by increasing productivity
Until now, profile extrusion has been an exclusively analog process. The dependence on the personal know-how of the personnel during the production process is enormous.
The[extru]sion / automation /[net]work brings transparency to the world of profile extrusion.
Sensors measure inline data in all areas of the process, in the machines and in the mold. Additional measuring equipment also allows inline control of the profile quality.
extrunet is a development partner of the new LIT Factory – a “smart research factory” on the premises of the Johannes Kepler University Linz.
…a self-learning extrusion line that produces a stable profile quality, within a specified tolerance range, over the entire production period and largely without operator intervention.
The start-up and shut-down process as well as the tool change should be simplified as much as possible.
extrunet develops a central control unit for the entire extrusion line on the basis of a B+R controller.
Using OPC UA interfaces, our systems can also communicate with external devices and transfer production data to a
central production data acquisition system (ERP-System).
A dense network of measuring points over the entire extrusion line.
Temperature/Pressure/ Speed of the Extruder
Scratch on profile surface
Temperature control of the extruder
Tool Temperature control
Cooling water control
Speed and trigger force control
Control Separation unit
Profile weight Control
State-of-the-art vacuum management with control valves. Required vacuum volume can be provided by one (preferably, highest energy efficiency) or several FU-controlled vacuum pumps. The vacuum levels are set via control valves that draw the vacuum from a large vacuum reservoir – this means that there are no mutual influences.
* Calculation basis: 1 line with 2 conventional vacuum pumps and 1 separation tank system
Vacuum supply in the dry area with frequency-controlled vacuum pumps, in the wet area with separating tank incl. Side channel compressor and water pump.
Vacuum management with one vacuum & water pump incl. Valve technology for extracting the calibrators and the vacuum/water tank
Modern air management to influence profile sections. Matched to the profile geometry, reproducible
e:MAC-C: Air control on dry calibre with contour plate.
e:MAC-D: Air control in the die Influencing the melt flow by local cooling or heating
The air control unit can be a stand-alone unit or built into the calibration table.
Profile-related data recording in the central control.
Can be retrofitted to existing tools!
*Calculation basis: 1 line with output 250kg/h and 1.5% weight reduction
State-of-the-art cooling water management – digital control of the cooling water flows in the cooling calibres – influencing the profile geometry through local additional or reduced cooling.
Cooling problems can be recognised by the flow rate before any impairment occurs on the profile!
Different cooling water temperature levels for special cooling, cooling in dry calibres and cooling in the tool tanks can be realised. As a result, enormous savings can be achieved in cooling water circulation.
Cooling regime can be saved for each tool and is therefore reproducible. Early warnings in the event of malfunctions (cooling problems).
*Calculation basis: 1 line with output 250kg/h and 0.5% scrap reduction
Early warning of profile breaks and partial profile breaks – optical, acoustic and digital – already within the dry calibration.
The automatic raising of the calibration table (increases the distance between the die and the calibration table) leads to relaxation and prevents material build-up between the die and the calibre.
Calculation basis: 1 line with output 250kg/h and 0.5 machine downtimes per week
Digital equipment to detect slippage on the profile with the initiation of countermeasures.
Only in conjunction with an external length measurement (measuring wheel).
Differential measurement between the encoder of the fume cupboard and the measuring wheel indicate slippage of the profile. The regulation influences the back pressure.
*Calculation basis: 1 line with an output of 250 kg/h and 0.5 machine downtimes per week.
extrunet systems are equipped with the digital data acquisition function.
The OPC-UA server integrated in the PLC makes the process data of the entire plant available.
The data transfer software “DATAFEED” retrieves this process data and transfers it to an SQL database.
All data are thus historically available and can be evaluated.
Scope of services:
Licence SQL database not included
Smart Data Mining methods are used to prepare and relativize the data.
The data can also be entered directly into existing ERP systems (e.g. SAP®).
Recording of all operating data in the line.
600 variables send data to the server every 150 ms.
with modern evaluation software such as Qlik-View® or Qlik-Sense®, the data can be prepared according to requirements.