FACTS Tech Blog

In developing control systems, FACTS monitors and controls various parameters in the extrusion process. Below is a starter list.

• Feed System
  • 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 heat only

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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.

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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 heat to the ambient and thus the TCU is actively heating the water loop. In this condition the roll surface temperature is between 10 degrees to 20 degrees F below the water temperature. Read 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 in turn causes increased wear.

In addition, most calenders still have fixed speed electric motors with mechanical brakes. The breaks particularly need periodic maintenance. Sticky brakes will adversely affect gauge control results.

Via Touchscreen

(2001FS system)

If the touchscreen is working well enough to navigate through the SubMenu, the calibration can be initiated here. If not, skip down below to see Keyboard instructions.

2. Select Submenu 1
3. Select System Service Menu
4. Enter password if needed.
5. Select Touch Screen Calibration

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1. Clean all debris from the Roller assembly wheels.
2. Clean all debris from the Gauging roll surface.
3. Put the gauges down on a bare roll.

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FACTS, Inc. control systems perform best with properly maintained rolls.

Calender rolls must be ground periodically to establish the proper profile.

The profile is selected so that the roll separating forces, which cause the rolls to bow apart in the center, are partially compensated for by grinding the center to a larger diameter. Read more…