Uz brzi napredak globalne industrijalizacije, potražnja za materijalima visokih performansi u automobilskoj industriji, električni i elektronski, izgradnja, medicinske i druge oblasti se povećavaju iz dana u dan. Inženjerske plastike, kao ključni materijal visokih performansi, postupno su zamijenili tradicionalne metalne materijale i općenito plastiku u mnogim scenarijima primjene zbog svojih odličnih mehaničkih svojstava, otpornost na toplotu, otpornost na koroziju, dimensional stability and processability. Twin-screw extrusion technology is the core processing technology of engineering plastic compounds, and the performance of extrusion equipment directly determines the quality, production efficiency and application effect of engineering plastic products.
We are committed to providing professional twin-screw extrusion solutions for engineering plastics processing, relying on our independently developed and manufactured HTS series extruders with high-torque gearboxes, which are specially designed for the processing characteristics and application needs of engineering plastics. This article will comprehensively elaborate on the performance characteristics, klasifikacija, processing difficulties of engineering plastics, the core role of twin-screw extrusion technology in engineering plastics processing, prednosti naših ekstrudera HTS serije i njihova ciljana adaptacija na inženjersku plastiku, kao i specifična područja primjene, tehnike obrade i uobičajene probleme i rješenja. Dopunom detaljnih tehničkih parametara, detalji obrade i slučajevi primjene u industriji, članak će biti obogaćen 3000-4000 riječi, pružanje sveobuhvatne i profesionalne reference za inženjerska preduzeća za preradu plastike, tehničara i relevantnih praktičara.
1. Pregled industrije inženjerske plastike i osnovne karakteristike performansi
1.1 Trenutna situacija i trend razvoja industrije inženjerske plastike
Inženjerska plastika se odnosi na klasu plastičnih materijala koji se mogu koristiti kao konstrukcijski materijali i podnose mehanička opterećenja u širokom temperaturnom rasponu. U poređenju sa opštom plastikom (kao što je polietilen PE, polipropilen PP, polivinil hlorid PVC), inženjerske plastike imaju odlične sveobuhvatne performanse, i može zadovoljiti oštre zahtjeve upotrebe u industrijskoj proizvodnji i proizvodnji vrhunskih proizvoda. Poslednjih godina, potaknut nadogradnjom nizvodnih industrija kao što je laka automobilska industrija, električna i elektronska inteligencija, i medicinski uređaji visoke klase, globalno tržište inženjerske plastike pokazalo je stalan i brz trend rasta.
Prema relevantnim industrijskim podacima, veličina globalnog tržišta inženjerske plastike je premašena 100 milijardi američkih dolara, i očekuje se da će održati složenu godišnju stopu rasta od 7%-10% u narednih pet godina. Među njima, Azijsko-pacifički region je najveće svjetsko tržište za proizvodnju i potrošnju inženjerske plastike, obračunava više od 55% udjela na svjetskom tržištu, uglavnom zbog brzog razvoja automobilizma, električne i elektronske industrije u Kini, Indije i drugih zemalja, as well as the continuous improvement of industrial supporting capacity and technological innovation level. Kina, as the world’s largest engineering plastics consumer and producer, has a huge market demand, and the annual output and consumption are growing at a double-digit rate, especially in the fields of new energy vehicles, 5G communications, and medical devices, the demand for high-performance engineering plastics is showing an explosive growth trend.
The development trend of the engineering plastics industry is mainly reflected in five aspects: prvo, visoke performanse i funkcionalnost. With the continuous improvement of use requirements in downstream fields, engineering plastics are developing towards higher heat resistance, higher strength, better wear resistance and special functions (such as flame retardancy, antistatik, antibacterial, radiation resistance), da se prilagodi surovim radnim okruženjem visoke temperature, visokog pritiska, korozija i zračenje; drugo, lagana i integrisana. U automobilskoj industriji, vazduhoplovstvo i druge oblasti, kako bi se postigli ciljevi uštede energije i smanjenja emisija, inženjerska plastika se sve više koristi za zamjenu metalnih materijala, a integracija dizajna proizvoda postaje sve veća i veća, što može smanjiti broj dijelova, pojednostaviti proizvodni proces i smanjiti troškove; treće, zaštita životne sredine i mogućnost reciklaže. Jačanjem globalne politike zaštite životne sredine i unapređenjem svesti o zaštiti životne sredine, razvoj i primjena inženjerske plastike koja se može reciklirati, biorazgradiva inženjerska plastika i ekološki prihvatljive tehnologije obrade postale su fokus industrije, smanjenje zagađenja okoliša uzrokovanog plastičnim otpadom; četvrto, inteligencija i preciznost opreme za obradu. Inženjerska plastika ima velike poteškoće u preradi i stroge zahtjeve kvaliteta, što postavlja veće zahtjeve za opremu za obradu. Inteligentan, precizni i efikasni ekstruderi s dva puža i automatske proizvodne linije postali su glavna struja industrije, realizacija praćenja u realnom vremenu, automatsko podešavanje parametara i prediktivno održavanje procesa obrade; peti, diverzifikacija oblasti primene. Inženjerska plastika se postupno širi od tradicionalnih automobila, električna i elektronska polja do nove energije, medicinski, vazduhoplovstvo, građevinarstvo i druga nova područja, otvaraju novi tržišni prostor.
Na ovoj pozadini, Tehnologija ekstruzije s dva vijka, kao osnovna tehnologija obrade inženjerskih plastičnih jedinjenja, has become the key to improving the competitiveness of engineering plastics enterprises. Engineering plastics are sensitive to overheating and hydrolytic degradation, and have high requirements on processing temperature, shear force, residence time and temperature control precision. Our HTS series extruders are specially designed for the processing characteristics of engineering plastics, with high torque, high speed, precise temperature control and excellent dispersibility, which can effectively solve the processing difficulties of engineering plastics and help enterprises achieve high-quality, efficient and stable production.
1.2 Core Performance Characteristics of Engineering Plastics
Compared with general plastics and metal materials, engineering plastics have unique comprehensive performance, which determines their wide application in various industrial fields. The core performance characteristics of engineering plastics are mainly reflected in the following five aspects, which also put forward special requirements for their processing technology and equipment:
1.2.1 Excellent Heat Resistance and Cold Resistance
Engineering plastics have a wide temperature adaptation range, which can maintain good mechanical properties (snagu, žilavost, tvrdoća) in both high and low temperature environments. U poređenju sa opštom plastikom, which usually lose their mechanical properties at 80-120℃, most engineering plastics can work stably at 100-250℃, and some special engineering plastics (such as PEEK, PI) can even work at temperatures above 300℃. U isto vreme, engineering plastics also have good cold resistance, which can maintain good toughness at low temperatures (below -40℃), and are not easy to brittle fracture. This performance makes engineering plastics suitable for use in harsh temperature environments, such as automotive engine parts (high temperature) and outdoor electrical equipment (low temperature).
The excellent heat resistance of engineering plastics is mainly due to their special molecular structure (such as aromatic rings, heterocyclic rings) and strong intermolecular forces, which makes them not easy to melt and decompose at high temperatures. Međutim, this also brings certain difficulties to processing: higher processing temperature is required to make them melt and plasticize, and precise temperature control is needed to avoid thermal decomposition.
1.2.2 Good Corrosion Resistance and Durability
Engineering plastics have excellent chemical stability and corrosion resistance, i nije lako nagrizati ih kiselinama, alkalije, soli, organski rastvarači i druge hemikalije. U poređenju sa metalnim materijalima, koji lako zarđaju i korodiraju, inženjerske plastike imaju duži vijek trajanja u teškim hemijskim okruženjima. Na primjer, poliamid (PA) inženjerske plastike su otporne na većinu organskih rastvarača i slabih kiselina i lužina; polikarbonat (PC) inženjerske plastike su otporne na koroziju neoksidirajućim kiselinama i solima; polifenilen sulfid (PPS) inženjerske plastike su otporne na koroziju od strane gotovo svih kemikalija osim jakih oksidirajućih kiselina.
Osim toga, inženjerske plastike imaju dobru otpornost na vremenske uvjete i starenje, i nije lako degradirati i stare pod dejstvom sunčeve svetlosti, kiša, kiseonik i drugi faktori okoline, što osigurava njihovu dugoročnu stabilnu upotrebu u vanjskim i teškim okruženjima. Ova izvedba čini inženjersku plastiku širokom upotrebom u hemijskoj opremi, vanjska električna oprema, automobilski vanjski dijelovi i druga polja.
1.2.3 Jednostavna obrada i visoka proizvodna efikasnost
U poređenju sa metalnim materijalima, inženjerska plastika ima prednosti lake obrade, jednostavan proizvodni proces i visoka proizvodna efikasnost. Metalni materijali obično zahtijevaju složene postupke obrade kao što je kovanje, livenje, mašinska obrada, koji imaju veliku potrošnju energije, niska efikasnost i visoka cijena; dok se inženjerska plastika može prerađivati ekstruzijom, brizganje, puhanje i druge metode, koji mogu da realizuju masovnu proizvodnju, pojednostaviti proizvodni proces, smanjiti potrošnju energije i troškove proizvodnje. Na primjer, ciklus obrade inženjerskog plastičnog automobilskog dijela brizganjem je samo nekoliko sekundi do desetina sekundi, while the processing cycle of the same metal part may take several hours to several days.
Međutim, engineering plastics also have certain processing difficulties: they are sensitive to overheating and hydrolytic degradation, and are easy to decompose if the processing temperature is too high or the residence time is too long; at the same time, some engineering plastics (such as PA) have high water absorption, which affects the processing effect and product quality. Stoga, it is necessary to use professional processing equipment and scientific processing techniques to ensure the processing quality.
1.2.4 Excellent Dimensional Stability and Electrical Insulation
Engineering plastics have good dimensional stability, and the shrinkage rate is small (usually 0.3%-1.5%) during processing and use, which can ensure the dimensional accuracy of products and avoid deformation. This performance is particularly important for high-precision parts, such as electrical connectors, automotive precision components, medicinskih uređaja, etc. The good dimensional stability of engineering plastics is mainly due to their high crystallinity, low water absorption (except for some varieties such as PA) and strong intermolecular forces.
Osim toga, most engineering plastics have excellent electrical insulation performance, which can maintain good insulation performance in a wide temperature range and frequency range, and are not easy to conduct electricity and arc. This makes engineering plastics widely used in electrical and electronic fields, such as wiring boards, cable ties, connectors, relays, motors and other electrical components.
1.2.5 Light Weight and High Specific Strength, Outstanding Wear Resistance
Engineering plastics have the characteristics of light weight (density is 1/3-1/5 of metal materials) and high specific strength (strength per unit weight is equivalent to or even higher than that of metal materials). Na primjer, the specific strength of glass fiber reinforced polyamide (PA66+GF30) is higher than that of ordinary carbon steel, which can effectively reduce the weight of products while ensuring the mechanical performance. This performance is particularly important in the automotive, aerospace and other fields that pursue lightweight and energy saving, which can reduce fuel consumption and carbon emissions.
U isto vreme, engineering plastics also have outstanding wear resistance and friction resistance, and the friction coefficient is small, which can be used in the production of wear-resistant parts (such as gears, bearings, sliding blocks) without additional lubrication or with less lubrication, reducing the maintenance cost of products. Na primjer, polyoxymethylene (POM) engineering plastics have excellent wear resistance and are known as “plastic steel”, which is widely used in the production of automotive gears, electrical components and other wear-resistant parts.
1.3 Common Classification of Engineering Plastics
Engineering plastics can be divided into different types according to their chemical structure, performance level and application field. The common classification methods are as follows, which helps to better understand the processing characteristics and application scenarios of different engineering plastics, and select appropriate extrusion equipment and processing techniques:
1.3.1 Classification by Performance Level
According to the performance level, engineering plastics can be divided into general engineering plastics and special engineering plastics.
- General Engineering Plastics: They are the most widely used engineering plastics, with relatively mature production technology, moderate price and good comprehensive performance. The main varieties include polyamide (PA), polikarbonat (PC), polyoxymethylene (POM), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), etc. General engineering plastics are mainly used in automotive, električni i elektronski, home appliances and other fields, kao što su automobilski dijelovi, electrical connectors, home appliance shells, etc.
- Special Engineering Plastics: They have more excellent performance (such as higher heat resistance, otpornost na koroziju, mechanical properties) than general engineering plastics, but the production technology is complex and the price is high. The main varieties include polyphenylene sulfide (PPS), polieter eter keton (PEEK), polyimide (PI), polysulfone (PSU), polyethersulfone (PES), etc. Specijalna inženjerska plastika se uglavnom koristi u vrhunskim oblastima kao što je vazduhoplovstvo, medicinskih uređaja, nova energija, i hemijsku opremu, kao što su vazduhoplovne komponente, medicinski implantati, električne komponente otporne na visoke temperature, etc.
1.3.2 Klasifikacija prema hemijskoj strukturi
Prema hemijskoj strukturi molekularnog lanca, Inženjerska plastika se može podijeliti na poliamid (PA), polikarbonat (PC), polyoxymethylene (POM), poliester (PET, PBT), polifenilen sulfid (PPS), polieter eter keton (PEEK), etc. Svaka vrsta inženjerske plastike ima svoje jedinstvene karakteristike performansi i zahtjeve obrade:
- poliamid (PA): Poznat i kao najlon, ima odličnu mehaničku čvrstoću, otpornost na habanje, žilavost i hemijsku otpornost, ali ima visoku apsorpciju vode, što utiče na dimenzionalnu stabilnost. Uobičajene sorte uključuju PA6, PA66, PA11, PA12, etc. Široko se koristi u automobilskim dijelovima (zupčanici, bearings, usisne grane), electrical connectors, tekstilna vlakna, etc.
- Polikarbonat (PC): Ima odličnu transparentnost, udarna čvrstoća, otpornost na toplinu i električnu izolaciju, ali ima slabu otpornost na habanje i lako se ogrebe. Široko se koristi u električnim i elektronskim poljima (ploče za ožičenje, poklopci lampi), automobilska polja (sočiva farova, instrument table), medicinske oblasti (medicinski kontejneri), etc.
- Polioksimetilen (POM): Ima odličnu otpornost na habanje, otpor trenja, stabilnost dimenzija i mehanička čvrstoća, i nije lako apsorbirati vodu. Poznato je kao “plastic steel” i široko se koristi u automobilskim dijelovima (zupčanici, sliding blocks), električne komponente (prekidači, bearings), mehanički dijelovi, etc.
- poliester (PET, PBT): PET ima odličnu transparentnost, otpornost na toplotu i mehaničku čvrstoću, i uglavnom se koristi u vlaknima, filmovi, flaše i druga polja; PBT ima odličnu hemijsku otpornost, električna izolacija i fluidnost obrade, i široko se koristi u električnim i elektronskim poljima (connectors, relays), automobilske dijelove, etc.
- Polifenilen sulfid (PPS): Ima odličnu otpornost na toplotu (temperatura dugotrajne upotrebe do 200-220℃), otpornost na koroziju, flame retardancy and electrical insulation, but has poor toughness. It is widely used in high-temperature resistant electrical components, automotive engine parts, chemical equipment, etc.
- Polyether Ether Ketone (PEEK): It has excellent comprehensive performance, long-term use temperature up to 250-300℃, good corrosion resistance, mechanical strength and biocompatibility. It is mainly used in high-end fields such as aerospace, medicinski implantati, and high-temperature resistant electrical components.
1.3.3 Klasifikacija prema području primjene
According to the application field, engineering plastics can be divided into automotive-grade engineering plastics, electrical-grade engineering plastics, medical-grade engineering plastics, aerospace-grade engineering plastics, etc. Different application fields have different requirements on the performance of engineering plastics. Na primjer, automotive-grade engineering plastics require good heat resistance, impact strength and weather resistance; electrical-grade engineering plastics require good electrical insulation and flame retardancy; medical-grade engineering plastics require good biocompatibility and sterility; aerospace-grade engineering plastics require good high-temperature resistance, low weight and high strength.
2. Core Processing Technology of Engineering Plastics: Twin-Screw Extrusion Technology
Engineering plastics processing mainly includes extrusion, brizganje, puhanje, molding and other methods, among which twin-screw extrusion technology is the core technology for the production of engineering plastic compounds (such as modified engineering plastics, reinforced engineering plastics) and semi-finished products (such as pipes, listovi, fibers). Compared with single-screw extrusion technology, twin-screw extrusion technology has the advantages of strong shearing force, good mixing effect, precizna kontrola temperature, kratko vrijeme zadržavanja i jaka prilagodljivost sirovinama, koji može efikasno riješiti poteškoće u preradi inženjerske plastike (kao što je osjetljivost na pregrijavanje i hidrolitičku degradaciju, loš efekat mešanja, niska efikasnost obrade) i osigurati kvalitetu inženjerskih plastičnih proizvoda.
2.1 Poteškoće u preradi inženjerske plastike i zahtjevi za ekstruzijsku opremu
Kao što je ranije spomenuto, inženjerske plastike imaju odlične sveobuhvatne performanse, ali je njihova poteškoća u preradi također veća nego kod opće plastike, uglavnom zbog njihove posebne molekularne strukture i karakteristika performansi. Glavne poteškoće obrade inženjerske plastike i odgovarajući zahtjevi za opremu za ekstruziju su sljedeći:
2.1.1 Osetljivost na pregrevanje i hidrolitičku degradaciju
Većina inženjerske plastike (such as PA, PBT, PPS) are sensitive to overheating and hydrolytic degradation. If the processing temperature is too high or the residence time in the extruder is too long, the molecular chain of the engineering plastic will break, resulting in thermal decomposition, which will reduce the mechanical properties, heat resistance and other performance of the product, and even cause discoloration, carbonization and other defects. Osim toga, some engineering plastics (such as PA) have high water absorption, and the moisture in the material will cause hydrolytic degradation during the high-temperature processing process, affecting the product quality.
This puts forward two key requirements for extrusion equipment: prvo, precise temperature control capacity, which can strictly control the processing temperature within the optimal range of engineering plastics, avoid local overheating, a preciznost kontrole temperature bi trebala doseći ±1℃; drugo, kratko vreme boravka, što može smanjiti vrijeme zadržavanja materijala u bačvi ekstrudera, izbjegavati termičku razgradnju i hidrolitičku degradaciju. Dvopužni ekstruderi imaju prednosti kratkog vremena zadržavanja (usually 1-5 minuta) i preciznu kontrolu temperature, koji su pogodniji za inženjersku preradu plastike od jednopužnih ekstrudera (vrijeme boravka 5-10 minuta).
2.1.2 Visoki zahtjevi za djelovanjem miješanja i dispergiranja
U inženjerskoj preradi plastike, često je potrebno dodati modifikatore (kao što su staklena vlakna, karbonska vlakna, talk, usporivači plamena, kompatibilizatori) za poboljšanje performansi proizvoda (kao što je ojačanje, kaljenje, usporivač plamena). Na primjer, dodavanje staklenih vlakana PA može poboljšati njegovu snagu i stabilnost dimenzija; dodavanje usporivača plamena u PBT može poboljšati njegovu otpornost na gorenje. The uniform mixing and dispersion of modifiers in the engineering plastic matrix is crucial to the performance of the final product. If the mixing and dispersing effect is poor, the modifiers will agglomerate, resulting in uneven performance of the product, and even reduce the mechanical properties of the product.
This requires the extrusion equipment to have strong shearing force and mixing capacity. Twin-screw extruders adopt intermeshing co-rotating or counter-rotating twin-screw structure, and the relative movement between the screws can generate strong shear force and kneading force, which can fully break the agglomerates of modifiers, make the modifiers uniformly dispersed in the engineering plastic matrix, and ensure the mixing and dispersing effect. Osim toga, the modular design of the twin-screw can freely combine different screw elements (such as conveying elements, elementi za mešanje, shearing elements) according to the type of engineering plastic and modifier, further improving the mixing and dispersing effect.
2.1.3 High Requirements on Wear Resistance of Equipment
In the processing of reinforced engineering plastics (such as glass fiber reinforced PA, carbon fiber reinforced PPS), the added glass fiber, carbon fiber and other modifiers have high hardness, which will cause serious wear to the screw and barrel of the extruder during the extrusion process. If the screw and barrel have poor wear resistance, they will be worn quickly, resulting in reduced shearing force and mixing capacity of the extruder, affecting the product quality and reducing the service life of the equipment.
This requires the screw and barrel of the extruder to be made of high-quality wear-resistant materials and processed by advanced manufacturing technology. Our HTS series extruders adopt imported wear-resistant alloy steel for the screw and barrel, and undergo bimetallic composite treatment or laser cladding treatment, which greatly improves the wear resistance and corrosion resistance of the screw and barrel, and can adapt to the processing of reinforced engineering plastics with high hardness modifiers.
2.1.4 High Requirements on Processing Fluidity and Pressure Control
Some engineering plastics (such as PPS, PEEK) have high viscosity and poor processing fluidity, which require the extruder to have strong conveying capacity and pressure control capacity to ensure the smooth progress of extrusion. Ako je kapacitet transporta nedovoljan ili je kontrola pritiska nestabilna, to će uzrokovati neravnomjernu brzinu ekstruzije, nestabilna veličina proizvoda, pa čak i blokada opreme.
Dvopužni ekstruderi imaju snažan transportni kapacitet i stabilan kapacitet kontrole pritiska. Spajanje dvostrukih vijaka može stvoriti jaku silu pumpanja, koji može efikasno prenijeti visokoviskozne inženjerske plastične materijale; at the same time, ekstruder je opremljen visoko preciznim senzorom pritiska, koji može pratiti pritisak ekstruzije u realnom vremenu i automatski podešavati brzinu zavrtnja i brzinu uvlačenja kako bi osigurao stabilnost pritiska ekstruzije i nesmetan napredak obrade.
2.2 Princip rada i tok procesa ekstruzije inženjerske plastike sa dva vijka
The twin-screw extrusion process of engineering plastics is a complex physical and chemical process, which involves the interaction of multiple factors such as temperature, pritisak, shear force and time. The core purpose is to melt and plasticize the engineering plastic raw materials and modifiers, mix them uniformly, and then extrude them into the required shape (such as particles, cijevi, listovi, fibers) through the die head. The specific working principle and process flow are as follows:
2.2.1 Raw Material Pretreatment
Raw material pretreatment is the foundation of engineering plastics extrusion processing, which directly affects the processing effect and product quality. The raw materials of engineering plastics mainly include engineering plastic resin (such as PA, PC, POM), modifiers (kao što su staklena vlakna, karbonska vlakna, talk, usporivači plamena), kompatibilizatori, lubricants and other additives. The pretreatment steps are as follows:
- Drying Treatment: Većina inženjerske plastike (such as PA, PBT, PPS) have high water absorption, a vlaga u sirovinama će uzrokovati hidrolitičku degradaciju tokom obrade na visokim temperaturama, što rezultira defektima proizvoda (kao što su mehurići, pukotine, smanjena mehanička svojstva). Stoga, sirovine se moraju osušiti prije obrade. Temperatura i vrijeme sušenja određuju se prema vrsti inženjerske plastike: na primjer, PA6 se suši na 80-100℃ for 4-6 sati, PA66 se suši na 100-120℃ for 6-8 sati, PBT se suši na 120-140℃ for 2-4 sati, PPS se suši na 150-160℃ for 3-5 sati. Sadržaj vlage u osušenim sirovinama treba kontrolisati u nastavku 0.1%-0.2%.
- Tretman prethodnog miješanja: Prema omjeru formule, osušena inženjerska plastična smola, modifikatori i aditivi se stavljaju u mikser velike brzine za prethodno mešanje. The purpose of premixing is to make the modifiers and additives uniformly adhere to the surface of the resin particles, improve the mixing effect during extrusion, and avoid local agglomeration of modifiers. The mixing speed is generally 800-1200 rpm, and the mixing time is 5-10 minuta. For some modifiers with poor compatibility (such as glass fiber and PA), a compatibilizer should be added during premixing to improve the compatibility between the modifier and the resin.
- Crushing and Sieving: For engineering plastic resins with large particle size or modifiers with uneven particle size (kao što su staklena vlakna), crushing and sieving treatment should be carried out to ensure the uniformity of raw materials and avoid affecting the mixing and dispersing effect during extrusion. The particle size of the crushed raw materials should be controlled at 20-40 mesh.
2.2.2 Feeding and Conveying
The premixed raw materials are sent to the feeding hopper of the twin-screw extruder through a screw feeder or a belt feeder. Uređaj za napajanje ekstrudera obično je opremljen funkcijom regulacije brzine pretvaranja frekvencije, which can adjust the feeding speed according to the screw speed and extrusion speed to ensure that the materials enter the extrusion cavity stably and uniformly, avoiding material accumulation or insufficient feeding. The feeding hopper is also equipped with a drying device to prevent the raw materials from absorbing moisture again during feeding.
2.2.3 Topljenje, Mixing and Shearing
Materijali koji ulaze u ekstruzijsku šupljinu dvopužnog ekstrudera kontinuirano se guraju naprijed pomoću rotirajućih vijaka. Šupljina za ekstruziju se sastoji od vijka i cijevi, a volumen ekstruzione šupljine postupno se smanjuje duž smjera ose. Kada se šrafovi okreću, materijali se postupno sabijaju pod djelovanjem vijaka i cijevi, a pritisak u ekstruzijskoj šupljini postepeno raste (generally 5-15MPa).
U isto vreme, materijali su izloženi jakoj sili smicanja i sili trenja koja nastaje relativnim kretanjem između vijaka i cijevi, kao i između vijčanih letvica. The shear force and friction force can fully break the agglomerates of modifiers, make the modifiers uniformly dispersed in the melted engineering plastic resin, and promote the fusion and compatibility between the modifier and the resin. Sila trenja također može stvoriti određenu količinu topline, koji je u kombinaciji sa vanjskim grijanjem cijevi (grijanje na struju ili parno grijanje) kako bi se inženjerska plastična smola postepeno otopila i plastificirala.
Cijev ekstrudera se obično dijeli na 4-6 sekcije za kontrolu temperature (odjeljak za hranjenje, sekcija za topljenje, dio za miješanje, homogenizujuća sekcija, presek glave matrice), a temperatura svake sekcije se precizno kontroliše prema vrsti inženjerske plastike. Na primjer, prilikom obrade PA66+GF30 (PA66 ojačan staklenim vlaknima), temperatura odjeljka za hranjenje je 120-140℃, dio topljenja je 250-260℃, dio za miješanje je 260-270℃, sekcija za homogenizaciju je 250-260℃, a presjek glave matrice je 240-250 ℃. Precizna kontrola temperature može osigurati da se smola potpuno otopi bez termičke razgradnje, a modifikatori su jednoliko dispergovani.
2.2.4 Ekstruzija i oblikovanje
Potpuno istopljen, mješoviti i dispergirani materijal guraju se na glavu ekstrudera pomoću vijaka. Glava matrice je dizajnirana prema obliku konačnog proizvoda: za proizvodnju inženjerskih plastičnih spojeva (granule), glava matrice je opremljena sa više kružnih otvora (broj i veličina otvora za kalupe određuju se prema veličini čestica granula); za proizvodnju cijevi, listovi, fibers, glava matrice je dizajnirana u odgovarajuće oblike (kao što je kružna matrica za cijevi, ravna matrica za listove).
Materijal se ekstrudira iz glave matrice velikom brzinom kako bi se formirali kontinuirani poluproizvodi (kao što su trake za granule, cijevi, listovi). Temperatura glave matrice je nešto niža od temperature sekcije za homogenizaciju, koji može spriječiti raspadanje materijala zbog previsoke temperature i osigurati efekat oblikovanja poluproizvoda. Brzina ekstruzije se kontrolira prema vrsti inženjerske plastike i obliku proizvoda, općenito u rasponu od 0,5-5m/min.
2.2.5 Hlađenje i učvršćivanje
The extruded semi-finished products are sent to a cooling device for rapid cooling and solidification. The cooling method is determined according to the shape of the product: for strips (granule production), water tank cooling is usually used, and the cooling water temperature is controlled at 20-30℃, and the cooling time is 2-5 minuta; for pipes and sheets, air cooling or water spray cooling is used, and the cooling speed should be controlled to avoid product deformation due to uneven cooling. Rapid cooling can make the semi-finished products solidify quickly, maintain the shape and size of the products, and improve the mechanical properties of the products.
2.2.6 Cutting and Post-Processing
After cooling and solidification, the semi-finished products are processed into the final product through cutting or other post-processing steps. For the production of engineering plastic compounds (granule), the cooled strips are sent to a granulator for cutting, and the granulator is equipped with a rotary knife, which can cut the strips into granular products with uniform size (veličina čestica je općenito 2-5 mm, koji se može prilagoditi potrebama kupaca). For the production of pipes and sheets, the cooled semi-finished products are cut into the required length through a cutting machine; for the production of fibers, the cooled filaments are drawn and wound to form fiber products.
Osim toga, the final product also needs to undergo post-processing steps such as screening, inspection and packaging. The screening step is to remove unqualified products (kao što je prevelika, premale ili aglomerirane čestice); the inspection step is to detect the performance (such as mechanical strength, otpornost na toplotu, tačnost dimenzija) proizvoda kako bi se osiguralo da ispunjava zahtjeve kupca; korak pakiranja je pakiranje kvalificiranog proizvoda na zatvoren način i na način otporan na vlagu kako bi se spriječilo da proizvod apsorbira vlagu i utječe na kvalitetu.
2.3 Ključni faktori koji utječu na učinak ekstruzije s dva vijka u inženjerskoj plastici
Učinak ekstruzije s dva vijka direktno utječe na kvalitetu i performanse inženjerskih plastičnih proizvoda. Mnogo je faktora koji utiču na efekat ekstruzije, uglavnom uključujući karakteristike sirovina, odnos formule, efekat premiksa, parametri ekstruzije i struktura glave matrice. Ovladavanje ovim ključnim faktorima i naučna prilagođavanja mogu osigurati stabilnost efekta ekstruzije i konzistentnost kvaliteta proizvoda.
2.3.1 Karakteristike sirovina
Tip, veličina čestica, sadržaj vlage i čistoća sirovina imaju veliki uticaj na efekat ekstruzije. Na primjer, veličina čestica inženjerske plastične smole i modifikatora treba da bude ujednačena; if the particle size is uneven, it will lead to uneven melting and mixing of materials. The moisture content of raw materials must be strictly controlled below 0.1%-0.2%; if the moisture content is too high, it will cause hydrolytic degradation of the material and bubbles in the product. The purity of raw materials is also very important; impurities in raw materials (such as metals, stones, dust) will not only affect the product quality, but also wear the screw and barrel of the extruder, and even cause equipment blockage.
2.3.2 Formula Ratio
The formula ratio of engineering plastic compounds (the ratio of resin, modifiers and additives) is the key to determining the performance of the product. The type and dosage of modifiers should be determined according to the performance requirements of the product. Na primjer, dodavanje 20%-40% of glass fiber to PA can significantly improve its strength and dimensional stability, but excessive glass fiber will reduce the toughness and processing fluidity of the product. The type and dosage of additives also need to be reasonably matched: compatibilizers can improve the compatibility between modifiers and resin, and the dosage is generally 0.5%-2%; lubricants can reduce the friction between materials and equipment, improve processing fluidity, and the dosage is generally 0.3%-1%; antioxidants can prevent the material from thermal oxidation degradation during processing, and the dosage is generally 0.1%-0.5%.
2.3.3 Premixing Effect
Premixing is the foundation of extrusion processing. The uniformity of premixing directly affects the mixing and dispersing effect of modifiers during extrusion. If the premixing is uneven, the modifiers cannot be uniformly adhered to the surface of the resin, resulting in local agglomeration of modifiers, uneven mixing of materials during extrusion, and reduced product performance. To ensure the premixing effect, it is necessary to control the mixing speed, mixing time and mixing temperature: the mixing speed is 800-1200 rpm, the mixing time is 5-10 minuta, and the mixing temperature is controlled at 40-60℃ (appropriate temperature can improve the adhesion of additives and promote uniform mixing).
2.3.4 Extrusion Parameters
Extrusion parameters are the most important factors affecting the extrusion effect, mainly including screw speed, extrusion temperature and extrusion pressure.
- Brzina zavrtnja: The screw speed of twin-screw extruders for engineering plastics generally ranges from 100 to 1000 rpm. Our HTS series extruders can reach a maximum speed of 1000 rpm. The higher the screw speed, the greater the shear force and friction force received by the materials, the better the mixing and dispersing effect of modifiers, and the higher the production efficiency. Međutim, if the screw speed is too high, the residence time of the materials in the extrusion cavity is too short, resulting in incomplete melting of the resin, insufficient mixing of materials, and uneven product quality; if the screw speed is too low, the shear force and friction force are insufficient, the modifiers cannot be fully dispersed, and the production efficiency is low. The screw speed should be adjusted according to the type of engineering plastic and the type of modifier: for high-viscosity engineering plastics (such as PPS, PEEK), a lower screw speed is needed to ensure sufficient melting and mixing; for reinforced engineering plastics (such as glass fiber reinforced PA), a higher screw speed is needed to ensure the uniform dispersion of glass fiber.
- Extrusion Temperature: The extrusion temperature is the key to ensuring the melting and plasticization of engineering plastics. The temperature of each section of the barrel and die head must be precisely controlled according to the type of engineering plastic. Temperatura odjeljka za hranjenje je niža (slightly higher than the drying temperature of the raw materials), što je uglavnom da bi se spriječilo zgrušavanje materijala i osiguralo nesmetano hranjenje; temperatura sekcije topljenja je srednja, which is mainly to promote the melting and plasticization of the resin; temperatura sekcije za miješanje je viša, što je uglavnom za poboljšanje efekta smicanja i miješanja, and promote the uniform dispersion of modifiers; temperatura sekcije za homogenizaciju je nešto niža od sekcije za miješanje, što je uglavnom za osiguranje ujednačene temperature i viskoznosti materijala, i izbjegavaju termičku razgradnju; temperatura preseka glave matrice je nešto niža od sekcije za homogenizaciju, which is to ensure the shaping effect of the semi-finished products. The temperature control precision should reach ±1℃ to avoid local overheating and thermal decomposition of the material.
- Pritisak ekstruzije: The extrusion pressure of engineering plastics twin-screw extrusion generally ranges from 5 to 15MPa. Pritisak u ekstruzijskoj šupljini uglavnom je određen omjerom kompresije vijka, veličina rupe i brzina zavrtnja. Što je veći pritisak ekstruzije, the better the mixing and dispersing effect of materials, and the denser the product. Međutim, ako je pritisak previsok, to će povećati potrošnju energije i trošenje opreme, pa čak i uzrokovati blokiranje glave matrice; ako je pritisak prenizak, materijali se ne mogu u potpunosti komprimirati i pomiješati, the product is loose, a performanse su nestabilne. The extrusion pressure should be adjusted according to the type of engineering plastic and the shape of the product: for high-viscosity materials and products with small die holes, a higher extrusion pressure is needed.
2.3.5 Struktura glave matrice
The die head structure mainly includes the shape, size and number of die holes, which directly affects the shaping effect and quality of the product. For the production of engineering plastic compounds (granule), the die head should be equipped with multiple uniform die holes, and the size of the die holes should be matched with the particle size of the product; for the production of pipes and sheets, glava matrice treba biti dizajnirana prema obliku i veličini proizvoda, a kanal protoka glave matrice treba da bude gladak kako bi se izbjeglo nakupljanje materijala i lokalno pregrijavanje. Glava matrice također treba biti opremljena uređajem za kontrolu temperature kako bi se osigurala ujednačena temperatura glave matrice i stabilno oblikovanje proizvoda.
3. Naši ekstruderi serije HTS: Profesionalna rješenja za inženjersku obradu plastike
Dugo smo se bavili istraživanjem, razvoj i proizvodnja dvopužnih ekstrudera visokih performansi, i stekli bogato iskustvo u oblasti inženjerske obrade plastike. Prema karakteristikama obrade inženjerske plastike (osjetljivost na pregrijavanje i hidrolitičku degradaciju, visoki zahtjevi za efektom miješanja i dispergiranja, visok viskozitet) i potrebe aplikacije, we have developed the HTS series twin-screw extruders specially for engineering plastics processing. Our HTS series extruders adopt high-torque gearboxes, with a specific torque of 14Nm/cm³ and a maximum speed of up to 1000rpm, which can obtain higher output, shorter residence time, better dispersibility and more precise temperature control, perfectly adapting to the processing needs of various engineering plastics.
3.1 Core Advantages of HTS Series Extruders for Engineering Plastics Processing
3.1.1 High Torque and High Speed, High Production Efficiency
Engineering plastics have high viscosity and poor processing fluidity, which require the extruder to have strong torque and conveying capacity. Our HTS series extruders adopt high-torque gearboxes independently developed and manufactured by us (HTS PLUS series and HTS SUPER series) ili uvezene od vodećih evropskih proizvođača (HTS BASIC serija), sa specifičnim obrtnim momentom od 14 Nm/cm³, koji je mnogo veći od običnih ekstrudera s dva puža (opšti obrtni moment je 8-12 Nm/cm³). Dizajn visokog obrtnog momenta osigurava da ekstruder može stabilno prenositi visokoviskozne inženjerske plastične materijale, izbjegavajte nakupljanje materijala i blokadu opreme, i poboljšati stabilnost procesa ekstruzije.
U isto vreme, ekstruderi serije HTS imaju dizajn velike brzine, sa maksimalnom brzinom do 1000 o/min. Velika brzina može stvoriti snažnu silu smicanja i silu miješanja, which can fully break the agglomerates of modifiers, čine modifikatore jednoliko dispergovanim u matrici smole, i poboljšati učinak miješanja i dispergiranja. Osim toga, dizajn velike brzine također uvelike poboljšava efikasnost proizvodnje: u poređenju sa običnim ekstruderima, efikasnost proizvodnje ekstrudera serije HTS može se povećati za 30%-50%, koji može zadovoljiti potrebe velike proizvodnje inženjerskih plastičnih preduzeća.
3.1.2 Kratko vrijeme boravka, Efikasno izbjegavanje termičke degradacije
Kao inženjerska plastika je osjetljiva na pregrijavanje i hidrolitičku degradaciju, vrijeme zadržavanja materijala u ekstruderu je ključno. Naši ekstruderi serije HTS imaju optimiziranu strukturu puža i dizajn cijevi, sa samo kratkim vremenom boravka 1-3 minuta, koji je mnogo kraći od običnih ekstrudera s dva puža (5-10 minuta) i jednopužni ekstruderi (10-15 minuta). Kratko vrijeme zadržavanja može učinkovito smanjiti vrijeme kontakta između materijala i visoke temperature, izbjegavati termičku razgradnju i hidrolitičku degradaciju materijala, i osigurati mehanička svojstva i otpornost proizvoda na toplinu.
Osim toga, puž ekstrudera HTS serije ima modularni dizajn, a različiti vijčani elementi mogu se slobodno kombinirati prema vrsti inženjerske plastike, što može dodatno prilagoditi vrijeme zadržavanja materijala, osiguravajući da različite vrste inženjerske plastike mogu postići optimalno vrijeme zadržavanja tokom obrade.
3.1.3 Precizna kontrola temperature, Stabilne performanse
Ekstruderi serije HTS imaju napredni inteligentni sistem kontrole temperature, koji može ostvariti preciznu kontrolu temperature svakog dijela cijevi i glave matrice. Preciznost kontrole temperature može doseći ±1℃, which can strictly control the processing temperature within the optimal range of engineering plastics, izbjegavajte lokalno pregrijavanje i termičku razgradnju materijala. Sistem kontrole temperature je opremljen funkcijom praćenja i alarma u realnom vremenu: if the temperature of any section exceeds the set range, the system will issue an alarm prompt in time, and even automatically adjust the heating power or shut down the equipment if necessary, to avoid equipment failure and product quality problems.
Osim toga, the barrel of the HTS series extruders adopts a double-layer jacket design, which can realize rapid heating and cooling, and improve the response speed of temperature control. The die head is also equipped with an independent temperature control device, which ensures the uniform temperature of the die head and the stable shaping of the product.
3.1.4 Excellent Mixing and Dispersing Effect
The HTS series extruders adopt an intermeshing co-rotating twin-screw structure, with a reasonable screw pitch, lead and compression ratio design. The intermeshing and rotating of the twin screws can generate strong shear force and kneading force, which can fully break the agglomerates of modifiers (kao što su staklena vlakna, karbonska vlakna, talk), make the modifiers uniformly dispersed in the engineering plastic resin matrix, and ensure the mixing and dispersing effect. The mixing uniformity of the HTS series extruders can reach more than 95%, koji je mnogo veći od običnih ekstrudera s dva puža (85%-90%).
The screw of the HTS series extruders adopts a modular design, and different types of screw elements (such as conveying elements, elementi za mešanje, shearing elements) can be freely combined according to the type of engineering plastic and modifier. Na primjer, when processing reinforced engineering plastics with glass fiber, more shearing elements can be configured to enhance the shearing effect and ensure the uniform dispersion of glass fiber; when processing engineering plastics with high viscosity (such as PPS), more mixing elements can be configured to improve the mixing effect and ensure the uniform viscosity of the material.
3.1.5 Visoka otpornost na habanje, Dug radni vek
In the processing of reinforced engineering plastics (such as glass fiber reinforced PA, carbon fiber reinforced PPS), dodani modifikatori imaju visoku tvrdoću, što će uzrokovati ozbiljno habanje zavrtnja i cijevi ekstrudera. Naši ekstruderi serije HTS usvajaju visokokvalitetne materijale otporne na habanje i naprednu proizvodnu tehnologiju kako bi osigurali otpornost na habanje osnovnih komponenti.
Puž i cijev ekstrudera serije HTS izrađeni su od uvezenog legiranog čelika otpornog na habanje (kao što je 38CrMoAlA), and undergo bimetallic composite treatment or laser cladding treatment. Površinska tvrdoća vijka i cijevi može doseći ≥65 HRC (HTS BASIC serija) i ≥70 HRC (HTS PLUS series and HTS SUPER series), koji ima izuzetno jaku otpornost na habanje i otpornost na koroziju, i može efikasno odoleti habanju uzrokovanom modifikatorima visoke tvrdoće. To uvelike produžuje vijek trajanja vijka i cijevi: vijek trajanja puža i cijevi ekstrudera HTS serije je 2-3 puta više od običnih ekstrudera, smanjenje učestalosti zamjene komponenti i troškova održavanja opreme.
Osim toga, također pružamo profesionalne usluge detekcije istrošenosti zavrtnja i cijevi. Naš tehnički tim će redovno detektovati stepen istrošenosti zavrtnja i cevi za kupce, izdati detaljan izvještaj o trošenju, i iznijeti ciljane prijedloge zamjene i održavanja, osiguravajući da kupci zamjenjuju komponente samo kada je to potrebno, izbjegavanje nepotrebnog otpada.
3.1.6 Širok raspon primjene, Jaka fleksibilnost
Ekstruderi serije HTS imaju širok raspon primjene, koji se može prilagoditi potrebama obrade raznih inženjerskih plastika, uključujući plastiku opšteg inženjeringa (PA, PC, POM, PET, PBT) i specijalne inženjerske plastike (PPS, PEEK, PSU, PES). Ekstruderi se također mogu prilagoditi preradi raznih modificiranih inženjerskih plastika, kao što je ojačana inženjerska plastika (ojačana staklenim vlaknima, ojačana karbonskim vlaknima), kaljene inženjerske plastike, inženjerske plastike otporne na plamen, antistatička inženjerska plastika, etc.
Modularni dizajn ekstrudera serije HTS (vijak, bure, die head, itd.) čini zamjenu komponenti praktičnijom i bržom. Kada kupci trebaju prilagoditi vrstu proizvoda (kao što je prelazak sa PA obrade na PPS obradu) ili izmijenite formulu, potrebno je samo zamijeniti odgovarajuće komponente, bez zamjene cjelokupne opreme, which reduces the cost of equipment transformation and improves the flexibility and adaptability of the equipment. Osim toga, the HTS series extruders can also be matched with different auxiliary equipment (such as high-speed mixers, dryers, coolers, granulators, screening machines, packaging machines) to form a complete automatic production line, realizing continuous production from raw material pretreatment to product packaging.
3.1.7 Intelligent Control, Easy Operation and Maintenance
The HTS series extruders adopt a PLC intelligent control system and a touch screen operation interface, which is simple and intuitive, easy to operate. The system can store multiple sets of product formulas and processing parameters. When customers produce different types of engineering plastics, oni samo trebaju pozvati odgovarajuću formulu i parametre, bez ponovnog otklanjanja grešaka, što štedi vrijeme i poboljšava efikasnost proizvodnje.
The system is also equipped with a real-time monitoring function, which can monitor the key parameters of the extrusion process (kao što je temperatura, pritisak, brzina zavrtnja, feeding speed) in real time, and record the production data (such as output, processing time) for later query and analysis. For the HTS SUPER series extruders, we also provide a cloud control function, which can realize remote parameter adjustment, production data monitoring and predictive maintenance of equipment, realizing intelligent production management.
Osim toga, the HTS series extruders adopt a reasonable structural design, which makes the maintenance more convenient. Šraf, bure, glava matrice i druge komponente mogu se brzo rastaviti i sastaviti, što smanjuje vrijeme održavanja i radni intenzitet. Naš tim za postprodajne usluge će pružiti profesionalnu instalaciju, usluge puštanja u rad i obuke za kupce, osiguravajući da kupci mogu nesmetano koristiti opremu.
3.2 HTS Series Extruder Product Types and Their Adaptation to Engineering Plastics
In order to meet the diverse processing needs of engineering plastics enterprises of different scales and product types, we have launched three main product types in the HTS series: HTS BASIC serija, HTS PLUS series and HTS SUPER series. Svaka serija ima svoje karakteristike i ciljane scenarije adaptacije, koje kupci mogu odabrati prema vlastitoj proizvodnoj skali, tip proizvoda, budžeta i drugih faktora.
3.2.1 Ekstruderi serije HTS BASIC: Fleksibilan i isplativ izbor za opštu inženjersku plastiku
Ekstruderi serije HTS BASIC su isplativa serija proizvoda dizajnirana za inženjering preduzeća za preradu plastike sa srednjim i malim proizvodnim skalama ili početnim ulaskom u industriju. Ova serija ekstrudera koristi mjenjače srednjeg obrtnog momenta vodećih europskih proizvođača, koje imaju prednosti stabilnih performansi, niska buka, visoka efikasnost i dug radni vek. Dizajn srednjeg obrtnog momenta (specifični obrtni moment 10-12Nm/cm³) može zadovoljiti potrebe obrade većine općih inženjerskih plastika (kao što je PA6, PA66, POM, PET, PBT) i nisko do srednje modifikovana inženjerska plastika (kao što je PA ojačan staklenim vlaknima sa količinom punjenja ≤30%).
U pogledu konstrukcijskog dizajna, ekstruderi serije HTS BASIC imaju paralelnu korotirajuću strukturu s dva vijka, sa prečnikom šrafa u rasponu od 30 mm do 65 mm, i omjer kompresije od 4～8, koji se može podesiti prema vrsti inženjerske plastike. Cijev je izrađena od legiranog čelika otpornog na habanje sa tretmanom nitriranja, a vijak je izrađen od legiranog čelika otpornog na habanje i koroziju, koji ima dobru otpornost na habanje. Ekstruder je opremljen PLC kontrolnim sistemom i interfejsom za rad sa ekranom osetljivim na dodir, koji može da realizuje automatsko hranjenje, automatska kontrola temperature, automatska kontrola pritiska i automatsko rezanje, i jednostavan je i lak za rukovanje.
Kapacitet proizvodnje ekstrudera serije HTS BASIC kreće se od 100 kg/h do 500 kg/h, which is suitable for medium and small-sized engineering plastics processing enterprises that mainly produce general engineering plastics and low-to-medium modified engineering plastics. Jedna od najvećih prednosti ove serije je da može pružiti fleksibilne opcije kroz različite kombinacije konfiguracije. Kupci mogu izabrati različite vijčane elemente, die heads, uređaji za hranjenje, uređaji za sušenje i oprema za naknadnu obradu prema vlastitim vrstama proizvoda, production capacity and budget, so as to form a production line suitable for their own needs. The HTS BASIC series extruders have a reasonable price, što može pomoći preduzećima da smanje početne troškove ulaganja.
3.2.2 HTS PLUS Series Extruders: High-Performance Choice for Engineering Plastics and Modified Products
The HTS PLUS series extruders adopt high-torque gearboxes independently developed and manufactured by us, sa specifičnim obrtnim momentom od 14 Nm/cm³, which has stronger torque and load-bearing capacity than the HTS BASIC series. This series of extruders is mainly designed for the processing of high-performance engineering plastics, high-modified engineering plastics and special engineering plastics (such as PPS), which is suitable for medium and large-scale engineering plastics processing enterprises that pursue high performance and high efficiency.
The HTS PLUS series extruders have a screw diameter ranging from 65mm to 110mm, a compression ratio of 5～10, and a screw speed range of 200～800 rpm. Vijak i cijev imaju bimetalni kompozitni tretman, koji ima veću otpornost na habanje i otpornost na koroziju (surface hardness ≥65 HRC), and can adapt to the processing of reinforced engineering plastics with high filling amount (such as glass fiber reinforced PA with filling amount 30%-50%, carbon fiber reinforced PPS) and high-hardness modifiers. The extruder is equipped with an advanced intelligent temperature control system and a high-precision pressure sensor, koji može ostvariti preciznu kontrolu parametara ekstruzije i praćenje proizvodnih podataka u realnom vremenu, ensuring the stability of the extrusion process and the quality of the product.
The production capacity of the HTS PLUS series extruders ranges from 500kg/h to 2000kg/h, which is suitable for the large-scale production of general engineering plastics, high-modified engineering plastics and special engineering plastics (such as PPS). This series of extruders has excellent mixing and dispersing effect, short residence time and high production efficiency, which can effectively solve the processing difficulties of high-viscosity and high-modified engineering plastics, and help enterprises improve product quality and production efficiency.
3.2.3 HTS SUPER Series Extruders: Top-End Choice for High-End Engineering Plastics
The HTS SUPER series extruders adopt the latest ultra-high torque transmission device independently developed by us, with a specific torque of 14Nm/cm³ and a maximum speed of up to 1000rpm. Aiming at the high torque and high speed characteristics of this series, the structural design of each key component of the extruder has been completely optimized, which is our highest-end extruder series, predstavlja napredni nivo razvoja kineskog ekstrudera. Ova serija ekstrudera je uglavnom dizajnirana za obradu vrhunske specijalne inženjerske plastike (such as PEEK, PI, PSU, PES) i modificirane inženjerske plastike visokih performansi (kao što je PEEK ojačan karbonskim vlaknima, PI ojačan staklenim vlaknima), koji je pogodan za velika preduzeća za preradu plastike visokog kvaliteta koja teže visokoj preciznosti, visoke performanse i inteligenciju.
Ekstruderi serije HTS SUPER imaju prečnik vijka u rasponu od 80 mm do 130 mm, omjer kompresije od 6～12, i raspon brzine zavrtnja od 250～1000 o/min. Vijak i cijev usvajaju uvezeni legirani čelik otporan na habanje i tehnologiju laserskog oblaganja, koji ima izuzetno visoku otpornost na habanje i koroziju (površinska tvrdoća ≥70 HRC), and can adapt to the processing of special engineering plastics with high temperature resistance, high viscosity and high-hardness modifiers. The extruder is equipped with an intelligent PLC + cloud touch screen control system, which can realize remote parameter adjustment, production data monitoring, predictive maintenance of equipment and data analysis, realizing intelligent production management.
Kapacitet proizvodnje ekstrudera serije HTS SUPER kreće se od 1000 kg/h do 3000 kg/h, which is suitable for the large-scale production of high-end special engineering plastics and high-performance modified engineering plastics. Ova serija ekstrudera ima prednosti visoke preciznosti, snažno prilagođavanje, multifunkcionalne i stabilne performanse, which can meet the most stringent processing requirements of high-end engineering plastics. The short residence time (1-2 minuta) and precise temperature control can effectively avoid the thermal decomposition of special engineering plastics, ensuring the excellent performance of the product. Osim toga, the HTS SUPER series extruders can also be customized according to the special processing needs of customers, providing personalized solutions.
3.3 Selection Suggestions for Engineering Plastics Extruders
When selecting twin-screw extruders for engineering plastics processing, preduzeća treba da sveobuhvatno sagledaju sopstvene proizvodne potrebe, vrste proizvoda, processing scale, budget and other factors to ensure that the selected equipment can meet the actual processing needs and bring maximum economic benefits. Slijede neki konkretni prijedlozi za odabir:
3.3.1 Determine the Extruder Series According to the Type of Engineering Plastics
Different types of engineering plastics have different processing requirements, which determine the selection of extruder series. For general engineering plastics (PA6, PA66, POM, PET, PBT) with low modification degree (filling amount ≤30%), the HTS BASIC series is sufficient to meet the processing needs. Its medium torque and flexible configuration can balance processing effect and cost, which is very suitable for small and medium-sized enterprises that just start to engage in engineering plastics processing or focus on general-purpose products. For high-modified engineering plastics (iznos punjenja 30%-50%, such as glass fiber reinforced PA, carbon fiber reinforced PBT) and special engineering plastics with moderate processing difficulty (such as PPS), the HTS PLUS series is the preferred choice. Its high torque of 14Nm/cm³ and excellent mixing and dispersing capacity can effectively solve the problem of uneven dispersion of high-content modifiers, and its wear-resistant screw and barrel can adapt to the wear of hard modifiers, ensuring stable production. For high-end special engineering plastics (PEEK, PI, PSU, PES) i modificirane inženjerske plastike visokih performansi (filling amount ≥50%, kao što je PEEK ojačan karbonskim vlaknima), the HTS SUPER series must be selected. Its ultra-high torque, maximum 1000rpm speed and fully optimized key structure can cope with the high viscosity, high temperature resistance and strict processing requirements of high-end materials, avoid thermal decomposition and material degradation, and ensure the high performance of the final product.
3.3.2 Determine the Screw Diameter and Production Capacity According to the Processing Scale
The screw diameter of the twin-screw extruder directly determines the production capacity, and enterprises need to select the appropriate screw diameter according to their own production scale and order demand. For small-scale production (100kg/h – 500kg/h), such as small-batch customization, product research and development or small orders, the HTS BASIC series with screw diameter of 30mm – 65mm is suitable; for medium-scale production (500kg/h – 2000kg/h), such as mass production of general modified engineering plastics, the HTS PLUS series with screw diameter of 65mm – 110mm can meet the demand; for large-scale production (1000kg/h – 3000kg/h), such as large-scale production of high-end special engineering plastics or large orders from downstream enterprises, the HTS SUPER series with screw diameter of 80mm – 130mm is the best choice. It should be noted that when selecting, enterprises should not blindly pursue large production capacity. They should also consider the fluctuation of order quantity. If the order quantity is unstable, they can choose equipment with adjustable speed and flexible production capacity (such as HTS BASIC series with frequency conversion speed regulation function) to avoid waste of equipment resources and energy.
3.3.3 Consider the Modification Demand and Mixing Effect
If the enterprise’s main products are modified engineering plastics, the mixing and dispersing effect of the extruder is the key factor to be considered. For products that need to add a variety of modifiers (such as flame retardants, kompatibilizatori, reinforcing agents) at the same time, it is necessary to select extruders with excellent mixing performance, such as HTS PLUS series and HTS SUPER series with modular mixing screw elements. These two series can freely combine conveying elements, mixing elements and shearing elements according to the type of modifier, adjust the mixing intensity and residence time, and ensure that various modifiers are uniformly dispersed in the resin matrix. Na primjer, when processing flame-retardant modified PBT, more mixing elements can be configured to ensure the uniform dispersion of flame retardants, avoid local flame retardancy insufficiency; when processing glass fiber reinforced PA, more shearing elements can be configured to break the agglomeration of glass fiber and improve the bonding force between glass fiber and resin. Osim toga, if the enterprise has the demand of multi-variety and small-batch modification, it is recommended to select the extruder with quick replacement of screw elements (such as the modular screw design of HTS series), which can reduce the time of equipment adjustment and improve production efficiency.
3.3.4 Consider the Cost Budget and Comprehensive Benefits
Cost budget is an important factor for enterprises to select equipment, but it is not advisable to pursue low cost blindly. It is necessary to balance the initial purchase cost, later maintenance cost, energy consumption and production efficiency to maximize the comprehensive benefits. The HTS BASIC series has the lowest initial purchase cost, low energy consumption and simple maintenance, which is suitable for enterprises with limited budget and small production scale; the HTS PLUS series has a moderate initial purchase cost, but its high production efficiency, long service life and stable processing effect can reduce the later maintenance cost and improve product qualification rate, which is suitable for medium and large-sized enterprises with certain budget and pursuit of high performance; the HTS SUPER series has the highest initial purchase cost, but it can process high-end products with high added value, and its intelligent control and long service life can reduce labor cost and maintenance cost in the later period, which is suitable for large-scale enterprises with sufficient budget and focus on high-end market. Osim toga, enterprises should also consider the after-sales service of the equipment. Our HTS series extruders provide a complete after-sales service system, uključujući instalaciju, puštanje u rad, technical training, regular maintenance and quick replacement of spare parts, which can reduce the later operation risk of enterprises.
3.3.5 Consider the Compatibility with Auxiliary Equipment
Twin-screw extrusion processing of engineering plastics needs to be matched with a series of auxiliary equipment, such as raw material drying equipment, high-speed mixer, cooler, granulator, screening machine, packaging machine, etc. When selecting the extruder, enterprises need to consider the compatibility between the extruder and auxiliary equipment to ensure the smooth operation of the entire production line. Our HTS series extruders can be perfectly matched with various standard auxiliary equipment, and can also be customized according to the enterprise’s existing auxiliary equipment to avoid the waste caused by the incompatibility between new equipment and old auxiliary equipment. Na primjer, if the enterprise already has a high-speed mixer with a mixing capacity of 500kg, it can select the HTS PLUS series extruder with a production capacity of 500kg/h – 800kg/h to match it, ensuring the coordination of raw material premixing and extrusion production.
4. Application Fields of Engineering Plastics and Matching HTS Series Extruder Solutions
Inženjerske plastike, with their excellent comprehensive performance, have been widely used in automotive, električni i elektronski, medicinski, vazduhoplovstvo, hemijski, construction and other fields. Different application fields have different requirements on the performance of engineering plastic products, which also puts forward different requirements on extrusion processing equipment. Ispod, we will elaborate on the application characteristics of engineering plastics in major fields and the matching HTS series extruder solutions, providing targeted reference for enterprises in different fields.
4.1 Automotive Field: Lightweight, High Temperature Resistance and Wear Resistance
With the development of automotive lightweight and energy-saving and emission-reduction, engineering plastics have become an important material for automotive parts, gradually replacing traditional metal materials. Inženjerska plastika koja se koristi u automobilskoj industriji uglavnom uključuje PA, POM, PC, PBT, PPS, itd., koji se uglavnom koriste u dijelovima motora, unutrašnji delovi, vanjski dijelovi i električne komponente. Osnovni zahtjevi za obradu ekstruzijom su: lagana, otpornost na visoke temperature, otpornost na habanje, dimenziona stabilnost i nizak VOC (hlapljiva organska jedinjenja), koje zahtijevaju da ekstruder ima preciznu kontrolu temperature, odličan efekat mešanja i disperzije i stabilan proizvodni kapacitet.
Za dijelove unutrašnjosti automobila (kao što su instrument table, paneli za vrata, vazdušni kanali) izrađene od opšte inženjerske plastike (PA6, POM, PC/ABS legura), ekstruderi serije HTS BASIC mogu zadovoljiti potrebe obrade. Njegova fleksibilna konfiguracija može prilagoditi parametre obrade prema zahtjevima performansi unutrašnjih dijelova, osigurati glatku površinu i stabilnost dimenzija proizvoda, and its low energy consumption and cost can reduce the production cost of automotive parts. For automotive engine parts (such as intake manifolds, cylinder head covers, oil pans) made of high-temperature resistant and wear-resistant engineering plastics (PA66+GF30, PPS), the HTS PLUS series extruders are more suitable. Its high torque and excellent mixing and dispersing effect can ensure the uniform dispersion of glass fiber, improve the strength and high temperature resistance of the product, and its wear-resistant screw and barrel can adapt to the wear of glass fiber, ensuring long-term stable production. For high-end new energy vehicle parts (such as battery shell, motor insulation parts) made of high-end special engineering plastics (PEEK, PI), the HTS SUPER series extruders are required. Its ultra-high torque, precizna kontrola temperature i kratko vrijeme zadržavanja mogu izbjeći termičku razgradnju materijala otpornih na visoke temperature, osigurati performanse izolacije i otpornost proizvoda na koroziju, i ispunjavaju stroge zahtjeve novih energetskih vozila u pogledu performansi dijelova.
Studija slučaja: Veliki proizvođač automobilskih dijelova specijaliziran za dijelove akumulatora za vozila za nove energije odabrao je naše ekstrudere serije HTS SUPER (prečnik šrafa 100mm) za obradu PEEK kućišta baterija ojačanih karbonskim vlaknima. PEEK materijal ima visoku viskoznost i otpornost na visoke temperature, i dostiže količinu punjenja od karbonskih vlakana 40%, koja ima izuzetno visoke zahtjeve za opremu za ekstruziju. Ekstruderi serije HTS SUPER, sa svojim ultra-visokim obrtnim momentom od 14Nm/cm³ i maksimalnom brzinom od 1000rpm, stvaraju jaku silu smicanja i silu miješanja, which makes the carbon fiber uniformly dispersed in the PEEK matrix; the precise temperature control system (precision ±1℃) strictly controls the processing temperature at 380-400℃, avoiding thermal decomposition of PEEK; the short residence time (1.5 minuta) effectively reduces the material degradation, ensuring the strength and insulation performance of the battery shell. After using the HTS SUPER series extruders, the production efficiency of the enterprise is increased by 40%, the product qualification rate is increased from 88% to 99%, and the production cost is reduced by 15%, which has won high recognition from the enterprise.
4.2 Electrical and Electronic Field: Electrical Insulation, Flame Retardancy and Dimensional Stability
The electrical and electronic field is one of the earliest and most widely used fields of engineering plastics. Engineering plastics are mainly used in electrical connectors, ploče za ožičenje, relays, motori, cable ties, lamp covers and other components. Osnovni zahtjevi za obradu ekstruzijom su: excellent electrical insulation, otpornost na plamen, dimensional stability, corrosion resistance and low toxicity, koje zahtijevaju da ekstruder ima preciznu kontrolu temperature, good mixing and dispersing effect and strict quality control capacity.
For general electrical components (such as cable ties, connectors) izrađene od opšte inženjerske plastike (PA6, PBT, PC), the HTS BASIC series extruders are suitable. Its flexible configuration can match different die heads to produce components of different shapes and sizes; the precise temperature control ensures the electrical insulation performance of the product, and the low cost can meet the mass production needs of general electrical components. For high-precision electrical components (such as relays, motor windings) made of flame-retardant modified engineering plastics (PBT+GF30+flame retardant, PA66+flame retardant), the HTS PLUS series extruders are preferred. Its high mixing and dispersing effect can ensure the uniform dispersion of flame retardants, avoid local flame retardancy insufficiency, and meet the UL94 V-0 flame retardant standard; the precise dimensional control can ensure the dimensional accuracy of high-precision components, avoiding assembly failure. For high-end electrical components (such as high-temperature resistant connectors, aerospace electrical components) made of special engineering plastics (PPS, PSU, PES), the HTS SUPER series extruders are required. Its ultra-high torque and excellent wear resistance can cope with the high viscosity and high hardness of special engineering plastics, and the precise temperature control and short residence time can ensure the electrical insulation performance and high temperature resistance of the product, meeting the strict requirements of high-end electrical and electronic products.
4.3 Medical Field: Biocompatibility, Sterility and Precision
The medical field has extremely strict requirements on materials, and engineering plastics used in the medical field must have good biocompatibility, sterility, corrosion resistance and dimensional stability, and must not produce toxic and harmful substances. The main engineering plastics used in the medical field include PC, PA, PEEK, PSU, itd., which are mainly used in medical containers, medical catheters, medicinski implantati, surgical instruments and other products. Osnovni zahtjevi za obradu ekstruzijom su: high precision, no pollution, stabilne performanse, which require the extruder to have high cleanliness, precise temperature control and strict quality control capacity.
For general medical products (such as medical containers, ordinary catheters) made of medical-grade general engineering plastics (medical-grade PC, medical-grade PA), the HTS BASIC series extruders with special cleanliness configuration can meet the requirements. We can customize the screw and barrel with high cleanliness, no dead angle design for the HTS BASIC series, avoid material residue and pollution, and match the sterile feeding and packaging system to ensure the sterility of the product. For high-precision medical products (such as precision catheters, medicinski implantati) made of medical-grade special engineering plastics (medical-grade PEEK, medical-grade PSU), the HTS SUPER series extruders with high-precision configuration are required. Its fully optimized screw structure and precise temperature control can ensure the dimensional accuracy of the product (tolerance ≤±0.01mm), and the clean production environment and no pollution design can meet the biocompatibility requirements of medical products; the cloud control function can realize real-time monitoring and recording of the production process, which is convenient for medical product traceability and meets the GMP (Dobra proizvodna praksa) requirements of the medical field.
4.4 Aerospace Field: High Temperature Resistance, Low Weight and High Strength
The aerospace field has extremely high requirements on the performance of materials, and engineering plastics used in the aerospace field must have excellent high temperature resistance, low weight, high strength, corrosion resistance and radiation resistance. The main engineering plastics used in the aerospace field include PEEK, PI, PSU, PES, itd., which are mainly used in aerospace components, aircraft interior parts, satellite components and other products. Osnovni zahtjevi za obradu ekstruzijom su: ultra-high precision, ultra-high temperature resistance, stabilne performanse, which require the extruder to have the highest level of torque, speed and temperature control capacity.
Due to the extremely strict processing requirements of aerospace-grade engineering plastics, only the HTS SUPER series extruders can meet the demand. Its ultra-high torque transmission device, maximum 1000rpm speed and fully optimized key components can cope with the high viscosity and high temperature resistance of aerospace-grade materials (long-term use temperature up to 300℃); the laser-clad screw and barrel have extremely high wear resistance and corrosion resistance, which can adapt to the processing of high-hardness modifiers (such as carbon fiber, ceramic fiber); the intelligent PLC + cloud touch screen control system can realize precise control of extrusion parameters, and the remote monitoring and predictive maintenance function can ensure the stable operation of equipment in long-term continuous production; the customizable configuration can meet the special processing needs of various aerospace components, ensuring the high performance and high reliability of the product.
4.5 Chemical Field: Corrosion Resistance and Wear Resistance
The chemical field has harsh working environment, and engineering plastics used in the chemical field must have excellent corrosion resistance, otpornost na habanje, high temperature resistance and pressure resistance. The main engineering plastics used in the chemical field include PPS, PEEK, PVDF (polyvinylidene fluoride), itd., which are mainly used in chemical equipment, pipelines, valves, pumps and other products. Osnovni zahtjevi za obradu ekstruzijom su: otpornost na koroziju, otpornost na habanje, stabilne performanse, which require the extruder to have excellent wear resistance and corrosion resistance, and stable pressure control capacity.
For chemical pipelines and valves made of general corrosion-resistant engineering plastics (PPS, PVDF), the HTS PLUS series extruders are suitable. Its bimetallic composite screw and barrel have excellent corrosion resistance and wear resistance, which can adapt to the corrosion of chemical media and the wear of materials; the stable pressure control capacity can ensure the uniform wall thickness of pipelines and valves, avoiding leakage caused by uneven wall thickness. For high-pressure chemical equipment and corrosion-resistant components made of high-end corrosion-resistant engineering plastics (PEEK, PI), the HTS SUPER series extruders are required. Its ultra-high torque and stable conveying capacity can cope with the high viscosity of high-end corrosion-resistant materials, and the laser-clad screw and barrel have extremely high corrosion resistance and wear resistance, which can meet the long-term use requirements in harsh chemical environments; the precise temperature control can avoid thermal decomposition of materials, ensuring the corrosion resistance and pressure resistance of the product.
5. Common Problems and Solutions in Engineering Plastics Twin-Screw Extrusion Processing
In the actual twin-screw extrusion processing of engineering plastics, due to the influence of raw materials, parametri obrade, equipment performance and other factors, various problems often occur, which affect the product quality and production efficiency. Ispod, we will summarize the common problems in engineering plastics extrusion processing, analyze their causes, and provide corresponding solutions combined with the characteristics of our HTS series extruders, helping enterprises solve practical processing problems and improve production efficiency.
5.1 Problem 1: Thermal Decomposition and Discoloration of Materials
Symptoms: During the extrusion process, the material appears yellowing, blackening, carbonization and other phenomena, and the final product has discoloration, mjehurići, cracks and other defects, and the mechanical properties are significantly reduced. This problem is mainly caused by the sensitivity of engineering plastics to overheating and hydrolytic degradation.
Uzroci: 1. The extrusion temperature is too high or the temperature of a certain section of the barrel is too high, resulting in thermal decomposition of the material; 2. The residence time of the material in the extruder is too long, leading to excessive heating and decomposition; 3. The raw materials are not dried thoroughly, and the moisture in the materials causes hydrolytic degradation during high-temperature processing; 4. Brzina zavrtnja je preniska, resulting in insufficient shear force and prolonged residence time; 5. The flow channel of the die head is blocked, resulting in material accumulation and local overheating.
Solutions: 1. Adjust the extrusion temperature according to the type of engineering plastic, strictly control the temperature of each section of the barrel and die head within the optimal range, and use the precise temperature control function of the HTS series extruders (temperature control precision ±1℃) to avoid local overheating; 2. Increase the screw speed appropriately (within the range suitable for the material) to shorten the residence time of the material. The HTS series extruders can reach a maximum speed of 1000rpm, which can effectively shorten the residence time to 1-3 minuta; 3. Strengthen the drying treatment of raw materials, strictly control the moisture content below 0.1%-0.2%, and use the drying device matched with the HTS series extruders to prevent the raw materials from absorbing moisture again during feeding; 4. Check and clean the die head regularly to ensure the smooth flow channel, avoid material accumulation; 5. If the problem persists, adjust the screw element combination, increase the number of conveying elements, and reduce the number of mixing elements to speed up the material conveying and shorten the residence time.
5.2 Problem 2: Uneven Dispersion of Modifiers
Symptoms: The final product has uneven texture, obvious agglomeration of modifiers (kao što su staklena vlakna, karbonska vlakna), and the mechanical properties (snagu, žilavost, otpornost na habanje) are uneven, which cannot meet the use requirements. This problem is common in the processing of modified engineering plastics.
Uzroci: 1. The premixing effect of raw materials is poor, and the modifiers are not uniformly adhered to the surface of the resin; 2. Brzina zavrtnja je preniska, resulting in insufficient shear force and kneading force, and the modifiers cannot be fully broken and dispersed; 3. The combination of screw elements is unreasonable, and the number of mixing elements and shearing elements is insufficient; 4. The extrusion temperature is too low, the material is not fully melted, and the modifiers cannot be uniformly dispersed in the resin matrix; 5. The particle size of the modifier is too large or uneven.
Solutions: 1. Optimize the premixing process, increase the mixing speed (800-1200rpm) and mixing time (5-10 minuta), add an appropriate amount of compatibilizer to improve the compatibility between the modifier and the resin, and use a high-speed mixer matched with the HTS series extruders to ensure uniform premixing; 2. Increase the screw speed appropriately, use the high-speed performance of the HTS series extruders to generate strong shear force and kneading force, and fully break the agglomerates of modifiers; 3. Adjust the combination of screw elements, increase the number of mixing elements and shearing elements, and use the modular screw design of the HTS series extruders to customize the optimal screw combination according to the type of modifier; 4. Properly increase the extrusion temperature to ensure that the material is fully melted, which is conducive to the uniform dispersion of modifiers; 5. Crush and sieve the modifier to ensure that its particle size is uniform (20-40 mesh) and meets the processing requirements.
5.3 Problem 3: Wear of Screw and Barrel
Symptoms: After a period of use, the extrusion capacity of the extruder decreases, the shear force and mixing effect are reduced, the product quality is unstable, and even the screw and barrel are stuck. This problem is mainly caused by the wear of high-hardness modifiers (kao što su staklena vlakna, karbonska vlakna) on the screw and barrel during the processing of reinforced engineering plastics.
Uzroci: 1. The screw and barrel are made of materials with poor wear resistance, which cannot resist the wear of high-hardness modifiers; 2. The filling amount of the modifier is too high (≥50%), and the wear is intensified; 3. The particle size of the modifier is too large, which increases the wear on the screw and barrel; 4. The extrusion pressure is too high, which increases the friction between the material and the screw and barrel; 5. The screw and barrel are not maintained regularly, and the material residue accelerates the wear.
Solutions: 1. Select extruders with high wear resistance, such as HTS PLUS series and HTS SUPER series. Their screws and barrels are made of imported wear-resistant alloy steel and undergo bimetallic composite treatment or laser cladding treatment, with surface hardness ≥65 HRC (HTS PLUS) i ≥70 HRC (HTS SUPER), which can effectively resist the wear of high-hardness modifiers; 2. Control the filling amount of the modifier within a reasonable range. If high filling amount is required, select the HTS SUPER series extruders with better wear resistance; 3. Crush and sieve the modifier to reduce its particle size and reduce wear; 4. Adjust the extrusion parameters to control the extrusion pressure within the optimal range (5-15MPa), avoid excessive pressure; 5. Regularly maintain the screw and barrel, clean the material residue in time, and apply lubricating oil appropriately to reduce friction and extend the service life. Osim toga, our professional technical team can provide regular wear detection services for the screw and barrel, i iznijeti ciljane prijedloge zamjene i održavanja.
5.4 Problem 4: Unstable Product Size and Dimensional Deformation
Symptoms: The size of the extruded product (such as granules, cijevi, listovi) is uneven, the shrinkage rate exceeds the standard (＞1.5%), and the product has deformation, warpage and other phenomena, which affects the assembly and use of the product.
Uzroci: 1. The extrusion temperature is unstable, resulting in uneven melting and plasticization of the material, and uneven shrinkage during cooling; 2. The extrusion speed is unstable, leading to uneven extrusion amount and unstable product size; 3. The cooling speed is uneven, resulting in uneven internal and external stress of the product, leading to deformation; 4. The die head structure is unreasonable, the flow channel is not smooth, and the material flow is uneven; 5. The raw materials have high water absorption, and the moisture causes uneven shrinkage during processing.
Solutions: 1. Use the precise temperature control system of the HTS series extruders to ensure the stability of the extrusion temperature, and avoid temperature fluctuation; 2. Adjust the feeding speed and screw speed to ensure the stability of the extrusion speed, and use the frequency conversion speed regulation function of the HTS series extruders to realize the synchronous adjustment of feeding and extrusion; 3. Optimize the cooling process, ensure uniform cooling speed, adjust the cooling water temperature (20-30℃) and cooling time (2-5 minuta) for strip cooling, and use air cooling or water spray cooling for pipes and sheets to avoid uneven cooling; 4. Check and optimize the die head structure, ensure the smooth flow channel, and adjust the die head temperature to ensure uniform material flow; 5. Strengthen the drying treatment of raw materials, strictly control the moisture content, and reduce the impact of moisture on product shrinkage.
5.5 Problem 5: Low Extrusion Efficiency and High Energy Consumption
Symptoms: The production capacity of the extruder is lower than the design standard, the energy consumption per unit product is high, and the production cost is increased, which affects the economic benefits of the enterprise.
Uzroci: 1. Brzina zavrtnja je preniska, the conveying capacity is insufficient; 2. The extrusion temperature is too low, the material viscosity is too high, the conveying resistance is increased, and the production capacity is reduced; 3. The combination of screw elements is unreasonable, the conveying efficiency is low; 4. The feeding device is blocked or the feeding speed is insufficient, resulting in insufficient feeding; 5. The screw and barrel are worn, the conveying capacity is reduced, and the energy consumption is increased.
Solutions: 1. Increase the screw speed appropriately (within the range suitable for the material) to improve the conveying capacity and production efficiency. The HTS series extruders can reach a maximum speed of 1000rpm, which can significantly improve production efficiency; 2. Properly increase the extrusion temperature to reduce the material viscosity, reduce the conveying resistance, and improve the conveying efficiency; 3. Adjust the combination of screw elements, increase the number of conveying elements, optimize the screw lead and compression ratio, and improve the conveying efficiency. The modular screw design of the HTS series extruders can realize the quick adjustment of screw elements; 4. Check and clean the feeding device regularly, ensure the smooth feeding, and adjust the feeding speed to match the screw speed, avoid insufficient feeding; 5. Regularly detect the wear degree of the screw and barrel, replace the worn components in time, and maintain the conveying capacity of the extruder, reducing energy consumption. Osim toga, the HTS series extruders adopt an optimized structural design and high-efficiency motor, which can reduce energy consumption by 15%-20% u poređenju sa običnim ekstruderima.
6. Conclusion and Future Development Trend
Inženjerske plastike, kao ključni materijal visokih performansi, are playing an increasingly important role in global industrial upgrading, and twin-screw extrusion technology is the core support for the high-quality processing of engineering plastics. The performance of extrusion equipment directly determines the quality, production efficiency and application effect of engineering plastic products. Our HTS series twin-screw extruders, including HTS BASIC, HTS PLUS and HTS SUPER, are specially designed for the processing characteristics of engineering plastics (osjetljivost na pregrijavanje i hidrolitičku degradaciju, visoki zahtjevi za efektom miješanja i dispergiranja, visok viskozitet), with the advantages of high torque, high speed, precizna kontrola temperature, excellent wear resistance, wide application range and intelligent control. They can provide targeted processing solutions for different types of engineering plastics and different scales of enterprises, helping enterprises solve processing difficulties, improve product quality and production efficiency, and enhance market competitiveness.
Looking forward to the future, with the continuous upgrading of downstream industries such as automotive lightweight, električna i elektronska inteligencija, new energy and medical high-endization, the demand for high-performance, functional and environmentally friendly engineering plastics will continue to grow, which will also put forward higher requirements on twin-screw extrusion technology and equipment. The future development trend of engineering plastics twin-screw extruders will be mainly reflected in four aspects:
Prvo, intelligence and digitalization. With the development of Industry 4.0, twin-screw extruders will be more integrated with intelligent technologies such as Internet of Things, big data and artificial intelligence. The HTS series extruders will further optimize the cloud control function, realize real-time monitoring, data analysis, predictive maintenance and intelligent adjustment of the entire production process, reduce labor intervention, and improve production efficiency and product consistency. U isto vreme, digital simulation technology will be widely used in the design and debugging of extruders, reducing the research and development cycle and debugging time of equipment.
Drugo, high performance and high efficiency. The demand for high-end engineering plastics (such as PEEK, PI) will continue to increase, which will promote the continuous upgrading of extruder performance. The future extruders will have higher torque, higher speed and more precise temperature control capacity, and the key components (vijak, bure, mjenjač) will be further optimized to improve wear resistance, corrosion resistance and service life. U isto vreme, the energy consumption of the equipment will be further reduced, realizing high-efficiency and energy-saving production.
Treće, customization and diversification. Different application fields and different products have increasingly personalized requirements for extrusion processing. The future extruders will adopt a more flexible modular design, which can quickly replace screw elements, die heads and other components according to customer needs, realizing the processing of multiple varieties and small batches. U isto vreme, we will provide more personalized customized solutions according to the special processing needs of customers, meeting the diverse market demands.
Četvrto, environmental protection and greenization. With the strengthening of global environmental protection policies, environmental protection will become an important development direction of extrusion equipment. The future extruders will adopt more environmentally friendly materials and manufacturing processes, reduce energy consumption and pollutant emissions; at the same time, they will be more compatible with recyclable engineering plastics and biodegradable engineering plastics, promoting the green development of the engineering plastics industry.
We will always adhere to the concept of technological innovation, focus on the development needs of the engineering plastics industry, continuously invest in research and development, optimize the performance of HTS series extruders, improve after-sales service, and provide more professional, efficient and intelligent twin-screw extrusion solutions for global engineering plastics processing enterprises, helping the high-quality development of the engineering plastics industry.