Ku e avansementu rápido di industrialisashon mundial, e demanda pa materialnan di haltu rendimentu den outo, eléktriko i elektróniko, konstrukshon, médiko i otro terenonan ta oumentando dia pa dia. Plastik di ingenieria, komo un material klave di rendimentu haltu, a remplasá gradualmente materialnan di metal tradishonal i plèstik general den hopi senario di aplikashon núkleo debí na nan propiedatnan mekaniko ekselente, resistensia na kalor, resistensia na koroshon, stabilidat dimenshonal i prosesabilidat. Teknologia di ekstrushon di dos skru ta e teknologia di prosesamentu sentral di komposishonnan di plèstik di ingenieria, i e rendimentu di ekipo di ekstrushon ta determiná direktamente e kalidat, efisiensia di produkshon i efekto di aplikashon di produktonan di plèstik di ingenieria.
Nos ta komprometé na proveé solushonnan profeshonal di ekstrushon di dos skru pa prosesamentu di plèstik di ingenieria, dependiendo di nos extrudernan di serie HTS desaroyá i fabriká independientemente ku kaha di engranahe di torsi haltu, ku ta spesialmente diseñá pa e karakterístikanan di prosesamentu i nesesidatnan di aplikashon di plèstik di ingenieria. E artíkulo aki lo elaborá ampliamente riba e karakterístikanan di rendimentu, klasifikashon, difikultatnan di prosesamentu di plèstik di ingenieria, e ròl sentral di teknologia di ekstrushon di dos skru den prosesamentu di plèstik di ingenieria, e bentahanan di nos extrudernan di serie HTS i nan adaptashon dirigí na plèstik di ingenieria, meskos ku e terenonan di aplikashon spesífiko, téknikanan di prosesamentu i problemanan i solushonnan komun. Dor di suplementá parameternan tékniko detayá, detayenan di prosesamentu i kasonan di aplikashon di industria, e artíkulo lo wòrdu enrikesé pa 3000-4000 palabranan, dunando referensia amplio i profeshonal pa empresanan di prosesamentu di plèstik di ingenieria, téknikonan i profeshonalnan relevante.
1. Bista di Industria di Plástik di Ingenieria i Karakterístika di Rendimentu di Núkleo
1.1 Situashon Aktual i Tendensia di Desaroyo di Industria di Plástik di Ingenieria
Plástikonan di ingenieria ta referí na un klase di materialnan di plèstik ku por wòrdu usá komo materialnan struktural i ta karga karganan mekaniko den un rango di temperatura amplio. Kompará ku plèstik general (manera polietileno PE, polipropileno PP, klorido di polivinil PVC), plèstiknan di ingenieria tin un rendimentu amplio mas ekselente, i por kumpli ku e rekisitonan di uso severo den produkshon industrial i fabrikashon di produkto di kalidat haltu. Den añanan resien, impulsá pa e mehorashon di industrianan abou manera peso lihé di outo, inteligensia eléktriko i elektróniko, i aparatonan médiko di kalidat haltu, e merkado mundial di plèstik di ingenieria a mustra un tendensia di kresementu konstante i rápido.
Di akuerdo ku datonan di industria relevante, e tamaño di e merkado mundial di plèstik di ingenieria a surpasá 100 bion dòler merikano, i ta antisipá pa mantené un tasa di kresementu anual komponé di 7%-10% den e próksimo sinku añanan. Entre nan, Asia-Pasífiko ta e merkado di produkshon i konsumo di plèstik di ingenieria mas grandi na mundu, ku ta konta pa mas ku 55% di e parti di merkado mundial, prinsipalmente debí na e desaroyo rápido di outo, industrianan eléktriko i elektróniko na China, India i otro paisnan, i tambe e mehorashon kontinuo di kapasidat di sosten industrial i nivel di inovashon teknológiko. China, komo e konsumidó i produktor di plèstik di ingenieria mas grandi na mundu, tin un demanda grandi riba merkado, i e produkshon i konsumo anual ta kresiendo na un tarifa di dos sifra, spesialmente riba tereno di vehíkulonan di energia nobo, 5G komunikashonnan, i aparatonan médiko, e demanda pa plèstik di ingenieria di haltu rendimentu ta mustrando un tendensia di kresementu eksplosivo.
E tendensia di desaroyo di e industria di plèstik di ingenieria ta wòrdu reflehá prinsipalmente den sinku aspekto: prome, rendimentu haltu i funshonalisashon. Ku e mehorashon kontinuo di e rekisitonan di uso den e terenonan abou, plèstiknan di ingenieria ta desaroyando pa un resistensia na kalor mas haltu, forsa mas haltu, mihó resistensia na desgaste i funshonnan spesial (manera retraso di kandela, antistátiko, antibakterial, resistensia na radiashon), pa adaptá na e ambiente di trabou duru di temperatura haltu, preshon haltu, koroshon i radiashon; segundo, lihé i integrashon. Den e outomobilista, aerospasio i otro terenonan, pa asina por logra metanan di sparmentu di energia i redukshon di emishon, plèstiknan di ingenieria ta wòrdu usá mas i mas pa remplasá materialnan di metal, i e integrashon di diseño di produkto ta birando mas i mas haltu, ku por redusí e kantidat di piesa, simplifiká e proseso di produkshon i baha gastunan; di tres, protekshon di medio ambiente i resiklabilidat. Ku e fortalesimentu di polítikanan di protekshon di medio ambiente mundial i e mehorashon di konsientisashon di protekshon di medio ambiente, e desaroyo i aplikashon di plèstik di ingenieria resiklabel, plèstiknan di ingenieria biodegradabel i teknologianan di prosesamentu ku ta respetá medio ambiente a bira e enfoke di e industria, redukshon di polushon di medio ambiente kousa pa desperdisio di plèstik; di kuater, inteligensia i presishon di ekipo di prosesamentu. Plastik di ingenieria tin difikultat haltu di prosesamentu i rekisitonan di kalidat estrikto, ku a pone rekisitonan mas haltu riba ekipo di prosesamentu. Sabí, ekstrudernan di dos skru presis i efisiente i liñanan di produkshon outomátiko a bira e koriente prinsipal di e industria, realisando monitoreo den tempu real, ahuste outomátiko di parameter i mantenshon prediktivo di e proseso di prosesamentu; di sinku, diversifikashon di terenonan di aplikashon. Plástiko di ingenieria ta ekspandé gradualmente for di outo tradishonal, terenonan eléktriko i elektróniko pa energia nobo, médiko, aeroespasio, konstrukshon i otro terenonan emergente, habriendo espasio di merkado nobo.
Kontra e fondo aki, teknologia di ekstrushon di dos skru, komo e teknologia di prosesamentu sentral di kompositonan di plèstik di ingenieria, a bira e yabi pa mehorá e kompetitividat di empresanan di plèstik di ingenieria. Plástiko di ingenieria ta sensitivo na sobrekalentamentu i degradashon hidrolítiko, i tin eksigensianan haltu riba temperatura di prosesamentu, forsa di kòrtamentu, presishon di kòntròl di tempu di residensia i temperatura. Nos extrudernan di serie HTS ta spesialmente diseñá pa e karakterístikanan di prosesamentu di plèstik di ingenieria, ku torsi haltu, velosidat haltu, kontrol di temperatura presis i dispersibilidat ekselente, ku por solushoná e difikultatnan di prosesamentu di plèstik di ingenieria i yuda empresanan logra kalidat haltu, produkshon efisiente i stabil.
1.2 Karakterístika di Rendimentu di Plástik di Ingenieria
Kompará ku materialnan general di plèstik i metal, plèstiknan di ingenieria tin rendimentu amplio úniko, ku ta determiná nan aplikashon amplio den vários tereno industrial. E karakterístikanan di rendimentu sentral di plèstik di ingenieria ta reflehá prinsipalmente den e siguiente sinku aspekto, ku tambe a pone dilanti rekisitonan spesial pa nan teknologia i ekipo di prosesamentu:
1.2.1 Resistensia Ekselente na Kalor i Resistensia na Friu
Plástiko di ingenieria tin un rango di adaptashon di temperatura amplio, ku por mantené bon propiedatnan mekaniko (forsa, duru, dureza) den tantu ambientenan di temperatura haltu komo abou. Kompará ku plèstik general, ku normalmente ta pèrdè nan propiedatnan mekaniko na 80-120°C, mayoria di plèstik di ingenieria por funshoná stabilmente na 100-250°C, i algun plèstik di ingenieria spesial (manera PEEK, PI) por asta traha na temperaturanan riba 300°C. Na mes momento, plèstiknan di ingenieria tambe tin bon resistensia na friu, ku por mantené bon resistensia na temperaturanan abou (bou di -40°C), i no ta fásil pa fraktura frágil. E rendimentu aki ta hasi plèstiknan di ingenieria adekuá pa uso den ambientenan di temperatura duru, manera piesanan di motor di outo (temperatura haltu) i ekipo eléktriko pafó (temperatura abou).
E ekselente resistensia na kalor di plèstik di ingenieria ta prinsipalmente debí na nan struktura molekular spesial (manera renchi aromátiko, renchi heterosíkliko) i forsanan intermolekular fuerte, loke ta hasi ku nan no ta fásil pa smelt i deskomponé na temperaturanan haltu. Pero, 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, and are not easy to be corroded by acids, alkalis, salts, organic solvents and other chemicals. Compared with metal materials, which are easy to rust and corrode, engineering plastics have longer service life in harsh chemical environments. Por ehèmpel, poliamida (PA) engineering plastics are resistant to most organic solvents and weak acids and alkalis; polikarbonat (PC) engineering plastics are resistant to corrosion by non-oxidizing acids and salts; polyphenylene sulfide (PPS) plèstiknan di ingenieria ta resistente na koroshon dor di kasi tur kímikonan ku eksepshon di ácidonan oxidante fuerte.
Ademas, plèstiknan di ingenieria tin bon resistensia na wer i resistensia na envehesimentu, i no ta fásil pa degradá i envehesié bou di akshon di lus di solo, awaseru, oksígeno i otro faktornan ambiental, ku ta garantisá nan uso stabil a largu plaso den ambientenan duru i pafó. E rendimentu aki ta hasi ku plèstiknan di ingenieria ta wòrdu usá ampliamente den ekipo kímiko, ekipo eléktriko pafó, piesanan di pafó di outo i otro terenonan.
1.2.3 Prosesamentu Fásil i Efisiensia di Produkshon Haltu
Compared with metal materials, plèstik di ingenieria tin e bentahanan di prosesamentu fásil, proseso di produkshon simpel i efisiensia di produkshon haltu. Materialnan di metal por lo general mester di proseduranan di prosesamentu kompleho manera forja, fundishon, mashin, ku tin un konsumo haltu di energia, efisiensia abou i kosto haltu; while engineering plastics can be processed by extrusion, moldura di inyekshon, blow molding and other methods, which can realize mass production, simplify the production process, reduce energy consumption and production cost. Por ehèmpel, the processing cycle of an engineering plastic automotive part by injection molding is only a few seconds to tens of seconds, while the processing cycle of the same metal part may take several hours to several days.
Pero, 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; na mes momento, algun plèstik di ingenieria (manera PA) tin absorshon haltu di awa, which affects the processing effect and product quality. P'esei, 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 (normalmente 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, aparatonan médiko, 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) i forsanan intermolekular fuerte.
Ademas, 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, konektornan, 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). Por ehèmpel, 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, ku por redusí konsumo di kombustibel i emishon di karbon.
Na mes momento, plèstiknan di ingenieria tambe tin resistensia di desgaste i resistensia di frikshon sobresaliente, i e koefisiente di frikshon ta chikitu, ku por wòrdu usá den produkshon di piesanan resistente na desgaste (manera engranahenan, bearingnan, blòkinan ku ta slip) sin lubrikashon adishonal òf ku ménos lubrikashon, redukshon di e gastu di mantenshon di produktonan. Por ehèmpel, polioksimetileno (POM) plèstiknan di ingenieria tin un resistensia na desgaste ekselente i ta konosí komo “staal di plèstik”, ku ta wòrdu usá ampliamente den produkshon di engranahenan di outo, komponentenan eléktriko i otro piesanan ku ta resistí desgaste.
1.3 Klasifikashon Komun di Plástik di Ingenieria
Plastiknan di ingenieria por wòrdu dividí den diferente tipo segun nan struktura kímiko, nivel di rendimentu i tereno di aplikashon. E métodonan di klasifikashon komun ta lo siguiente, which helps to better understand the processing characteristics and application scenarios of different engineering plastics, i selektá ekipo di ekstrushon i téknikanan di prosesamentu apropiá:
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), polioksimetileno (POM), tereftalato di polietileno (BESTIA DI KAS), polybutylene terephthalate (PBT), etc. General engineering plastics are mainly used in automotive, eléktriko i elektróniko, home appliances and other fields, manera piesanan di outo, konektornan eléktriko, home appliance shells, etc.
- Special Engineering Plastics: They have more excellent performance (such as higher heat resistance, resistensia na koroshon, propiedatnan mekaniko) than general engineering plastics, but the production technology is complex and the price is high. E variedatnan prinsipal ta inkluí sulfuro di polifenileno (PPS), poliéter éter keton (PEEK), poliimida (PI), polisulfona (PSU), polietersulfon (PES), etc. Plastiknan di ingenieria spesial ta wòrdu usá prinsipalmente den terenonan di kalidat haltu manera aerospasio, aparatonan médiko, energia nobo, i ekipo kímiko, manera komponentenan aeroespasio, implantenan médiko, komponentenan eléktriko ku ta resistí temperatura haltu, etc.
1.3.2 Klasifikashon pa Struktura Kímiko
Di akuerdo ku e struktura kímiko di e kadena molekular, plèstiknan di ingenieria por wòrdu dividí den poliamida (PA), polikarbonat (PC), polioksimetileno (POM), poliéster (BESTIA DI KAS, PBT), polyphenylene sulfide (PPS), poliéter éter keton (PEEK), etc. Kada tipo di plèstik di ingenieria tin su propio karakterístikanan di rendimentu i rekisitonan di prosesamentu úniko:
- Poliamida (PA): Tambe konosí komo nylon, e tin un forsa mekaniko ekselente, resistensia na desgaste, duru i resistensia kímiko, pero tin absorshon haltu di awa, ku ta afektá e stabilidat dimenshonal. Variedadnan komun ta inkluí PA6, PA66, PA11, PA12, etc. E ta wòrdu usá ampliamente den piesanan di outo (engranahenan, bearingnan, manifoldnan di entrada), konektornan eléktriko, fibranan di textil, etc.
- Polikarbonat (PC): E tin transparensia ekselente, forsa di impakto, heat resistance and electrical insulation, but has poor wear resistance and is easy to scratch. It is widely used in electrical and electronic fields (wiring boards, lamp covers), automotive fields (headlamp lenses, instrument panels), medical fields (medical containers), etc.
- Polioksimetileno (POM): It has excellent wear resistance, friction resistance, dimensional stability and mechanical strength, and is not easy to absorb water. It is known as “staal di plèstik” and is widely used in automotive parts (engranahenan, blòkinan ku ta slip), komponentenan eléktriko (switches, bearingnan), piesanan mekaniko, etc.
- Polyester (BESTIA DI KAS, PBT): PET has excellent transparency, heat resistance and mechanical strength, and is mainly used in fibers, pelíkulanan, bottles and other fields; PBT has excellent chemical resistance, electrical insulation and processing fluidity, and is widely used in electrical and electronic fields (konektornan, relays), piesanan di outo, etc.
- Polyphenylene Sulfide (PPS): E tin un resistensia na kalor ekselente (long-term use temperature up to 200-220℃), resistensia na koroshon, flame retardancy and electrical insulation, pero tin mal resistensia. E ta wòrdu usá ampliamente den komponentenan eléktriko resistente na temperatura haltu, piesanan di motor di outo, ekipo kímiko, etc.
- Poliéter Eter Ketona (PEEK): E tin un rendimentu amplio ekselente, temperatura di uso a largu plaso te ku 250-300°C, bon resistensia na koroshon, forsa mekaniko i biokompatibilidat. E ta wòrdu usá prinsipalmente den terenonan di kalidat haltu manera aerospasio, implantenan médiko, i komponentenan eléktriko resistente na temperatura haltu.
1.3.3 Klasifikashon pa Kampo di Aplikashon
Di akuerdo ku e kampo di aplikashon, plèstik di ingenieria por wòrdu dividí den plèstik di ingenieria di kalidat di outo, plèstik di ingenieria di kalidat eléktriko, plèstik di ingenieria di kalidat médiko, plèstik di ingenieria di kalidat aeroespasial, etc. Diferente tereno di aplikashon tin diferente rekisito riba e rendimentu di plèstik di ingenieria. Por ehèmpel, plèstiknan di ingenieria di kalidat di outo ta rekerí un bon resistensia na kalor, forsa di impakto i resistensia na wer; plèstiknan di ingenieria di kalidat eléktriko ta rekerí bon isolashon eléktriko i retraso di kandela; plèstiknan di ingenieria di kalidat médiko ta rekerí bon biokompatibilidat i sterilidat; plèstiknan di ingenieria di kalidat aeroespasial ta rekerí bon resistensia na temperatura haltu, peso abou i forsa haltu.
2. Teknologia di Prosesamentu di Plástik di Ingenieria: Teknologia di Ekstrushon di Dos Skruf
Prosesamentu di plèstik di ingenieria ta inkluí prinsipalmente ekstrushon, moldura di inyekshon, moldura di supla, moldura i otro métodonan, entre kua teknologia di ekstrushon di dos skru ta e teknologia sentral pa e produkshon di komponentenan di plèstik di ingenieria (manera plèstik di ingenieria modifiká, plèstiknan di ingenieria reforsá) i produktonan semi-finí (manera tubonan, blachinan, fibranan). Kompará ku teknologia di ekstrushon di un solo skru, teknologia di ekstrushon di dos skru tin e bentahanan di forsa di kòrtamentu fuerte, bon efekto di meskla, kòntròl di temperatura presis, tempu di residensia kòrtiku i adaptabilidat fuerte na materia prima, ku por solushoná e difikultatnan di prosesamentu di plèstik di ingenieria (manera sensitividat na sobrekalentamentu i degradashon hidrolítiko, mal efekto di meskla, efisiensia di prosesamentu abou) i garantisá e kalidat di produktonan di plèstik di ingenieria.
2.1 Difikultatnan di Prosesamentu di Plástik di Ingenieria i Rekisitonan pa Ekiponan di Ekstrushon
Manera menshoná anteriormente, plèstiknan di ingenieria tin un rendimentu amplio ekselente, pero nan difikultat di prosesamentu tambe ta mas haltu ku esun di plèstik general, prinsipalmente debí na nan struktura molekular spesial i karakterístika di rendimentu. E difikultatnan prinsipal di prosesamentu di plèstik di ingenieria i e rekisitonan korespondiente pa ekipo di ekstrushon ta lo siguiente:
2.1.1 Sensibilidat pa Sobrekalentamentu i Degradashon Hidrolítiko
Mayoria di plèstik di ingenieria (manera PA, PBT, PPS) ta sensitivo na sobrekalentamentu i degradashon hidrolítiko. 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. Ademas, algun plèstik di ingenieria (manera PA) tin absorshon haltu di awa, 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: prome, precise temperature control capacity, which can strictly control the processing temperature within the optimal range of engineering plastics, avoid local overheating, and the temperature control precision should reach ±1℃; segundo, short residence time, which can reduce the time that the material stays in the extruder barrel, avoid thermal decomposition and hydrolytic degradation. Twin-screw extruders have the advantages of short residence time (normalmente 1-5 minütnan) i kòntròl di temperatura presis, which are more suitable for engineering plastics processing than single-screw extruders (ora di residensia 5-10 minütnan).
2.1.2 High Requirements on Mixing and Dispersing Effect
In engineering plastics processing, it is often necessary to add modifiers (such as glass fiber, fibra di karbon, talko, retardantenan di kandela, kompatibilisadónan) to improve the performance of the product (such as reinforcing, toughening, retardante di kandela). Por ehèmpel, adding glass fiber to PA can improve its strength and dimensional stability; adding flame retardants to PBT can improve its flame retardancy. 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. Ademas, the modular design of the twin-screw can freely combine different screw elements (such as conveying elements, elementonan di meskla, 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. If the conveying capacity is insufficient or the pressure control is unstable, it will cause uneven extrusion speed, unstable product size, and even equipment blockage.
Twin-screw extruders have strong conveying capacity and stable pressure control capacity. The intermeshing of the twin screws can generate strong pumping force, which can effectively convey high-viscosity engineering plastic materials; na mes momento, the extruder is equipped with a high-precision pressure sensor, which can monitor the extrusion pressure in real time and adjust the screw speed and feeding speed automatically to ensure the stability of the extrusion pressure and the smooth progress of processing.
2.2 Working Principle and Process Flow of Engineering Plastics Twin-Screw Extrusion
The twin-screw extrusion process of engineering plastics is a complex physical and chemical process, ku ta enserá e interakshon di múltiple faktor manera temperatura, preshon, forsa di kòrtamentu i tempu. 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, tubonan, blachinan, fibranan) through the die head. E prinsipio di trabou spesífiko i e fluho di proseso ta lo siguiente:
2.2.1 Pretratamentu di Materia Prima
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 (manera PA, PC, POM), modifiers (such as glass fiber, fibra di karbon, talko, retardantenan di kandela), kompatibilisadónan, lubricants and other additives. The pretreatment steps are as follows:
- Drying Treatment: Mayoria di plèstik di ingenieria (manera PA, PBT, PPS) tin absorshon haltu di awa, and the moisture in the raw materials will cause hydrolytic degradation during high-temperature processing, resulting in product defects (such as bubbles, kraak, reduced mechanical properties). P'esei, the raw materials must be dried before processing. The drying temperature and time are determined according to the type of engineering plastic: Por ehèmpel, PA6 is dried at 80-100℃ for 4-6 oranan, PA66 is dried at 100-120℃ for 6-8 oranan, PBT is dried at 120-140℃ for 2-4 oranan, PPS is dried at 150-160℃ for 3-5 oranan. The moisture content of the dried raw materials should be controlled below 0.1%-0.2%.
- Premixing Treatment: Di akuerdo ku e relashon di fórmula, the dried engineering plastic resin, modifiers and additives are put into a high-speed mixer for premixing. 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. E velosidat di meskla ta generalmente 800-1200 rpm, and the mixing time is 5-10 minütnan. 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 (such as glass fiber), 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 Alimentashon i Transmishon
The premixed raw materials are sent to the feeding hopper of the twin-screw extruder through a screw feeder or a belt feeder. The feeding device of the extruder is usually equipped with a frequency conversion speed regulation function, 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 Smeltmentu, Mixing and Shearing
The materials entering the extrusion cavity of the twin-screw extruder are pushed forward continuously by the rotating screws. The extrusion cavity is composed of a screw and a barrel, and the volume of the extrusion cavity gradually decreases along the axis direction. When the screws rotate, the materials are gradually compressed under the action of the screws and the barrel, and the pressure in the extrusion cavity gradually increases (generally 5-15MPa).
Na mes momento, e materialnan ta wòrdu sometí na forsa di kòrtamentu fuerte i forsa di frikshon generá dor di e moveshon relativo entre e skru i e bari, meskos ku entre e buelonan di skru. 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. E forsa di frikshon tambe por generá un sierto kantidat di kalor, ku ta kombiná ku e keintamentu eksterno di e bari (keintamentu eléktriko òf keintamentu di vapor) to make the engineering plastic resin gradually melt and plasticize.
E bari di e extruder ta wòrdu dividí generalmente den 4-6 sekshonnan di kòntròl di temperatura (sekshon di alimentashon, sekshon di smelt, sekshon di meskla, sekshon di homogenisashon, sekshon di kabes di muri), and the temperature of each section is precisely controlled according to the type of engineering plastic. Por ehèmpel, when processing PA66+GF30 (glass fiber reinforced PA66), the temperature of the feeding section is 120-140℃, the melting section is 250-260℃, the mixing section is 260-270℃, the homogenizing section is 250-260℃, and the die head section is 240-250℃. The precise temperature control can ensure that the resin is fully melted without thermal decomposition, and the modifiers are uniformly dispersed.
2.2.4 Extrusion and Shaping
The fully melted, mixed and dispersed material is pushed to the die head of the extruder by the screws. The die head is designed according to the shape of the final product: for the production of engineering plastic compounds (granulonan), the die head is equipped with multiple circular die holes (the number and size of die holes are determined according to the particle size of the granules); for the production of pipes, blachinan, fibranan, the die head is designed into corresponding shapes (such as circular die for pipes, flat die for sheets).
The material is extruded from the die head at a high speed to form continuous semi-finished products (such as strips for granules, tubonan, blachinan). The temperature of the die head is slightly lower than that of the homogenizing section, which can prevent the material from decomposing due to excessive temperature and ensure the shaping effect of the semi-finished products. The extrusion speed is controlled according to the type of engineering plastic and the shape of the product, generally ranging from 0.5-5m/min.
2.2.5 Cooling and Solidification
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 minütnan; 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 (granulonan), 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 (the particle size is generally 2-5mm, which can be adjusted according to customer needs). 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.
Ademas, the final product also needs to undergo post-processing steps such as screening, inspection and packaging. The screening step is to remove unqualified products (such as too large, too small or agglomerated particles); the inspection step is to detect the performance (such as mechanical strength, resistensia na kalor, eksaktitut dimenshonal) of the product to ensure that it meets the customer’s requirements; the packaging step is to package the qualified product in a sealed and moisture-proof manner to prevent the product from absorbing moisture and affecting the quality.
2.3 Key Factors Affecting Engineering Plastics Twin-Screw Extrusion Effect
The effect of twin-screw extrusion directly affects the quality and performance of engineering plastic products. There are many factors affecting the extrusion effect, prinsipalmente inkluyendo karakterístika di materia prima, formula ratio, premixing effect, parameternan di ekstrushon i struktura di kabes di matris. Mastering these key factors and making scientific adjustments can ensure the stability of the extrusion effect and the consistency of product quality.
2.3.1 Karakterístika di Materia Prima
E tipo, tamaño di partikulo, moisture content and purity of raw materials have a great impact on the extrusion effect. Por ehèmpel, the particle size of engineering plastic resin and modifiers should be uniform; 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, stòf) 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. Por ehèmpel, agregando 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, mehorá fluides di prosesamentu, 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 minütnan, and the mixing temperature is controlled at 40-60℃ (appropriate temperature can improve the adhesion of additives and promote uniform mixing).
2.3.4 Parameternan di Ekstrushon
Extrusion parameters are the most important factors affecting the extrusion effect, prinsipalmente inkluyendo velosidat di skru, temperatura di ekstrushon i preshon di ekstrushon.
- Velosidat di Schroef: The screw speed of twin-screw extruders for engineering plastics generally ranges from 100 pa 1000 rpm. Our HTS series extruders can reach a maximum speed of 1000 rpm. Mas haltu e velosidat di e skru, mas grandi e forsa di kòrtamentu i forsa di frikshon risibí pa e materialnan, the better the mixing and dispersing effect of modifiers, and the higher the production efficiency. Pero, si e velosidat di skru ta muchu haltu, e tempu di estadia di e materialnan den e kavidat di ekstrushon ta muchu kòrtiku, resulting in incomplete melting of the resin, insufficient mixing of materials, and uneven product quality; si e velosidat di skru ta muchu abou, e forsa di kòrtamentu i forsa di frikshon ta insufisiente, 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. The temperature of the feeding section is lower (slightly higher than the drying temperature of the raw materials), which is mainly to prevent the materials from caking and ensure smooth feeding; the temperature of the melting section is medium, which is mainly to promote the melting and plasticization of the resin; the temperature of the mixing section is higher, which is mainly to enhance the shear and mixing effect, and promote the uniform dispersion of modifiers; the temperature of the homogenizing section is slightly lower than the mixing section, which is mainly to ensure the uniform temperature and viscosity of the materials, and avoid thermal decomposition; the temperature of the die head section is slightly lower than the homogenizing section, 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.
- Preshon di Ekstrushon: The extrusion pressure of engineering plastics twin-screw extrusion generally ranges from 5 to 15MPa. The pressure in the extrusion cavity is mainly determined by the compression ratio of the screw, the die hole size and the screw speed. The higher the extrusion pressure, the better the mixing and dispersing effect of materials, and the denser the product. Pero, if the pressure is too high, it will increase the energy consumption and wear of the equipment, and even cause the die head to block; if the pressure is too low, the materials cannot be fully compressed and mixed, the product is loose, and the performance is unstable. 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 Die Head Structure
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 (granulonan), 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, the die head should be designed according to the shape and size of the product, and the flow channel of the die head should be smooth to avoid material accumulation and local overheating. The die head should also be equipped with a temperature control device to ensure the uniform temperature of the die head and the stable shaping of the product.
3. Our HTS Series Extruders: Professional Solutions for Engineering Plastics Processing
Nos ta enbolbí pa hopi tempu den e investigashon, development and production of high-performance twin-screw extruders, and have accumulated rich experience in the field of engineering plastics processing. According to the processing characteristics of engineering plastics (sensitivity to overheating and hydrolytic degradation, high requirements on mixing and dispersing effect, viskosidat haltu) and application needs, 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 (Serie HTS PLUS i serie HTS SUPER) or imported from leading European manufacturers (HTS BASIC series), with a specific torque of 14Nm/cm³, which is much higher than that of ordinary twin-screw extruders (general torque is 8-12Nm/cm³). The high torque design ensures that the extruder can stably convey high-viscosity engineering plastic materials, avoid material accumulation and equipment blockage, and improve the stability of the extrusion process.
Na mes momento, the HTS series extruders have a high speed design, with a maximum speed of up to 1000rpm. The high speed can generate strong shear force and mixing force, which can fully break the agglomerates of modifiers, make the modifiers uniformly dispersed in the resin matrix, and improve the mixing and dispersing effect. Ademas, the high speed design also greatly improves the production efficiency: compared with ordinary extruders, the production efficiency of HTS series extruders can be increased by 30%-50%, which can meet the large-scale production needs of engineering plastics enterprises.
3.1.2 Short Residence Time, Effectively Avoiding Thermal Degradation
As engineering plastics are sensitive to overheating and hydrolytic degradation, the residence time of materials in the extruder is crucial. Our HTS series extruders adopt an optimized screw structure and barrel design, with a short residence time of only 1-3 minütnan, which is much shorter than that of ordinary twin-screw extruders (5-10 minütnan) and single-screw extruders (10-15 minütnan). The short residence time can effectively reduce the contact time between the material and high temperature, avoid thermal decomposition and hydrolytic degradation of the material, and ensure the mechanical properties and heat resistance of the product.
Ademas, the screw of the HTS series extruders adopts a modular design, and different screw elements can be freely combined according to the type of engineering plastic, which can further adjust the residence time of the material, ensuring that different types of engineering plastics can obtain the optimal residence time during processing.
3.1.3 Kontrol di Temperatura Presiso, Stable Performance
The HTS series extruders adopt an advanced intelligent temperature control system, which can realize precise control of the temperature of each section of the barrel and the die head. The temperature control precision can reach ±1℃, which can strictly control the processing temperature within the optimal range of engineering plastics, avoid local overheating and thermal decomposition of the material. The temperature control system is equipped with a real-time monitoring and alarm function: 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.
Ademas, 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 Efekto di Meskla i Dispershon Ekselente
The HTS series extruders adopt an intermeshing co-rotating twin-screw structure, ku un pitch di skru rasonabel, 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 (such as glass fiber, fibra di karbon, talko), 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%, which is much higher than that of ordinary twin-screw extruders (85%-90%).
The screw of the HTS series extruders adopts a modular design, and different types of screw elements (such as conveying elements, elementonan di meskla, shearing elements) can be freely combined according to the type of engineering plastic and modifier. Por ehèmpel, 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 High Wear Resistance, Long Service Life
In the processing of reinforced engineering plastics (such as glass fiber reinforced PA, carbon fiber reinforced PPS), the added modifiers have high hardness, which will cause serious wear to the screw and barrel of the extruder. Our HTS series extruders adopt high-quality wear-resistant materials and advanced manufacturing technology to ensure the wear resistance of the core components.
The screw and barrel of the HTS series extruders are made of imported wear-resistant alloy steel (such as 38CrMoAlA), and undergo bimetallic composite treatment or laser cladding treatment. The surface hardness of the screw and barrel can reach ≥65 HRC (HTS BASIC series) and ≥70 HRC (Serie HTS PLUS i serie HTS SUPER), which has extremely strong wear resistance and corrosion resistance, and can effectively resist the wear caused by high-hardness modifiers. This greatly extends the service life of the screw and barrel: the service life of the screw and barrel of the HTS series extruders is 2-3 biaha esun di ekstrudernan komun, reducing the frequency of component replacement and the maintenance cost of the equipment.
Ademas, we also provide professional wear detection services for the screw and barrel. Our technical team will regularly detect the wear degree of the screw and barrel for customers, issue a detailed wear report, and put forward targeted replacement and maintenance suggestions, ensuring that customers only replace components when necessary, avoiding unnecessary waste.
3.1.6 Rango di Aplikashon Amplio, Strong Flexibility
The HTS series extruders have a wide application range, which can adapt to the processing needs of various engineering plastics, including general engineering plastics (PA, PC, POM, BESTIA DI KAS, PBT) and special engineering plastics (PPS, PEEK, PSU, PES). The extruders can also adapt to the processing of various modified engineering plastics, such as reinforced engineering plastics (glass fiber reinforced, carbon fiber reinforced), toughened engineering plastics, flame-retardant engineering plastics, antistatic engineering plastics, etc.
The modular design of the HTS series extruders (skruf, bari, muri kabes, etc.) makes the replacement of components more convenient and quick. When customers need to adjust the product type (such as switching from PA processing to PPS processing) or modify the formula, they only need to replace the corresponding components, sin remplasá henter e ekipo, which reduces the cost of equipment transformation and improves the flexibility and adaptability of the equipment. Ademas, the HTS series extruders can also be matched with different auxiliary equipment (manera mesklernan di velosidat haltu, sekudónan, frishidèr, granuladónan, mashinnan di screening, mashinnan di pakete) pa forma un liña di produkshon outomátiko kompleto, realisando produkshon kontinuo for di pretratamentu di materia prima te na empaketahe di produkto.
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, fásil pa operá. The system can store multiple sets of product formulas and processing parameters. When customers produce different types of engineering plastics, they only need to call the corresponding formula and parameters, without repeated debugging, which saves time and improves production efficiency.
The system is also equipped with a real-time monitoring function, which can monitor the key parameters of the extrusion process (such as temperature, preshon, velosidat di skru, velosidat di alimentashon) 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, realisando maneho di produkshon inteligente.
Ademas, the HTS series extruders adopt a reasonable structural design, which makes the maintenance more convenient. The screw, bari, die head and other components can be disassembled and assembled quickly, which reduces the maintenance time and labor intensity. Our after-sales service team will provide professional installation, commissioning and training services for customers, ensuring that customers can use the equipment smoothly.
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 series, Serie HTS PLUS i serie HTS SUPER. Each series has its own characteristics and targeted adaptation scenarios, which can be selected by customers according to their own production scale, product type, budget and other factors.
3.2.1 HTS BASIC Series Extruders: Flexible and Cost-Effective Choice for General Engineering Plastics
The HTS BASIC series extruders are a cost-effective product series designed for engineering plastics processing enterprises with medium and small production scales or initial entry into the industry. This series of extruders uses medium-torque gearboxes from leading European manufacturers, which have the advantages of stable performance, zonido abou, high efficiency and long service life. The medium-torque design (torsi spesífiko 10-12Nm/cm3) can meet the processing needs of most general engineering plastics (such as PA6, PA66, POM, BESTIA DI KAS, PBT) and low-to-medium modified engineering plastics (such as glass fiber reinforced PA with filling amount ≤30%).
Pa loke ta trata diseño struktural, the HTS BASIC series extruders adopt a twin-screw parallel co-rotating structure, with a screw diameter ranging from 30mm to 65mm, and a compression ratio of 4～8, which can be adjusted according to the type of engineering plastic. The barrel is made of wear-resistant alloy steel with nitriding treatment, and the screw is made of wear-resistant and corrosion-resistant alloy steel, which has good wear resistance. The extruder is equipped with a PLC control system and a touch screen operation interface, which can realize automatic feeding, kòntròl di temperatura outomátiko, automatic pressure control and automatic cutting, and is simple and easy to operate.
The production capacity of the HTS BASIC series extruders ranges from 100kg/h to 500kg/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. One of the biggest advantages of this series is that it can provide flexible options through different configuration combinations. Customers can choose different screw elements, kabesnan muri, feeding devices, drying devices and post-processing equipment according to their own product types, 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, which can help enterprises reduce the initial investment cost.
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, with a specific torque of 14Nm/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. The screw and barrel adopt bimetallic composite treatment, which has higher wear resistance and corrosion resistance (duru di superfisie ≥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, which can realize precise control of extrusion parameters and real-time monitoring of production data, 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, representing the advanced level of China’s extruder development. This series of extruders is mainly designed for the processing of high-end special engineering plastics (manera PEEK, PI, PSU, PES) and high-performance modified engineering plastics (such as carbon fiber reinforced PEEK, glass fiber reinforced PI), which is suitable for large-scale high-end engineering plastics processing enterprises that pursue high precision, high performance and intelligence.
The HTS SUPER series extruders have a screw diameter ranging from 80mm to 130mm, a compression ratio of 6～12, and a screw speed range of 250～1000 rpm. The screw and barrel adopt imported wear-resistant alloy steel and laser cladding technology, which has extremely high wear resistance and corrosion resistance (duru di superfisie ≥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, monitoreo di dato di produkshon, predictive maintenance of equipment and data analysis, realisando maneho di produkshon inteligente.
The production capacity of the HTS SUPER series extruders ranges from 1000kg/h to 3000kg/h, which is suitable for the large-scale production of high-end special engineering plastics and high-performance modified engineering plastics. This series of extruders has the advantages of high precision, strong customization, multi-function and stable performance, which can meet the most stringent processing requirements of high-end engineering plastics. The short residence time (1-2 minütnan) and precise temperature control can effectively avoid the thermal decomposition of special engineering plastics, ensuring the excellent performance of the product. Ademas, 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, enterprises need to comprehensively consider their own production needs, product types, processing scale, budget and other factors to ensure that the selected equipment can meet the actual processing needs and bring maximum economic benefits. The following are some specific selection suggestions:
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, BESTIA DI KAS, 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 (kantidat di yena 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) and high-performance modified engineering plastics (filling amount ≥50%, such as carbon fiber reinforced PEEK), 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 (manera retardante di kandela, kompatibilisadónan, reinforcing agents) na mes momento, 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. Por ehèmpel, 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. Ademas, 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. Ademas, enterprises should also consider the after-sales service of the equipment. Our HTS series extruders provide a complete after-sales service system, inkluyendo instalashon, enkargo, entrenamentu tékniko, 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, meskladó di velosidat haltu, 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. Por ehèmpel, 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
Plastik di ingenieria, with their excellent comprehensive performance, have been widely used in automotive, eléktriko i elektróniko, médiko, aeroespasio, kímiko, 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. Abou, 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: Lihé, 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. The engineering plastics used in the automotive field mainly include PA, POM, PC, PBT, PPS, etc., which are mainly used in engine parts, interior parts, exterior parts and electrical components. E rekisitonan prinsipal pa prosesamentu di ekstrushon ta: lihé, resistensia na temperatura haltu, resistensia na desgaste, stabilidat dimenshonal i VOC abou (kompositonan orgániko volátil), ku ta rekerí pa e ekstruder tin un kòntròl di temperatura presis, efekto di meskla i dispershon ekselente i kapasidat di produkshon stabil.
Pa piesanan interior di outo (manera panelnan di instrumento, panelnan di porta, kanalnan di aire) trahá di plèstik di ingenieria general (PA6, POM, Aleashon PC/ABS), e ekstrudónan di e seri HTS BASIC por kumpli ku e nesesidatnan di prosesamentu. Su konfigurashon fleksibel por ahusta e parameternan di prosesamentu segun e rekisitonan di rendimentu di partinan interior, garantisá e superfisie liso i stabilidat dimenshonal di e produkto, i su konsumo i kosto abou di energia por redusí e kosto di produkshon di piesanan di outo. Pa piesanan di motor di outo (manera manifoldnan di entrada, tapa di kabes di silinder, bòter di zeta) 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, precise temperature control and short residence time can avoid thermal decomposition of high-temperature resistant materials, ensure the insulation performance and corrosion resistance of the product, and meet the strict requirements of new energy vehicles on parts performance.
Estudio di Kaso: A large automotive parts manufacturer specializing in new energy vehicle battery parts selected our HTS SUPER series extruders (screw diameter 100mm) to process carbon fiber reinforced PEEK battery shells. The PEEK material has high viscosity and high temperature resistance, and the carbon fiber filling amount reaches 40%, which has extremely high requirements on extrusion equipment. The HTS SUPER series extruders, with their ultra-high torque of 14Nm/cm³ and maximum speed of 1000rpm, generate strong shear force and mixing force, 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 minütnan) 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% pa 99%, and the production cost is reduced by 15%, which has won high recognition from the enterprise.
4.2 Electrical and Electronic Field: Isolashon Eléktriko, 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, wiring boards, relays, motornan, cable ties, lamp covers and other components. E rekisitonan prinsipal pa prosesamentu di ekstrushon ta: excellent electrical insulation, retraso di kandela, stabilidat dimenshonal, corrosion resistance and low toxicity, ku ta rekerí pa e ekstruder tin un kòntròl di temperatura presis, good mixing and dispersing effect and strict quality control capacity.
For general electrical components (such as cable ties, konektornan) trahá di plèstik di ingenieria general (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, etc., which are mainly used in medical containers, kateternan médiko, implantenan médiko, surgical instruments and other products. E rekisitonan prinsipal pa prosesamentu di ekstrushon ta: presishon haltu, no pollution, rendimentu stabil, 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, implantenan médiko) made of medical-grade special engineering plastics (PEEK di grado médiko, 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 (Bon Práktika di Fabrikashon) 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, etc., which are mainly used in aerospace components, aircraft interior parts, satellite components and other products. E rekisitonan prinsipal pa prosesamentu di ekstrushon ta: ultra-high precision, ultra-high temperature resistance, rendimentu stabil, 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, resistensia na desgaste, high temperature resistance and pressure resistance. The main engineering plastics used in the chemical field include PPS, PEEK, PVDF (polyvinylidene fluoride), etc., which are mainly used in chemical equipment, pipelines, valves, pumps and other products. E rekisitonan prinsipal pa prosesamentu di ekstrushon ta: resistensia na koroshon, resistensia na desgaste, rendimentu stabil, 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, processing parameters, equipment performance and other factors, various problems often occur, which affect the product quality and production efficiency. Abou, 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, burbujanan, 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.
Causes: 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. The screw speed is too low, 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.
Solushonnan: 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 (presishon di kòntròl di temperatura ±1°C) 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 minütnan; 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 (such as glass fiber, fibra di karbon), and the mechanical properties (forsa, duru, resistensia na desgaste) are uneven, which cannot meet the use requirements. This problem is common in the processing of modified engineering plastics.
Causes: 1. The premixing effect of raw materials is poor, and the modifiers are not uniformly adhered to the surface of the resin; 2. The screw speed is too low, 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.
Solushonnan: 1. Optimize the premixing process, increase the mixing speed (800-1200rpm) and mixing time (5-10 minütnan), 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 (such as glass fiber, fibra di karbon) on the screw and barrel during the processing of reinforced engineering plastics.
Causes: 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.
Solushonnan: 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) and ≥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. Ademas, our professional technical team can provide regular wear detection services for the screw and barrel, and put forward targeted replacement and maintenance suggestions.
5.4 Problem 4: Unstable Product Size and Dimensional Deformation
Symptoms: The size of the extruded product (such as granules, tubonan, blachinan) 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.
Causes: 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. E materia prima tin un absorshon haltu di awa, i e humedat ta kousa enkohimentu desigual durante prosesamentu.
Solushonnan: 1. Usa e sistema di kòntròl di temperatura presis di e ekstrudónan di e seri HTS pa garantisá e stabilidat di e temperatura di ekstrushon, i evitá fluktuashon di temperatura; 2. Ahustá e velosidat di alimentashon i velosidat di skru pa garantisá e stabilidat di e velosidat di ekstrushon, i usa e funshon di regulashon di velosidat di konvershon di frekuensha di e ekstrusornan di e seri HTS pa realisá e ahuste sinkróniko di alimentashon i ekstrushon; 3. Optimalisá e proseso di friamentu, garantisá un velosidat di friamentu uniforme, ahusta e temperatura di awa di friamentu (20-30°C) i tempu di friamentu (2-5 minütnan) pa friamentu di strip, i usa friamentu di aire òf friamentu di spuit di awa pa tubo i blachi pa evitá friamentu desigual; 4. Kontrolá i optimalisá e struktura di kabes di die, garantisá e kanal di fluho suave, 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.
Causes: 1. The screw speed is too low, 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.
Solushonnan: 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. Ademas, the HTS series extruders adopt an optimized structural design and high-efficiency motor, which can reduce energy consumption by 15%-20% compared with ordinary extruders.
6. Conclusion and Future Development Trend
Plastik di ingenieria, komo un material klave di rendimentu haltu, 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, efisiensia di produkshon i efekto di aplikashon di produktonan di plèstik di ingenieria. Our HTS series twin-screw extruders, inkluyendo HTS BASIC, HTS PLUS and HTS SUPER, are specially designed for the processing characteristics of engineering plastics (sensitivity to overheating and hydrolytic degradation, high requirements on mixing and dispersing effect, viskosidat haltu), with the advantages of high torque, velosidat haltu, kòntròl di temperatura presis, ekselente resistensia na desgaste, 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.
Mirando padilanti pa futuro, with the continuous upgrading of downstream industries such as automotive lightweight, inteligensia eléktriko i elektróniko, 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:
Prome, 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. Na mes momento, 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.
Segundo, high performance and high efficiency. The demand for high-end engineering plastics (manera 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 (skruf, bari, kaha di engranahe) will be further optimized to improve wear resistance, corrosion resistance and service life. Na mes momento, the energy consumption of the equipment will be further reduced, realisando produkshon di haltu efisiensia i sparmentu di energia.
Di tres, personalisashon i diversifikashon. Diferente tereno di aplikashon i diferente produkto tin rekisitonan mas i mas personalisá pa prosesamentu di ekstrushon. E futuro ekstrudónan lo adoptá un diseño modular mas fleksibel, ku por remplasá elementonan di skru lihé, kabesnan di die i otro komponentenan segun nesesidatnan di kliente, realisando e prosesamentu di múltiple variedat i lotenan chikitu. Na mes momento, nos lo proveé solushonnan personalisá mas personalisá segun e nesesidatnan spesial di prosesamentu di klientenan, kumpli ku e demandanan diverso di merkado.
Di kuater, protekshon di medio ambiente i bèrdè. Ku e fortalesimentu di polítikanan mundial di protekshon di medio ambiente, protekshon di medio ambiente lo bira un direkshon di desaroyo importante di ekipo di ekstrushon. E futuro ekstrudónan lo adoptá materialnan i prosesonan di fabrikashon mas amigabel pa medio ambiente, redusí konsumo di energia i emishon di kontaminante; na mes momento, nan lo ta mas kompatibel ku plèstiknan di ingenieria resiklábel i plèstiknan di ingenieria biodegradabel, promoviendo e desaroyo bèrdè di e industria di plèstik di ingenieria.
Semper nos lo atené nos mes na e konsepto di inovashon teknológiko, enfoká riba e nesesidatnan di desaroyo di e industria di plèstik di ingenieria, invertí kontinuamente den investigashon i desaroyo, optimalisá e rendimentu di e ekstrudónan di e seri HTS, mehorá servisio despues di benta, i proveé mas profeshonal, solushonnan di ekstrushon di dos skru efisiente i inteligente pa empresanan di prosesamentu di plèstik di ingenieria mundial, yudando e desaroyo di kalidat haltu di e industria di plèstik di ingenieria.