In developing control systems, FACTS monitors and controls various parameters in the extrusion process. Below is a starter list. Extrusion Control Points Blending ratios of multiple ingredients Extruder throughput in lbs/hour or lbs/ft Extruder barrel temperature zones – These are usually have heating & cooling Tooling temperature zones – These are usually heat only Die temperature zones – These are usually... --more
The control system is an integral part of the extrusion machinery and extrusion process. It has a very large impact on the productivity, quality, uniformity, and cost per production unit for the extruder and overall extrusion process. This post answers what benefits a computer has over operator/discrete controls. –more Read More →
The following relates to fabric calenders, both textile and steel cord only. Localized cord disturbance in cord distribution does not usually affect fabric weight, whereas overall cord distribution problems can affect fabric weight, sheet gauge, and quality. –more Read More →
A consistent feed to the calender will substantially reduce gauge variations. Consistent, uniform, dwell times on the break down and feed mills, as well as consistent bank size, will result in consistent stock temperatures, work history, and reduced variations in roll separating forces. The stock temperatures, bank sizes, and work history all directly influence roll-separating forces. Minimizing variations in these 3... --more
When the calender is running there are forces generated that try to separate the rolls. These separating forces are proportional to calender speed, although the relationship is not linear. The hardness of the rubber stock and bank temperature determines the magnitude of separating forces. The thickness of the gum wall being calendered also affects the separating force, with thinner gum walls generating larger separating... --more
Increase the temperature by 20 to 40 degrees F when the rolls are stopped to maintain a more uniform roll surface temperature. The TCU (Temperature Control Unit) controls the temperature of the water exiting the calender not the roll surface temperature. This is an important distinction. When the calender is not actively processing rubber, i.e. during warm-up and when the calender is stopped, the roll surface is losing... --more
Severe thermal run-out can be introduced during warm-up of the calender if it is not kept running. Remember that the calender gap will be reduced as the rolls grow (get larger) as their temperature increases. Good practice is to open the calender at least 100 mils (0.10”) before starting to increase the roll temperature above ambient. Keeping the calender rolls turning during warm-up and cool down also eliminates the... --more
Keep the calender running – stops cause the rolls to become egg shaped and introduce significant gauge thickness variation. When the calender is stopped, roll heat loss is not uniform around the roll. Heat loss along the circumference near adjacent rolls is minimal while heat loss in other areas is much higher. This leads to different temperatures and therefore different degrees of roll expansion. A few degrees on a... --more
Force induced variations result from the way the calender is operated and from previous process steps such as feed mill operation compound consistency from mixing In rubber calendering, separating forces generated are quite high; typically 160,000 lbs to 300,000 lbs at each actuator for a 66 inch active roll face producing a 60-inch wide rubber sheet. Those forces literally stretch the calender frame. Variations in... --more
Electric screw actuators are the most common type of calender roll end positioning system. The screw and nut operate under very high loads and thus experience significant wear even with proper lubrication. As the actuators wear, back lash develops. As the back lash increases, the response to small changes or corrections deteriorates. Also with increased backlash the number of corrections required would increase, which... --more