Process Optimization Workshop

Transcription

1 Process Optimization Workshop Handling Equipment Panel Alessandro Guerrini, Turla Carsten Dede, OMAV David Jenista, Granco Clark, Inc. David Turnipseed, Belco Industries Raffaele D Andrea, Emmebi Chicago, Illinois October 25-26, 2016 Moderator: Mark Butterfield, Magnode

2 HANDLING EQUIPMENT PANEL DISCUSSION During the POW you will learn to "pay attention to the pennies, so the pounds (dollars) will look after themselves" The Handling equipment plays a significant role in this. Paying simple attention to proper billet lengths or proper runout lengths, prevents wasting time extruding profile lengths that will only be scrapped.

3 Q# 2 David J: Can you give us an overview of why the handling system is such a crucial part of a successful extrusion operation? Photos Courtesy of Granco Clark

4 Q# 3 (1 of 2) David J: What are the basic different types of handling system layouts? Photos Courtesy of Granco Clark

5 Q# 3 (2 of 2) David J: What are the basic different types of handling system layouts? Photo Courtesy of Granco Clark

6 Q# 4 Neil: Older systems use wood & carbon surfaces for the hot extrusions to run on. How can carbon marks on the extrusions be reduced? Graphite marking transfer onto the extrusion either in exit direction or transfer off runout Denting from both types of products, especially on walking beam transfer tables due to hard contact onto material with thin wall extrusions Ghosting marks from the difference in localized cooling rates when in contact with graphite or wood. Both wood and graphite do not dissipate heat from the extrusion compared to areas not in contact with the aluminum Scratches on the profiles due to the extremely hard surface versus the soft aluminum. Photo s Courtesy of Albarrie Canada

7 Q# 5 Neil: What is the difference between graphite & High Temperature felt? Graphite Retains the heat that is transfer to it when the profile come in contact with it Brittle thus breaks easily or cracks Dust created from constant wearing of the surface goes everywhere creating other issues within the plant Transfer to the hot profiles happens due to friction and wearing that causing quality issues for both painting and anodizing High Temperature Felts Are self cooling, therefore they cool down very quickly and dissipate heat easily Soft or harden types, do not crack or break under normal conditions Depending on the type of fiber used and density, some fiber can be pulled from the product No transfer to the hot profiles happens due to friction and wear

8 Q# 6 David J: Can you help the attendees understand some different types of systems to separate the extrusions horizontally and vertically, while properly supporting the extrusions? Photos Courtesy of Granco Clark

9 Q# 7 David J: Different alloys and tempers require different quench rates. How are these accomplished while avoiding undue profile distortion? Photo Courtesy of Granco Clark

10 Q# 8 David J: Some profiles have a mix of thick and slender components. How can quenches help to provide successful quenching on these types of shapes? Photo Courtesy of Granco Clark

11 Q# 9 David J: Is the same quench setting used throughout the length of a water quench unit? Photo Courtesy of Granco Clark

12 Q# 10 Alessandro: How can extruders reliably measure and record actual quench rates? Accurate diagnostics Accurate and repeatable cooling recipes Precise cooling simulation parameters Feedback with temperature control systems Photo Courtesy of Turla

13 Q# 11 (1 of 2) David J: What is a "progressive quench"? Photo Courtesy of Granco Clark

14 Q# 11 (2 of 2) Carsten: What is a "progressive quench"? Photo Courtesy of OMAV

15 Q# 12 Carsten: Can you describe a system where pullers can pass through the water quench and why this is a useful design? Photo Courtesy of OMAV

16 Q# 13 David T: Please describe how handling system designs can optimize yield by adjusting the minislat to the proper position. Adjustable Hot Saw Photo Courtesy of Belco Industries

17 Q# 14 (1 of 2) David T: Please discuss the various means to separate emerging extrusions into runout lengths. Manual Cut Vs. Hot Saw Cutting manually can be unsafe to the operator and can add cycle time to the process. Cutting automatically reduces operator exposure to the cutting process and can speed up the full extrusion cycle by becoming a total automatic cycle. Video Courtesy of Belco Industries

18 Q# 14 (2 of 2) David T: Please discuss the various means to separate emerging extrusions into runout lengths. Hot Shear Vs. Hot Saw Extrusion Hot Saw Does not close hollow profiles. More noise. Produces saw fine. Extrusion Hot Shear Quite No Chips Can pinch together hollows. Video Courtesy of Belco Industries

19 Q# 15 David T: What types of support materials have been used, and are currently recommended for the minislat area? Runout Slat Vs. Powered Roller Conveyor Powered Roller (High Temp. Covers) Gentle of extrusion profiles. No marks. Low maintenance. Slat Conveyor Graphite marks. High Maintenance. Hard surfaces. Video Courtesy of Belco Industries

20 Q# 16 David T: How do cable drive pullers work? How are they controlled? Single Puller Cable Puller Drive Photo Courtesy of Belco Industries

21 Q# 17 David T: What are the advantages of a chain drive puller? Dual Puller Chain Puller Drive Chain Dive Puller Advantages Higher pull forces available ( > 500 lb.) No slippage. Positive engagement between sprocket teeth and chain links. Longer distances of puller. Photo Courtesy of Belco Industries

22 Q# 18 David J: How does a linear motor puller work?

23 Q# 19 Carsten: What is an "all electric" puller? Movie Courtesy of OMAV

24 Q# 20 Alessandro: Pullers come in a variety of setups - single, double, alternating, handoff Benefits of double lateral puller Overhead air cooling system Important to balance overhead and bottom cooling. Both have to grant the same air speed This makes you get the best balanced cooling results. Photo Courtesy of Turla Lower overhead air cooling system 24

25 Q# 21 David T: Please describe the function of a single or double reciprocating puller. Single Puller Releases the extrusion during the press dead cycle. No handoff or hand over cycle. For welding died, Cutting takes place between the die and the saw. Puller dead cycle is at the same time as the press dead cycle. Single and Dual Pullers Dual Puller Maintains control of the extrusion billet to billet. Allows for cut cycle to take place on the weld mark and on the fly. Puller dead cycle does not have to be synchronized with the press dead cycle. Photo Courtesy of Belco Industries

26 Q# 22 Alessandro: How do double length runouts and double puller hand offs work? Working cycle: Puller #1 starts the extrusion. Press stops extrusion and loads new billet. Pller #1 stops with the press and then starts pulling when the press starts again. Hot saw and puller #2 get close to the cutting point. When extrusion stops, hot saw cuts. Puller #1 moves profile in-line with the stretcher head. Puller #2 takes new head and restart the extrusion Puller #1 rotates its head and returns to the hot mobile saw Photo Courtesy of Turla

27 Q# 23 Alessandro: Please describe the system where extrusions are always kept under tension? The Pinze System : the Turla-invented real no-man stretcher 24/24h which can be installed even years after a standard DPC Turla puller has been installed. - No profile released until stretcher - Adjustable tensionig - Stringer cooling on very light profiles Photo Courtesy of Turla

28 Q# 24 Carsten: What is a "three puller system with flying saw?" Movie Courtesy of OMAV

29 Q# 25 Carsten: Please discuss past and current runout table slat - roller systems. Pros and cons? Photo Courtesy of OMAV

30 Q# 26 David T: When are carbon slats a good choice for cooling tables?

31 Q# 27 Carsten: What are the advantages of using a timing belt on a cooling table? Photo Courtesy of OMAV

32 Q# 28 David T: What is the difference between walking beam and rectalinear beam cooling table systems - when would each be currently recommended? Cooling Table Traversing vs. Walking Beam Walking Beam Moves extrusion profiles across the cooling table using eccentric bearings producing a circular motion in small steps. Traversing Beam Moves extrusion profiles across the cooling table in a square wave motion in fixed increments. Videos Courtesy of Belco Industries

33 Q# 29 David T: What are the advantages of using a moving belt system on the cooling table? Cooling Table Belt System Handling Extrusions with Belts Fluid transfer of extrusion profiles across the handling system. No dragging or sliding of profiles required. New high tech fabrics allow for delicate transfer wile the extrusions are hot. Batching and transfer cycles performed wot better precision and efficiency. Maintain gaps while cooling for automatic stretching operation. ROLT w/ Belts Downstream All Belts Photo and Video Courtesy of Belco Industries

34 Q# 30 David J: Are there limitations for the use of high temperature belts on cooling tables? Wt/ft? What materials are used? Neil: Can high temperature felt be used everywhere on handling systems? Photo Courtesy of Granco Clark

35 Q# 31 (1 of 2) David J: Please describe the use of air quench systems in an extrusion operations and the different types. Photo Courtesy of Granco Clark

36 Q# 31 (2 of 2) David J: Please describe the use of air quench systems in an extrusion operations and the different types. Photo Courtesy of Granco Clark

37 Q# 32 David J: What temperature does the extrusion need to be at before stretching? Why? Photo Courtesy of Granco Clark

38 Q# 33 David J: How do you calculate the tonnage required on a stretching system? Photo Courtesy of Granco Clark

39 Q# 34 David J: When are de twisting jaws recommended and how do they work evenly along the length of the extrusion? Photo Courtesy of Granco Clark

40 Q# 35 David J: Please describe the different types of jaws on stretchers. Photo Courtesy of Granco Clark

41 Q# 36 David J: What is the advantage of controlled crush or "pre crushing" the ends of extrusions? Photo Courtesy of Granco Clark

42 Q# 37 Carsten: What other types of stretcher jaw/clamping systems exist? Photos Courtesy of OMAV

43 Q# 38 Carsten: Is there a safe and efficient way to internally support profiles during stretching? Stretcher Systems Automatic Mandrel Insertion Photo Courtesy of OMAV

44 Q# 39 David J: What is "prestretching" and how does it differ from stretching? Photo Courtesy of Granco Clark

45 Q# 40 Carsten: What can be done to prevent orange peel during stretching? Can equipment help prevent this defect? Photo Courtesy of OMAV

46 Q# 41 David J: What types of systems were used and are currently used on batching tables? How should a batching table be properly sized? Photo Courtesy of Granco Clark

47 Q#42 David T: What are different ways to advance extrusions toward the saw gauge? Saw Infeed Gravity Rollers with Belts Gravity rollers with wide grip belts. Photos Courtesy of Belco Industries Inc.

48 Q# 43 (1 of 2) Alessandro: What are the pros and cons of under and over table saws? Under table saws - Sturdier frame - Less deformation through the years - Better levelling of the machine - Better alignment of the blade - Better cut accuracy Magnified deformation with uneven floor and weak machine = BAD CUT RESULTS! Photo Courtesy of Turla

49 Q# 43 (2 of 2) Alessandro: What are the pros and cons of under and over table saws? Under-table saws - Better chip aspiration - Cut only what is needed.. - No hydraulics - No oil leackages - Easier maintenance - Full control (remote) of blade feed Photo Courtesy of Turla

50 Q# 44 Alessandro: Please discuss proper saw lubrication. Photo Courtesy of Turla

51 Q# 45 Alessandro: What are the latest thoughts on clamping before and after the finish saw? How can noise be controlled? The clamp is pneumatic controlled by a PROPORTIONAL VALVE so to control very precisely the pressure on the profiles and thus prevent damage. This screen raises only during manual operations. During automatic cycle is always lowered to protect the saw operator and dump noise Photo Courtesy of Turla

52 Q# 46 David T: How do different saw blade designs figure into the equation? How should they be maintained?

53 Q# 47 David T: What types of chip control are in use and what are the pros and cons? Photo Courtesy of

54 Q# 48 David T: What types of mechanized or automated systems can be used to handle front, back, weld and culled mill length scrap Automated Scrap Handling Extrusion Line Finish Saw Front end scrap cuts are automatically dumped and conveyed to scrapper hopper. Photo Courtesy of Belco Industries

55 Q# 49 Alessandro: Describe dual saw systems designed to both keep up with the press and provide the accuracy of cut required? - Double length with one cutting cycle - No more bottle-necks for long and short profiles Huge production advantages for fabrication and automotive extrusions Photo Courtesy of Turla

56 Q# 50 Alessandro: What is a "two saw" system? Does this differ from what we just discussed?? - Systems for different products type - Different accuracy required for different profiles - Particular logistic requirement Photo Courtesy of Turla

57 Q# 51 Alessandro: How does a saw infeed and saw gauge system work to accurately and efficiently cut material? Proper support of heavy and light profiles Ability to support heads and tails of extrusion Infeed speed control Multiple drives for flexible management of double lengths Photo Courtesy of Turla

58 Q# 52 Alessandro: Please describe the action and purpose of a "lifting saw gauge"? Lifting saw gauge Accurate measurement Lifting for profile evacuation Double length cut Chip cleaning Photo Courtesy of Turla

59 Q# 53 Alessandro: What are some considerations for air flow requirements in aging systems? Comb type baskets No deformation of lower layers Automatic stacking/de-stacking operations Better air flow at ageing Photo Courtesy of Turla

60 Q# 54 (1 of 2) Alessandro: Please describe how material is moved from the sawing station. From finishing saw to basket Finished profile friendly movement Management of multiple batches Batch re-sizing Infeed to scrap shear Photo Courtesy of Turla

61 Q# 54 (2 of 2) David J: Please describe how material is moved from the sawing station. Photo Courtesy of Granco Clark

62 Q# 55 David J: What types of mechanized assistance can be provided to manual stacking? Photo Courtesy of Granco Clark

63 Q# 56 (1 of 2) David J: Please describe how a gantry stacker works and its pros and cons Photo Courtesy of Granco Clark

64 Q# 56 (2 of 2) Alessandro: Please describe how a gantry stacker works and its pros and cons. Profile stacker Smooth movement Accurate management of spacers Possible combined solution for long profiles Comb stacking in racks Photo Courtesy of Turla

65 Q# 57 Carsten: Please describe how different types of stackers work and when to consider using it. Movie Courtesy of OMAV

66 Q# 58 Carsten: Please describe how a retracting belt stacker works and what types of profiles this is best suited for. Retracting belt Stacker (semi-auto stacker) * also video Stacking Systems Photo Courtesy of OMAV

67 Q# 59 Carsten: Are there other types of stackers? Fork style? Movie Courtesy of OMAV

68 Q# 60 Carsten: Please describe how robotics are currently used in stacking extrusions. Photo Courtesy of OMAV

69 ATTENDEE QUESTIONS