Date: August 27, 2024
Customer Name: Umasree Texplast Pvt Ltd.
Service Location: 728/1, Village Moti Bhuyan, Taluka, Khatraj Kalol Rd, Kalol, Gujarat 382721
Technician Name: A J SHETTY
1. Service Overview
Machine Details:
- Machine Type: Tape Extrusion Line
- Model Number:- Lorex-E135SB.1600HS
- Service Type: Preventive Maintenance and Performance Optimization
Machine Technical Specification:
a. Line Speed 450 MPM
b. Screw RPM 50 RPM (It starts AMP fluctuation/ Denier)
c. Holding MPM 41 MPM
d. No Of Tapes 192 NOS
e. Tape Width 3 MM
f. Spacer 7 MM
g. Die Width 1600 MM
h. Denier 780
i. Approximately Production /Day 6Tons-6.5 Tons
2. Machine Performance
Before Service:
- Issue: Trim cutter Limit switch was not fitted with the machine. In a tape extrusion line, a trim cutter is used to remove excess material, known as "trim," from the edges of the extruded tape or film. This trimming process ensures that the final product has the desired width and quality. The trim material is usually waste and can be recycled back into the process or discarded.
Placement of the Trim Cutter:
The trim cutter is typically placed after the die where the tape or film has been extruded and just before the tape or film enters the cooling section or the wind-up unit.
It is positioned precisely to cut off the excess material from the edges of the tape or film, ensuring that the final product maintains a uniform width and meets the required specifications.
After Service:
- Outcome: Application of the Trim Cutter Limit Switch
Purpose: The trim cutter limit switch is a crucial component in the tape extrusion line, primarily serving as a safety and control device. It ensures that the trim cutter operates correctly and only when necessary.
Operation: The limit switch is mechanically actuated by the movement of the trim cutter. When the cutter moves into its cutting position, the limit switch is triggered, sending a signal to the control system.
- Performance Metrics: There are three points which are mentioned below.
Safety: The limit switch can act as a safety interlock, preventing the cutter from operating unless it is in the correct position. This helps to avoid damage to the machinery or the product and ensures operator safety.
Automation: The limit switch can also be part of an automated control system. For instance, it can signal the system to adjust the speed of the cutter or to start/stop the cutting operation based on the position of the cutter or the presence of the material.
Quality Control: By ensuring that the trim cutter is activated only when necessary, the limit switch helps maintain consistent product quality by preventing over-trimming or under-trimming.
Before Service:
- Issue: Blower was not working properly. It was not cooling Steam.
Application:
· The blower in a tape extrusion line is used primarily for cooling purposes. It directs a stream of air onto the extruded tape or film to rapidly cool it down after it exits the die. This cooling process is crucial for solidifying the material and setting its final properties, such as thickness and strength.
Placement:
· The blower is typically placed immediately after the extrusion die and before the tape or film enters the winding or further processing sections. The exact placement ensures that the extruded material is cooled uniformly and quickly, preventing deformation or defects.
After Service:
- Outcome: We cleaned the blower properly. Because of which the dust comes out of the blower.
Importance of Cleaning:
· Performance: Over time, the blower can accumulate dust, debris, or residue from the extrusion process, which can reduce its efficiency. A dirty blower may not provide adequate airflow, leading to uneven cooling and potential defects in the final product.
· Energy Efficiency: A clogged or dirty blower has to work harder to move air, which increases energy consumption and operational costs.
· Longevity: Regular cleaning extends the blower's lifespan by preventing the buildup of materials that can cause wear and tear or lead to mechanical failures.
· Safety: In some cases, accumulated material in the blower can pose a fire hazard, especially in high-temperature environments.
3. Changes and Work Completed
Diagnostics and Initial Assessment:
Adjustments and Repairs:
- Spindle Recalibration:
- Tool Calibration:
- Firmware Update:
- Component Replacement:
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