently extendable or retractable manually to allow stretcher traffic. The booms are tilted 20mm to prevent back movement knocking of cooling table extrudate
3.41 Height 950 mm
Length of Belt 50 meters
Pitch of booms 1000mm
Booms Extruded aluminum
Belts Marathon white low temperature type
Belt width 100 mm
Belt effective work length 1700 mm
Belt speed 7.6 M/min
Drive 2 Hp
Boom movement Control air cylinder assisted – forward reverse
3.50 No 4 à Aft Stretcher belts
The aft stretcher belts is set comb into a small section of the trailing X stretcher belts to receive stretched extrudate. This belt serves to be a transit storage of stretched extrudate for the saw batching belts to be able to batch to size and move the sorted extrudate in correct width to the saw feed table
3.51 Height 950 mm
Length of Belt 50 meters
Pitch of booms 1000mm
Booms Extruded aluminum
Belts Marathon white low temperature type
Belt width 100 mm
Belt effective work length 1600 mm
Belt speed 7.6 M/min
Drive 2 Hp
Control Manual one batch
3.60 No 5 à Saw batching belts
The saw batching belts acts to control a precise batch width of extrudate to be presented traverse to the saw feed table
3.61 Height 950 mm
Length of Belt 50 meters
Pitch of booms 1000mm
Booms Extruded aluminum
Belts Marathon white low temperature type
Belt width 100 mm
Belt effective work length 2200 mm
Belt speed 7.6 M/min
Drive 2 Hp
Control Manual forward reverse
• Saw feed table – Up/Down with fully powered forward/reverse rollers
This saw feed table with full powered rollers on a single tension compensated chain is designed to give long service life to the rollers. Pitch of rollers is set close to ensure effective positive movement to feeding in extrudate. The width of the table is widened to ensure maximum clearance of extrudate into the Finishing saw
3.7 Height of table 950 mm
Length of table 50 meters
Width 1100 mm
Roller type Low Temp blue type
Roller width 1000 mm
Roller Diameter 86 mm
Roller pitched 350 mm
Rollers driven by Top mount sprockets
Sprocket driven by spring tension link chain
Drive power Hydraulic motor
Full table Up/Down Hydraulic cylinder
Mechanism Rollers on taper cam bottom mount chassis
Control Manual forward reverse
4.00 FINISHING SAW – Saw blade Top cut/under return type
The finishing saw offered is a top cut/under return type to ensure minimal saw rubbing on the return stroke - resulting in longer saw blade life and less burrs on cut extrudate. Cutting stroke is full width to complement the saw feed table to provide maximum cut processing ability so as not to back log the handling table.
Cut materials are clamp on a sponge lined air clamp straddling the cut line minimizing sound and saw chips. A chip collection cyclone is provided with suction at the bottom saw blade area and the air clamp to clear off sawn chips
• OUTLINE SPECIFICATION – SY26
Saw blades Standard TCT for aluminum
Size 26 ins
Stroke Hydraulic drive
Cut height 230 mm
Cut stroke 1000 mm
Clamps compressed air
Saw blade motor 10 Hp
Chip collection Twin suction to Box drawer chip collector
Cyclone motor 7.5 Hp with suction at saw and clamp
Control PLC - Auto/one cycle/Manual
• SAW GAUGE TABLE – Up/Down with mechanized & stopper length digital display
The saw gauge table offered is complimentary to our offered Finishing saw to take cut full width extruded batches. Basically this gauge table is a welded steel chassis similar to the construction of the saw feed table and also having inverter controlled single chain driven powered rollers with the independent ability to drop down and return up in interlock to the sawing operations. The up/down actions traverse dispatch out cut batches of extrudate to a set of take off belts away from the gauge table to enable a quick next cut sequence. Mounted at the sides with sturdy rails is a gear rack driven motorized stopper with a tee arm that drops into position. The tee arm then extends a square wear plate to present a digitally displayed. An encoder on the moving stopper assembly keeps track and display the position of the stopper.
• OUTLINE SPECIFICATIONS
Table height 840 -810 mm
Gauge length max 8000 mm
min 1600 mm
Tolerance +/- 1.0 mm
Cut batch width max 1000 mm
Min 1 bar
Table rollers diameter 86 mm
Pitched 100 mm
Width 1000 mm
Roller drive Inverter motor 1.5 Hp
3 set speed
Stopper drive Inverter motor 1 Hp
2 set speed
Face plate Air cylinder
Stopper clamp Air cylinder
Up/down movement Hydraulic
Stopper lower/raise Air cylinder
Take off belts No of units 7 belts
Effective Length 3000 mm
Width 100 mm
Control PLC - Auto/one cycle/Manual
6.00 STRETCHER
The offered stretcher is a “one man stretcher type” where only one operator at the tailstock is needed to execute the stretcher operations
• STRUCTURE
The Stretcher consists of;
• Headstock
• Tailstock
• Long bed base
• Headstock
The headstock is a heavy duty welded steel plate assembly on wheels set with a set of hydraulic driven fingers to grip the batched extrudate. Across the jaws is mounted a chain boom to present the edges of the extrudate into the finger jaws for clamping. The headstock end is connected to a hydraulic cylinder of appropriate power. Hydraulic pumps and control valves are located at the end of this cylinder base
• Tailstock
The tailstock is a carriage assembly similar in construction (hydraulic powered fingers and chain presenter device) to the headstock but without the hydraulic cylinder. The tailstock has an additional control panel mounted on it to enable the operator to control the stretcher operations. At the back of the tailstock is engineered a tail hook assembly to locate firmly the tailstock to the machine base. The tailstock is motorized driven with a small motor for easy up/down movement along the long bed base rails
6.13 Machine base
The full length base of the stretcher is of a twin heavy steel plate construction to act as anchor and guide rails to the headstock and tailstock. Pitched across these plates are welded steel bars for the tailstock hooks
• SPECIFICATIONS
Max Work Length of stretcher 50 meters
Min Work Length of stretcher 6 meters
Stretching extrudate width (jaws width) 380mm
Stretching extrudate height (jaws height) 380mm
Stretching power 50 M tons
Tailstock motorized speed 7.6 Meters/min
Nom. Approach stretching speed 56 mm/sec
Stretching length 1000 mm
13.00 Through water initial table quench unit
Equipment description
Type : Direct extrude through full water quench with quench channel
Rotate able for non quenching actions
The unit is basically a base flood tank made of stainless steel containing storage cooling water supported by float actuated in feed water. A reverse able channel is constructed with a flat base bottom. This unit is bearing mounted at both ends of the unit top tank edge allowing it to be channel up or flat up. In normal extrusion without the need for T6 quenching, the flat top is presented and the unit operates as a normal initial run out table. When the channel side is presented it acts as a side retaining wall for water. At the inlet and outlet of this channel is a flat nozzle directing a high speed flow of water powered with a low pressure high volume centrifugal pump which is stationed at the base of the flood tank. This flat flow of water seals in a full channel of water allowing a totally unobstructed space for the hot extrusion to enter and exit
Length 2.5m