ZSK 70 Mc - K-Tron

Transcription

ZSK 70 Mc - K-Tron

Coperion_Omiya_Ktron_Seminar_20130423 I 2013-04-23 I Seite 1
Coperion High Efficiency Twin Screw Compounding
Technology
科倍隆高效的双螺杆配混技术
Speaker 演讲者:
Joanne Shen – Sales Director
沈君 – 销售总监
Coperion Nanjing Machinery Co., Ltd.
科倍隆南京机械有限公司
Contents 内容
1. Coperion - Company History 公司历史
2. Product Range - Compounding & Extrusion 配混系统产品范围
3. Coperion China – 15 Years Development 科倍隆中国的15年发展
4. Coperion Twin-screw Compounders and Effective Compounding
Technology 科倍隆双螺杆配混挤出机及其高效配混技术
5. Application 应用
6. Coperion Nanjing Quality Control 科倍隆南京质量控制
1. Coperion - Company History公司历史
Coperion
Werner & Pfleiderer
1879 Foundation of Werner &
Pfleiderer, manufacturing
of the first UK kneader
1953 License agreement with
BAYER for continuous
mixing and kneading
extruders (”Erdmenger
Patents”)
1957 Twin-screw compoun-der,
type ZSK for plastics
processing
2001
Coperion Waeschle
Coperion Keya
Coperion Hartmann
1900 Foundation mill
manufacturing
1993
Foundation of
Keya Corp.
1885
1935 Rationalization of
small mills
2003
Sales cooperation with
Coperion
Foundation of
Maschinenfabrik F.A.
Hartmann & Co
1980
1955 Bulk materials
processing in the plastics
industry
2004
Transformation to
Hartmann
Fördertechnik GmbH
2007
1998 Acquisition & integration
of the plastics operations
of Bühler AG
2005
Acquisition and
integration of
Hartmann to the
Coperion Group
Acquisition and
integration of Keya to
the Coperion Group
New production facility
in Nanjing, China
Merger to form the Coperion Group
2002
ZSK NT development
2004
ZSK MEGAcompounder
PLUS introduction
2007
ZSK MEGAvolume PLUS
introduction
2010
ZSK Mc18 introduction
2004
Start of production of
components at Coperion
Machinery & Systems,
Shanghai
2007/ Realization of the world‘s
2008 largest plants for
polyolefin production
2008
PELL-TEC
Weicom
2012
2012
Acquisition of majority
stake in PELL-TEC
Acquisition of majority
stake in Weicom
Brand consolidation / merger to form Coperion
Compounding & Extrusion
Materials Handling
Service
Hillenbrand, Inc.
(Hillenbrand Industries)
2007
Hillenbrand Industries
announces a plan for the
separation of Hill-Rom
and Batesville Casket into
two independent publicly
traded companies
2008
Hillenbrand, Inc. (parent
of Batesville Casket
Company) began
operation as a public
company traded on the
New York Stock
Exchange April 1, 2008
2009
2010
2011
2012
Facts and Figures
Key figures of Coperion 科倍隆集团
Compounding systems installed worldwide, over
已安装的挤出系统
10,000
Bulk materials handling systems installed worldwide, over
已安装的输送系统
8,000
Employees worldwide, over 员工数
1,700
Network of locations worldwide 全球分支机构
29
Three Competence Centers三个事业部
Clear structures for fast, efficient and reliable solutions – worldwide
compounding & extrusion
配混挤出
materials handling
物料输送
Service
全球服务
ZSK, STS and CTE – three
letters embody modern processing
machinery and plant design for
compounding technology. Our twinscrew compounders continually
set new standards in the plastics,
chemical and food processing
industries.
Hand in hand – we master all
process steps in the treatment and
handling of bulk materials. Quality is
our benchmark when conveying,
elutriating, homogenizing, storing,
dosing or thermally treating the
products.
Your success is our success –
already during installation and commissioning of a machine or plant a
service team is on-site. Maintenance,
spare parts service, service consulting,
training and modernization – we use
our experience and competence to the
advantage of our customers.
Coperion Worldwide 科倍隆在全球
Headquarters
Stuttgart, Germany
Competence Center
Compounding & Extrusion
Stuttgart, Germany
Materials Handling
Weingarten, Germany
Service
Stuttgart / Weingarten, Germany
Coperion companies and
offices
Agencies
Implemented Compounding and Extrusion Systems
已安装的配混挤出系统
Polyolefins 聚合烯烃
814
Engineering Plastics 工程塑料
4.350
Masterbatch 母料
1,160
Long Fiber Reinforced Plastics 长玻纤增强
36
Temperature- and Shear-Sensitive Plastics
(PVC, Cable, TPE) 温度和剪切敏感材料
1,659
Powder Coating, Toner 粉末涂料，炭粉
602
Direct Extrusion / Calender 直接挤出 / 压延
160
Chemical Reaction Technology 化学反应技术
543
Food Extrusion 食品挤出
270
Others 其他
766
Total
+ Coperion Nanjing科倍隆南京制造
10,360
+ 5,500
More than 25% of all compounding
and extrusion systems worldwide
were installed by Coperion
超过25％的全球已安装的的配混系
统来自科倍隆
Facts and Figures
Competence Center Compounding & Extrusion
配混挤出系统业绩
Over 130 years of experience with mixing and kneading processes
超过130年在配混挤出工艺的经验
Pioneering work and continuous development of the closely
intermeshing, co-rotating twin-screw extruder
啮合同向双螺杆挤出机的先驱和持续研发
Over 10,000 compounding systems installed worldwide
超过10,000套配混挤出系统在全球运转
Comprehensive product portfolio: from laboratory extruder
ZSK 18 MEGAlab to largest extruder ZSK 380 MEGAcompounder
全面的产品：从试验用18机型到最大380mm
Throughput rates from 1 kg/h to 100 t/h
产量从1公斤到100吨/小时
Turnkey compounding systems from raw material feeding to
downstream pelletizing and handling equipment
交钥匙工程：从原材料喂料到下游切粒和输送
Research & Development 技术研发
The most comprehensive test labs in the industry: in Stuttgart (D),
Ramsey (USA) and Nanjing (CN) 德国斯图加特，美国朗姆西和中国
南京均有试验室
30 compounding systems worldwide permanently available for testing
30条试验用配混挤出系统
Experience from 5,000 compounding tests and 40,000 product
analyses in our own laboratories
超过5,000次配混试验和40,000种物料分析
Simulation programs to calculate flow processes, optimize existing
processes and the design of individual components
融体流动、优化现有工艺和度身设计的模拟程序
Over 950 patents and patent applications since 1980
自1980年以来超过950项专利和专利申请
2. Product Range - Compounding & Extrusion 配混系统产品范围
ZSK series
STS series
CTE / CKY series
Product Range - Compounding & Extrusion 配混系统产品范围
Melt pumps
Screen pack changers
Pelletizers
Modular and turnkey plants
Product Range - Bulk Materials Plants for the Plastics Industry
产品范围 - 集成式物料混炼系统
Product Range - Materials Handling Components
产品范围 – 部件
Rotary valves
Diverter valves
Slide gate valves
Special components
Förderleitungskomp.
Piping
PELL-TEC Pelletizing Technology （A Coperion Company)
切粒机技术 PELL-TEC (科倍隆子公司）
Since January 2012 a Coperion company as a further consistent step
in strengthening Coperion‘s competence as a systems supplier
Specialized in pelletizing technology for plastics processing and
recycling
Technical solutions for entire pelletizing process from melt discharge
through to the ready-to-use pellets
Throughput rates of up to 6,000 kg/hr, for small and medium-size
extrusion systems
From planning and commissioning through to the after-sales supply
of spare parts
Packaging & Palletizing Technologies for Plastic Compounds
包装码垛设备（科倍隆子公司）
Plastics manufacturing
Plastics compounding
 The complete process chain from one single source
Coperion Service Product Portfolio 科倍隆服务产品
Competence Center Service
Service Consulting
-
Training
-
Training Academy
Maintenance training on site
Process training
Control training
Analyses
Engineering Studies
Repair/Resale
Pilot plant /laboratory
Safety concepts
Energy savings
Service
24h-Hotline
Maintenance Management
Modernization
-
-
Service Contracts
Barrel bore measurement
Screw change out service
Teleservice via modem
Spare parts store
Emergency parts management
Turnaround Management
Maintenance
-
General maintenance
Barrel refurbishment
Knife rotor refurbishing
Gearbox overhaul
Gearbox exchange program
Die plate refurbishing
-
Debottlenecking
Gear box replacement
Control modernization
Process optimization
- Feeder improvement
- Barrel extension etc.
State of the art solutions
Increase of availability
Customer product changes
Reduction of cleaning cycles
3. Coperion China 科倍隆中国
Development of Competence in China 在中国业务扩展
2012 Extension of components production portfolio (diverter valves)
Preparation for local production of MTS modules
Preparation for local production of filters
Further extension of production site and office (Shanghai)
Modernization of machining centres (Nanjing)
Staff: Shanghai 60, Nanjing 300
A3
A2
15 Years
Coperion China
科倍隆
在中国15年
Coperion Nanjing - Facts and Figures 科倍隆南京
Compounding systems installed worldwide, over
已安装挤出系统
Employees 公司员工
Employees Design Process Lab 设计部和工艺试验室员工
Employees Service 售后服务部员工
Rep offices in China 中国分支机构（广州，余姚，北京，成都）
5,500
300
16+6
38
4
Coperion Test Labs – Compounding and Extrusion.
科倍隆实验室 – 配混系统
Test Lab Stuttgart
Test Lab Ramsey
Test Lab Nanjing
2 x ZSK 26 Mc
1 x ZSK 25
1 x STS 50 advanced
1 x ZSK 32 Mcc PLUS / 34 Mvc
1 x ZSK 40 Mc
1 x ZSK 34 Mvc
1 x ZSK 58 Mc
1 x ZSK 40 Mcc PLUS / 43 Mv
1 x ZSK 58 SC
1 x ZSK 50 Mcc PLUS / 54 Mv
1 x ZSK 62 Mv
1 x ZSK 58 Mcc PLUS
1 x ZSK 70 Mcc
1 x ZSK 70 SC
1 x ZSK 76 Mv
1 x ZSK 90 / 92 Mc
2 x ZSK 18 Ml
1 x STS 35
Open in 2013.05
4. Coperion Twin-screw Compounders Compounding Technology
科倍隆双螺杆配混挤出机及其高效的配混技术
Taylormade
ZSK Mc18 and Mv PLUS
made in Germany
(for world market)
Standardized Twin-Screw / Two Stage STS
advanced assembled by Coperion Nanjing
(for world market)
CTE and CKY manufactured by Coperion Nanjing
(China + Asian market)
Md: 18
Md: 10
Md: 5.5
Design criteria of the ZSK
ZSK设计原理和世界专利
Do = Outer diameter
Di = Inner diameter
a = Centerline distance
Do / Di = Diameter ratio
determines shear, degassing and powder intake
Do
Md / a3 = Specific torque
determines power density and filling degree
Di
a
n = Screw speed
determines shear and mixing
Do / Di = 1,5 to 1,6
Md / a3 ≥ 11,0 Nm/cm3
n ≥ 800 min-1
ZSK – evolution of torque and volume 发展历程
ZSK Standard
Do / Di = 1,22
Md / a3 = 5,0 Nm/cm3
ZSK variable
Do / Di = 1,44
Md / a3 = 5,0 Nm/cm3
ZSK Supercompounder
Do / Di = 1,55
Md / a3 = 8,7 Nm/cm3
Increase of
free volume (100%)
and of specific torque
Increase of free volume
(additional 40%)
ZSK MEGAcompounder
Do / Di = 1,55
Md / a3 = 11,3 Nm/cm3
ZSK MEGAcompounder
PLUS
Do / Di = 1,55
Md / a3 = 13,5 Nm/cm3
ZSK Mc18
Do / Di = 1,55
Md / a3 = 18 Nm/cm3
ZSK MEGAvolume
Do / Di = 1,80
Md / a3 = 8,7 Nm/cm3
Increase of torque
ZSK MEGAvolume
PLUS
Do / Di = 1,80
Md / a3 = 11,3 Nm/cm3
Increase of torque
ZSK Mc18
配混挤出的最新里程碑
比扭矩18 Nm/cm3
Do/Di = 1.55
螺杆转速 1,200 rpm
ZSK Mc18 – 新功率密度 18 Nm/cm³
ZSK Mc18 – 新功率密度 18 Nm/cm³
产量显著提升
ZSK Mc18 – ZSK的剪切率
Barrel
barrel
h1
h2
h3
h4
400
剪切率 [1/s]
Da/Di=1,55
(Mc, Mc PLUS, Mc18)
300
v
200
Da/Di=1,22
(3-flighted)
Da/Di=1,44
(2-flighted)
h
Da/Di=1,55
(Sc)
Da/Di=1,80 (Mv, Mv PLUS)
.
.
gminimum = 0,9 gaverage
100
.
.
.
gmaximum = 30 gaverage
剪切率 g = 速度 v / 高度 h
0
0
300
600
900
螺杆转速
1200
1500
1800
ZSK Mc18 – 平均剪切率降低
低喂料量
Higher feed rate
高喂料量
螺杆转速恒定
筒体
筒体
Q2
Q2
Q1
Q1
h
screw
screw
剪切率 = f(speed / h)
剪切率 = f(speed / h)
Average value
SEI (kWh/kg)
Average value
Rate kg/h)
ZSK Mc18 – 新能量密度 18 Nm/cm³
能耗显著降低
ZSK Mc18 – 传动箱和花键套
科倍隆与制造商合作开发了最新的传动箱，以适用于
ZSK Mc18 高扭矩的需求
ZSK Mc18 – 最优的外内径比值 1.55
• 芯轴可以承受更高的扭矩，螺杆更耐磨
• 所有的机型的外内径比统一为1,55，保证不同机型之间
的准确工艺放大
自由容积
与扭矩之间的平衡
• 外内径比 1,55 保证了不同年代机型之间的准确放大
容积
扭矩
槽深
槽深与自由容积
以及可承受扭矩之间的关系
ZSK Mc18 – 优势概览
扭矩提升 30%
填充率高，平均剪切低，物料加工比较柔和，进而最终
产品品质提升
更宽操作窗口带来更大的工艺操作弹性
产量增加，在相同螺杆转速下，熔温降低
比能耗降低，能效提升
产量最高提升 30%
新的设计和发展保证设备安全运行
ZSK Mc18 – 新筒体保温隔热罩
•
新的筒体隔热罩包裹整个筒体 !
•
更有效节能
„尿不湿“ 保温，甚至是底部 !
ZSK Mc18 – 冷缩式安装的筒体进一步提升热传导
• 筒体修改
- 冷缩式安装的衬套
- 径向冷却水道，进一步减少热变形
- 无焊接工艺  减少加工制造中的故障率
- 完全的隔热保温
• 与现有设备的筒体可以进行互换
冷缩式安装的筒体衬套:
最优化的热传导
ZSK Mc18 – new barrel heating and cooling design
筒体加热冷却新设计
ZSK 70 Mc – former version
ZSK 70 Mc18 – new version
ZSK Mc18 – new barrel heating and cooling design
筒体加热冷却新设计
Cooling process: FE-Modell with 10s – impulse time frame conditions
10s – 1. Impulse
20s – 2. Impulse
30s – 3. Impulse
ZSK Mc18 – 新的筒体加热和冷却设计
加热工艺：3300s 后的温度分布
原 ZSK 70 – t = 3300 s
新 ZSK 70 – t = 3300 s
ZSK Mc18 – 新的筒体加热和冷却设计
加热部分节能高至 35%
能量需求 [kJ]
ZSK 70 Mc –
原设计
Mc18 –
节能 [%]
ZSK 70
新设计
加热 55 min
13,650
8,932
35
完全加热 80 min 后
15,680
10,582
33
保温 10 min
420
293
30
ZSK Mc18 – 机头
•
•
•
•
•
•
The die head for ZSK systems
features optimum flow geometry
优化流道设计
It ensures maximum throughputs
with gentle product handling
保证最大产能化及柔和处理物料
The quick-release device enables
fast, easy assembly and
disassembly
快速拆卸设计
ZSK Mc18 – 机头（SK70为例）
• Homogeneous
temperature distribution
• 温度分布均匀
• No local overheating
• 无局部过热
• No freezing of polymer
• 无熔体凝结
ZSK Mc18 – 防磨的模板
Hard metal inserts (carbide)
Wear protected border
Base material (standard material)
机头体
Lifetime extension by factor 100 for
glass filled polymers (GF > 30%wt)
玻纤增强（>30%重量比）使用寿命系
数增加100
ZSK Mc18 – twin screw side devolatilization unit (ZS-EG)
侧脱挥装置
•
Co-rotating twin screws to keep the product within
the processing zone and ensure a safe and constant
devolatilization 保持物料留在工艺段内，保证稳定脱
挥
•
deep flighted co-rotating twin screws that provide
high venting capacity 深槽设计，大脱挥能力
•
large free cross-sectional area of the flow channel
ensures low gas velocity 大截面设计，确保低气体
流速
ZSK Mc18 – Feed Enhancement Technology FET
Patented FET equipment, the product feed can be optimized so that drive power of the ZSK Mc18
is fully transferred into the process section – even when processing powder bulk materials.
•
•
•
•
Increases in throughput up to 300 % 喂料能力提高
Maximum productivity 生产力最大化
Maximum operating safety 操作安全最大化
Increased flexibility of the processing system
工艺灵活性提升
Working principle 工作原理
Air
FET insert
Vacuum
Effects:
• air is removed  higher bulk density
• friction is changed in the area of insert
Filter cake: densified powder
Working principle
Friction and higher bulk density
increase the conveying angle:
FET not active
Angle of conveying approx. 20°
FET active
Angle of conveying approx. 40°
Conveying angle
 capacity
Installation possibilities for FET 安装位置
In the feed section
of the ZSK
upstream of the
feeding point
In the feed section
of the ZSK
downstream of
feeding point
FET can only be used for
solids conveying!
ZSB
ZSK
In the side feeder
(ZSB)
STS Advanced 10Nm/cm3 产品特性
- Certified
Gear box 传动箱
(Flender/Siemens)
Optimized die head with
braker plate 优化的机头体和
Bibbygard safety
clutch (UK) 安全连轴器
（英国）
快开板式换网
Profile steel baseframe
型钢材质底座
SS hose with flexible
connection
STS side-feeder (core parts
from Coperion Stuttgart)
STS 专用侧喂料（核心部件来自德国
总部）
Wear and/or corrosion
protection for barrels and screw elements
螺纹元件和筒体的耐磨耐腐保护
Core Parts Manufactured by Coperion In-house.
核心部件 - 科倍隆制造
• Screw Shaft 能承载极扭矩的花键螺杆芯轴
• Screw Elements 螺纹元件
• Barrels 筒体
• Baseframes 机架
• Control Cabinets 电气控制柜
Construction Material. 螺纹元件、筒体材质
Construction Material STS Advanced
Material
code
Elements
螺纹元件
Barrels
筒体
Material 材质
Design
Wear Protection Corrosion Protection
耐磨保护
耐腐保护
CE00
CE50
CE71
CE150
Nitrided steel
High-speed Tool steel
PM Chromium steel
PM composite material
surface hardened
through hardened
composite material
composite material
+
+++
++(+)
+++++
+
+
++
+
CB00
CB50
CB71
CB150
Nitrided steel
Bimetallic liner
Chromium steel
Cast chromium steel
surface hardened
2-piece bushings
Oval liner
Oval liner
+
+++
++(+)
++++
+
+
++
++
Mixing mechanism in compounding machines 挤出机的配混功能
Dispersive mixing
=
break up agglomerates
Distributive mixing
=
homogeneously place particles
Do
Dt
Dispersive mixing elements
Distributive mixing elements
Wide variety of screw elements for best material quality.
高质量和种类齐全的螺纹元件
Conveying elements 输送元件
Large
Pitch 大导程
Small
pitch 小导程
Undercut profile elements
缺角螺纹元件
Kneading elements 捏合元件
Left handed elements
左旋螺纹元件
Large
Short
Conveying & Kneading elements
输送及捏合元件
kneading disks kneading disks
厚捏合块
薄捏合块
Special elements 特殊元件
90 ° - blocks 45 ° - blocks
90°捏合块
45°捏合块
Optimum cooling system for barrels.筒体冷却系统的优化
- Bores for barrel cooling are located
as close as possible to processing bores
筒体内腔的冷却管路最大可能靠近内腔壁
- Minimum pressure drop due to special design
特殊设计确保冷却介质最小的压力降
- Optimized flow of cooling water
优化的冷却水流道
Electrical heating
shells
电加热板
Water
水道
HIP PM-bonded Steel CE 71 for Screw Elements
复合材料螺杆块
• For high torque and tension
适用于高扭矩应用
• Soft steel core, more toughness, less breakage
与芯轴接触部分软，强度高，不易崩碎
• Better wear protection
防磨性更好
• Better corrosion resistant
防腐性更好
• No gap, better heat transfer
无间隙，更好热交换
Standard Vent Ports.脱挥口设计
Form A
• Up turning screw is covered
• Intermeshing area is covered
Form B
• Up turning screw is covered
• Intermeshing area is covered
Form C
• Up turning screw partly covered
• Down turning screw is partly
covered
Polymer melt, which doesn’t
stick to screws (polyolefins)
STS / CTE : Form A & B
ZSK: For A, B & C
Polymer melt, which tends to
stick to screws (PA, PET)
Low viscous polymer melt
(degassing of solvents)
Copper Casting Heater. 铸铜加热器
• Connecting box is far away from heater
• Longer life
• Easier for maintance
• Better material standard
• Improved surface, better heat transfer
Optimized Barrel Support, with 3D Compensation 机筒支撑
old STS
new STS advanced
New Designed Baseframe. 机架新设计
-
steel profiles welded
closed box structure
calculated at Coperion Stuttgart
higher rigidity
higher stiffnes
Features of new diehead STS adv. 带加热棒的新STS机头
• Use of heater cartridges instead of heat
shells, temperature of die body can be
accurately controlled. The width of die
plate extended approximately 25% to
reach higher throughput. 加热棒的使用，
机头温控更精确。机头宽度增加25%，增
产成为可能。
• Optimized flow channel to have even
distribution of flow speed and
temperature for wide range of material.
流道优化，是的熔体流速和料温均匀一
致。
• Precise fixation and better sealing 精确
固定和更佳密封
• Easy operation 容易操作
STS advanced Side Feeders - Coperion Stuttgart Technology.
STS advanced 侧喂料机 – 技术来自科倍隆德国.
Side feeder technology
with high duty side-feeders
for incorporation of:
Feed stock from
loss-in-weight feeder
原料从失重秤喂入
高扭矩侧喂料用于喂入下列物料：
• Chopped glass fibers 短玻纤料
• Mineral fillers 矿物填料
• Additives 添加剂
Technology and core
parts come from
Coperion Stuttgart
• Polymer powder/pellets
技术和核心部件来自科倍隆斯图
加特
• Pigments 颜料
聚合物粉料/粒料
Australia
China
6
199
Hongkong
Number of STS Sold by Region 2004 – 2013.01
3
India
12
Japan
6
Korea
5
Malaysia
1
Others
8
Taiwan
2
Thailand
9
Vietnam
Indonesia
6
1
258
EUROPE / MIDDLE EAST
11%
12%
17%
Austria
8
Belgium
2
Egypt
Germany
60%
ASIA PACIFIC
EUROPE
NAFTA
Great Britain
6
Israel
2
Italy
7
Russia
5
Spain
7
Sweden
4
Turkey
3
UAE
8
Ukraine
1
Czekh
Total STS sold up to Jan. 2013: 408 units
1
67
NORTH/SOUTH AMERICA
Argentina
SOUTH AMERICA
1
12
Brazil
4
49
Canada
1
Colombia
1
Mexico
5
Peru
1
USA
22
83
STS Application Distribution
5%
5%
2%
17%
20%
Engineering plastics
Masterbatch
51%
Wood Plastic Comp
TPE
Recycling
Others
5. Application - Classification of polymers. 应用
PEEK
PAI LCP
PES PPS
PSU PVDF
PEI HT-PA
High performance
plastics
PC
PPE/mod
PMMA
Engineering
plastics
Bulk
polymers
PS; ABS; SAN
PVC
amorph
Heat distortion
temperature (HDT)
PBT/PET
PA
POM
150°
C
100°
C
PP
PE
semi-crystalline
Plant for production of filled and reinforced compounds. 填充增强配混
1
2
3
4
5
5
5
7
6
Polymer
Additivs
Filler
glass or filler
Alternative: glass or carbon
fibre rovings
6 ZS-B twin-screw side feeder
7 ZSK twin-screw compounder
8 Devolatilizing
9 Strand die head
10 Water bath
11 Air knife unit
12 Pelletizer
13 to bagging station
7
7
10
10
8
9
12
Reinforcing of PA 6 with glass. 尼龙 6 加玻纤
1
1 Polymer A + polymer B + additives
(premix, alternative separate feeders)
2 Chopped glass fibers
3 Chopped glass fibers (alternative to 2)
or fillers
4 Alternative: glass or carbon fiber rovings
5 ZS-B twin-screw side feeder
6 ZSK MEGAcompounder PLUS
7 Devolatilizing
8 Strand die head
9 Water bath
10 Air knife unit
11 Pelletizer
3
4
2
5
5
8
6
4
9
7
10
Alloying and Coloring 合金和着色
1
1
2
3
4
5
2
4
4
3
5
Polymer A
Polymer B
ZSK MEGAcompounder PLUS
Devolatilizing
Strand die head
Degassing Polymer Melts with Co-rotating Twin Screw
Extruders. 脱挥
Degassing of
monomers
Degassing of
low molecular
weight
components
Degassing of
reaction
components
solvents
Degassing of
polymer melt
Degassing of
moisture
Principle of degassing.
c1
c2
Separation of the gas from the polymer melt by diffusion. The gas, which is
incorporated in the melt has to come to the surface of the melt layer.
The diffusion is influenced by:
• residence time
• viscosity of the melt
• thickness of the melt layer
• renewal of the melt surface
• pressure difference
---> long degassing zone
---> low viscosity (= high temperature)
---> low fill factor of the screw (40%)
---> intensive mixing
---> vacuum
High Temperature Polymers. 高温材料
- Alloys for screw tips with higher strength at 450°C
- Higher heating power and surface temperature control of heaters
- Heat insulation shells
- Temperature sensor for 450°C
Plant for the production of wood plastic composites 木塑材料
2
1
9
3
8
5
4
5
5
6
7
12
14
13
1 Polymer
2 Additiv
3 Woodfiber
4 Twin screw extruder
5 Degassing
10
6 Start up valve
7 Water Ring Pelletizer
8 Dewatering
11 9 Pellet drying
10 Dryer
12 Pelletizing water tank
13 Pump
14 Heat exchanger
5. Coperion Nanjing Quality Control
Cross_Section.mpg
科倍隆南京质量控制
A. 进货质量检验 Quality Control Incoming Goods
A1 材料化学成分检测分析,确保原材料质量100%合格
Chemical elements test to ensure the raw material 100% qualified
Chemical elements test report
常用材料化学成分测试报告
Test Equipment
A. 进货质量检验 Quality Control Incoming Goods
A2 材料探伤 Material Crack Detection
通过超声波、磁粉、着色探伤方式对芯轴、齿轮轴、螺杆元件毛胚等进行缺陷检查
- 确保零件无裂纹
Ultrasonic scanning, magnetic inspection and permeation detection on key parts
shaft, gear and elements roughcast - no crack.
芯轴超声波探伤
Ultrasonic scanning
齿轮轴表面磁粉探伤
Magnetic inspection
焊缝着色探伤
Permeation detection
B. 过程质量控制 Production Quality Control
B1 热处理质量检验 Hardness test
表面硬度检测和硬度梯度检测，保证热处理表面和内在质量
Surface hardness and interior hardness grads test to ensure heat treatment quality
硬度及硬度梯度全自动化自动检测系统 Hardness test system
B. 过程质量控制 Production Quality Control
B2 三坐标仪测量控制加工精度 3D Measuring System to Ensure Precise Dimensions
严格控制筒体、箱体、花键套等关键部件加工精度
Strictly control manufacturing precision on Barrels, gearbox houses and screw
couplings by 3D Measuring System FARO
C. 装配质量控制 Assembling Quality Control
主机同轴度检查与控制 Concentricity Control
传动箱输出轴、螺杆和筒体“∞ ”孔三者同心轴控制在0.1mm内，保证螺杆平稳运转，减少
非正
常磨损，延长机筒、螺杆使用寿命
The coaxiality (concentricity ) along gearbox out-shaft, screw shaft and barrel 8 holes to be
controlled in less than 0.1mm, to ensure ensure smooth running of screw shaft, and reduce
abnormal abrasion and prolong using life of barrels and screws.
Thank you very much for your attention.
非常感谢。

ZSK 70 Mc - K-Tron

Transcription

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