3000T Hydraulic Aluminum Extrusion Press Machine Automatic Mode

1. Technical Parameters

(1) Dimensions of aluminium ingot

(2) Extrusion capability

(3) Stroke

(4) Speed (Maximum speed during manual operation)

(5) Hydraulic system parameters

1. Oil pump

2. The master cylinder, quick cylinder, container cylinder, shears and sliding mode cylinder adopt the logical valve integration control, and the retainer support, etc. adopt the three-position four-way electro-hydraulic reversing valve integration control.

3. Main hydraulic components: Rexroth applied for high-pressure reversing-face valve selected from Rexroth.

(6) Electrical system:

Motors:

(7) Die base

(8) Dimensions of die platen discharge hole: Φ300X380 Quincunx

Main cylinder

Main cylinder plunger: Φ1120mm

Slave cylinder: Φ250mmXΦ160mm Quantity: 2pcs

Stroke: 1700mm

(10) Container

(11) Shearing system

(12) Cooling system:

(13) Hydraulic operating oil (self-prepared by customer)

2. Structure

The extrusion press is composed of main cylinder components, die platen components and four heavy tie rods and four heavy prestressing pipe sleeves connecting these two parts, crosshead including extrusion stem and with sliding mechanism, container, billet loader, box-type die replacement device, shears including residual pressure knocking device and hydraulic units. The extrusion press is supported by the base in the welded steel structure.

(1) Prestressing equipment structure:

• Four heavy steel bushings apply 1.2 times of the pre-tensioning stress of the design tension of the tie rod between the die platen and main cylinder rack.
• The prestress design has the following advantages:
• The main tie rod is tensioned by the prestress within the range of the whole length, enables the movement of the die platen to the minimum level under the pre-tensioning stress by the prestressing pipe sleeves and makes the alignment precision deviation of the equipment to the minimum level under the extrusion force.
• After the die platen and main cylinder rack are tightly connected, the equipment structure becomes quite rigid and firm

(2) Main cylinder components:

• The main cylinder and side cylinder are respectively equipped with the suitable single-acting main cylinder. The V-shaped seal ring is used for the main cylinder as sealing and guiding for the tin bronze bushing. The spacer shim is applied between the seal ring cylinder and flange for adjustment to ensure the sealing precision.
• The back end of main cylinder is equipped with the prefill valve in mass flow to ensure that the working oil can freely flow into the main cylinder from the fuel tank during the fast shutdown of the primary plunger. Meanwhile, the main cylinder rack is equipped with four container cylinders.

(3) Die platen components and box-type die replacement device:

• The die platen is cast by35# steel with high quality, and the central part of the die platen has the discharge hole in the dimensions and shape meeting the largest production requirements to make the extruded products pass through.
• The hole is equipped with the die platen hard pad manufactured by hard steel to support the pressure applied in the die platen.
• The extrusion press is equipped with two die boxes, which are driven by double acing hydraulic cylinder. Sliding inside the die platen will realize the fast replacement of the die pre-installed, effectively reduce the shutdown time of loading and unloading during the replacement of die. If necessary, the sliding formwork hydraulic cylinder can also be used as shearing.

(4) Main crosshead and extrusion stem components

• The material of main walking beam is 35# forged steel. It is installed at the front end of the primary plunger and uses the main tie rod sleeve as the supporting and guiding for the X guide rail. It is used to balance the partial gravity of the primary plunger and driven by the main cylinder and side cylinder.
• The extrusion stem is firmly installed on the extrusion stem base at the front end of the crosshead by a clamping device with easy assembly and disassembly, and can moves horizontally from the left to the right to reserve space for the manipulator into it.

(5) Container components:

• The container components contain the container, thermal insulation base, resistance heater, etc.
• The thermal insulation base has X-shaped support and six points for guiding. The lower sliding spacer is guided within the whole stroke along the guide rail of the base in 2 directions, namely vertical and horizontal directions. The upper sliding spacer is guided by the wear plate contacting the upper prestressing pipe to make the thermal insulation base move stably.
• The thermal insulation base is driven by four thermal insulation base cylinders on the main cylinder rack, and equipped with the adjustable positioning bolts, and plays a role in regulating the alignment of the container support.
• The container is heated by the directly inserted resistance elements. These heating elements are distributed within the container out sleeve area and are automatically controlled in SSR to to keep the working temperature required for the container.
• At the same time, a locking device is provided to ensure the alignment precision of extrusion stem and container.

(6) Main shears:

• The vertical shears are installed inside the die platen and manufactured by #45 steel.
• The guiding part of the shears is the rectangular design, which will adjust the gap between the shear blade and die. Besides, the compensation for the wear of guiding plate will be realized through the adjustment for the block gap in use, to make the swing of the shearing stem to the minimum level during the shearing and maintain the best shearing effect for a long time. The residual pressure knocking device is installed on the main shear components and plays a role in knocking the residual pressure out from the shears.
• During the shearing, the die base is fixed by the locking device to ensure the shearing precision. Such locking device system is composed of longitudinal and transverse die assemblies.

(7) Billet loader:

• The billet loader is driven by servo motor and composed of gear wheels, gear racks, linear guide rail, encoder, etc. and moves in straight line under the fixation and support by the linear guide rail, to ensure that the aluminium ingot is fast and stably conveyed to the extrusion center line of the container with accurate positioning during the loading.
• In case of the changes in the aluminum ingot diameter and dimensions, the center of aluminum ingot can be conveniently adjusted to the center of container through adjusting the support location of the movable pulley.
• When the billet loader delivers the aluminium ingot to the center of the container, the aluminium ingot is pushed into the container by the extrusion stem.

(8) Hydraulic system:

• The hydraulic power for the operation of extrusion press: the main pump is provided by a German Rexroth A4VSO series high precision variable spit variable electro-hydraulic proportional valve control plunger piston pump and the auxiliary pump is provided by a Ke Da A4VSO variable displacement plunger pump.
• The oil throughput rate of the Primary oil-pressure pump is controlled by the Rexroth control system electronics, PLC central processor, main cylinder displacement sensor, etc.
• The Primary oil-pressure pump and the secondary oil-pressure pump are installed vertically behind the main cylinder through the vertical motor and connect the bottom of the fuel tank through the large drift diameter seamless steel tube, anti-shock stainless steel soft connection, switch valve, etc., to ensure that the oil suction end of the Primary oil-pressure pump maintains the role of positive oil pressure for a long time and will not generate such phenomena as empty suction or cavitation during the oil absorption damaging the oil pump and enable the oil pump to generate small noise with more stable working pressure and long service life. The vertical installation can save space for the oil pump motor unit and make the equipment more compact and beautiful.
• The logical valves like directional valve, pressure relief valve and safety valve are installed on the integrated oil-way valve station for use, so as to form the simple pipelines and prevent the oil leakage to the greatest extent. The logical valve is characterized by high pressure control, large flow and no impact.
• The sealed pump of container is used to maintain the sealing pressure inside the locking cylinder of container before and during the extrusion.
• All high-pressure pipelines are welded by seamless steel tubes and welding neck flanges, and the face-to-face flanges with O-rings are applied at the connected places or the deep thread connection is applied for connection. The incoming and outgoing oil pipes are installed with the anti-shock connections.
• The suction valve (butterfly valve) of the main cylinder is installed outside the fuel tank, and can be closed during the maintenance. There is no necessity to empty the hydraulic oil inside the fuel tank.

(9) Servo-driven energy saving systems

• Motor performance: servo motors and traditional frequency asynchronous motor comparison has the following advantages
• High mechanical efficiency of the motor, servo motor in any load efficiency can reach 95%, while the asynchronous motor generally only in the rated power near the efficiency can reach 85%, in deviation from the rated power conditions efficiency will drop sharply.
• No-load current is small, the servo motor no-load current is almost 0, while the no-load current of the stepper motor is generally 40% or more of the rated motor current.
• Short acceleration time, servo motor full load acceleration to rated speed can reach 0.3 seconds at the fastest, the fastest acceleration time in the case of no-load stepper motor are more than 6 seconds, with load starting time is longer. And the rapid starting current of the stepper motor is particularly high, and the impact on the power grid is very large.

Energy saving principle:

• Servo motor using its variable speed, torque, fast response time and other advantages, according to the actual requirements of the extruder press power conditions, through the control of motor speed and hydraulic oil pump to achieve the best working conditions of displacement and energy-saving control as required. Effectively reduce the power loss of the machine operation without work.
• Combination of start and stop: The servo motor works quickly and powerfully, and the control is precise and stable. When there is no control signal for the equipment (e.g. die change, profile quality inspection and monitoring, stopping midway for minor repairs, etc.), the motor can automatically start and stop quickly. The energy-saving effect can be achieved without affecting the speed of the machine.

Energy-saving effect:

• Under normal working conditions, the servo motor drive can save energy by about 15%-25% compared with the traditional asynchronous motor drive. If the production of carbide or special industrial profiles that require a slower extrusion speed, the energy saving effect will be even more obvious, even up to 40%, and the extrusion speed will be more stable, which will guarantee the quality of the products.

Drive servo motor cooling system:

• The machine adopts our unique closed-loop liquid-cooled cooling system.
• The system is composed of a special water-cooled servo motor, circulating water pump, professional refrigerator, special coolant and temperature control system. The advantages of this system: 1. to ensure that the temperature of the torque motor is guaranteed to be below 40 degrees, to avoid the demagnetization of the motor stator caused by the high working temperature of the motor, which will affect the service life of the motor and the energy-saving effect.
• The use of special coolant to ensure better heat exchange, not easy to volatilize, long-term use will not produce scale or oil scale in the motor waterway leading to permanent damage to the motor.
• The design effectively improves the traditional high-power servo motor heat dissipation problems and the traditional oil-cooled high-power servo motor for a long time after the use of oil scale affects the motor heat dissipation effect of the drawbacks. Greatly improve the service life of the motor and give full play to the energy-saving effect of the servo motor.

3. Operation

(1) Extrusion circulation

For the control of the extrusion press, the repeated full-automatic circulation or semi-continuous automatic circulation is allowed.

The extrusion press will realize the following circulating actions:

Circulating action based on the control mode selection

a. Manual

b. Single circulating automation (from the container forward)

c. Full automatic (continuous circulating)

(2) Extrusion speed

• The extrusion speed can be regulated to the maximum speed value from the zero stepless speed by the pre-set device on the operation cabinet. In the full-automatic circulation, the extrusion speed can be controlled by program so as to determine the filling speed, extrusion speed and speed reduction ratio.
• Constant speed and segment speed selection operation (constant speed control system: closed loop control consisting of speed sensor, pressure sensor, CNC processor and touch screen, etc., extrusion speed and filling pressure are conveniently preset and displayed from the operating screen).
• Non-extrusion time: no more than 23 seconds at 50 Hz in no-load cycle operation.

(3) Temperature control of container

• According to the signal detected by the thermocouple, the thyristor power controller, according to the preset temperature value, inputs the appropriate electrical energy into the heater to control the heating temperature of the container. This ensures a balanced temperature balance between the front and rear of the container, prevents over-temperature heating and extends the life of the container.

(4) Safety control

• The extrusion press is controlled by the interlocking device to prevent the equipment damage possibly due to the mis-operation. For example, only after the billet loader is returned to the safe position, the primary plunger will run forwards.
• The main oil cylinder, auxiliary oil cylinder and container cylinder are equipped with pressure sensors to detect the working pressure of each cylinder for safety protection, interlock control and over-pressure limit protection, which are displayed on the console screen.
• The oil tank is equipped with an electric contact level meter and a thermometer to detect the level of the hydraulic oil and the oil temperature respectively, which will promptly alarm and stop when the liquid level exceeds the limit or the oil temperature exceeds the preset upper limit.
• The operating cabinet is equipped with an emergency stop button to terminate the extruder at any time.

(5) Video monitoring

• The extruder press is equipped with a real time monitoring camera, with two high temperature resistant cameras monitoring the position of the front beam outlet and the container cylinder inlet respectively, and displaying them on the monitor screen of the operator's console, making it easy for the start-up personnel to observe its working status.