extrusion thermoforming line

10
Project Information Project Information Retrofit an existing line with an updated Retrofit an existing line with an updated control system. control system. We worked in co-ordination with the original We worked in co-ordination with the original Vendor who supplied the new controls, operator Vendor who supplied the new controls, operator interface and the PLC. They built panels to interface and the PLC. They built panels to install, replacing 15 existing drives, and install, replacing 15 existing drives, and programmed the PLC. programmed the PLC. We specified the Drive configurations, provided We specified the Drive configurations, provided the integration to the gauge system, and the integration to the gauge system, and started up the line. started up the line. Installation, wiring and start-up were completed Installation, wiring and start-up were completed in 5 days, which was two days ahead of schedule. in 5 days, which was two days ahead of schedule.

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Page 1: Extrusion thermoforming line

Project InformationProject Information• Retrofit an existing line with an updated control Retrofit an existing line with an updated control

system.system.• We worked in co-ordination with the original Vendor We worked in co-ordination with the original Vendor

who supplied the new controls, operator interface who supplied the new controls, operator interface and the PLC. They built panels to install, replacing and the PLC. They built panels to install, replacing 15 existing drives, and programmed the PLC.15 existing drives, and programmed the PLC.

• We specified the Drive configurations, provided the We specified the Drive configurations, provided the integration to the gauge system, and started up the integration to the gauge system, and started up the line.line.

• Installation, wiring and start-up were completed in 5 Installation, wiring and start-up were completed in 5 days, which was two days ahead of schedule.days, which was two days ahead of schedule.

Page 2: Extrusion thermoforming line

Plastic Extrusion Plastic Extrusion ThermoformingThermoforming

• Continuous Extrusion ProcessContinuous Extrusion Process• Four Extruder/Melt Pump Drive Four Extruder/Melt Pump Drive

combinations.combinations.• Two Casting Roll DrivesTwo Casting Roll Drives• Pull Roll DrivePull Roll Drive• Five operator stations with touch screens.Five operator stations with touch screens.• Three Analogue I/O cards.Three Analogue I/O cards.• Four Digital I/O cards.Four Digital I/O cards.

Page 3: Extrusion thermoforming line

Extruder/Melt PumpExtruder/Melt Pump• Each combined unit Each combined unit

ratios the Melt Pump ratios the Melt Pump speed to the line speed to the line speed, and has speed, and has automatic control of automatic control of the extruder to the extruder to maintain pressure at maintain pressure at inlet of the Melt Pump.inlet of the Melt Pump.

• There are four There are four separate combined separate combined units.units.

Page 4: Extrusion thermoforming line

Operator InterfaceOperator Interface• There are five Link There are five Link

Touch-screens for Touch-screens for operators to input operators to input ratios and monitor ratios and monitor drive speeds & amps.drive speeds & amps.

• Extruder pressures Extruder pressures and temperatures are and temperatures are also monitored on Link also monitored on Link Touch-screens.Touch-screens.

• Conventional meters Conventional meters and push buttons were and push buttons were kept in parallel with kept in parallel with Link screen push Link screen push buttons and meters for buttons and meters for operator convenience.operator convenience.

Page 5: Extrusion thermoforming line

Casting SectionCasting Section• There is a 3 Roll There is a 3 Roll

stack of casting rolls.stack of casting rolls.• The first Roll is the The first Roll is the

Line master speed Line master speed control. All others control. All others ratio to it. ratio to it.

• The second roll is The second roll is geared to the first.geared to the first.

• The third roll The third roll operates in electronic operates in electronic ratio to the first.ratio to the first.

Page 6: Extrusion thermoforming line

Pull RollPull Roll• The Pull Roll The Pull Roll

operates in ratio or operates in ratio or torque mode to torque mode to provide controlled provide controlled pull on the pull on the material. material.

Page 7: Extrusion thermoforming line

Thermo-former & Cutout Thermo-former & Cutout DieDie

• Product goes into cutout Product goes into cutout unit after Thermo-unit after Thermo-forming, but during forming, but during startup, the cutout unit startup, the cutout unit is bypassed until process is bypassed until process stabilizes, as shown.stabilizes, as shown.

• Any waste material Any waste material during startup or while during startup or while running, is reground and running, is reground and fed back into the fed back into the Extruders.Extruders.

• These are separate free-These are separate free-standing units, but we standing units, but we provide a speed signal to provide a speed signal to co-ordinate the whole co-ordinate the whole process.process.

Page 8: Extrusion thermoforming line

Material after Product Material after Product removedremoved

• Top photo is the cut-Top photo is the cut-out die in operation.out die in operation.

• Product is removed Product is removed by air conveying by air conveying system to be system to be packaged.packaged.

• Bottom photo shows Bottom photo shows base material base material entering regrind entering regrind machine.machine.

Page 9: Extrusion thermoforming line

Drive UnitsDrive Units• Panels were built by the Panels were built by the

original vendor to original vendor to replace originalsreplace originals

• Existing wiring, motors Existing wiring, motors and encoders were used and encoders were used to minimize mechanical to minimize mechanical and electrical work, and electrical work, saving thousands of saving thousands of dollars.dollars.

• From Shutdown to new From Shutdown to new production took five production took five days. Schedule was days. Schedule was seven days.seven days.

Page 10: Extrusion thermoforming line

Unforeseen Customer Unforeseen Customer Benefits Benefits

• Melt Pump/Extruder combination can Melt Pump/Extruder combination can be restarted into a running line. They be restarted into a running line. They never could before.never could before.

• Troubleshooting can be done Troubleshooting can be done remotely by modem from anywhere. remotely by modem from anywhere. (and has been, on several occasions (and has been, on several occasions in four years, each time getting them in four years, each time getting them back in operation without requiring a back in operation without requiring a service trip).service trip).