Presentation on theme: "ALWAYS IN THE FOREFRONT IN EXTRUSION SYSTEM SINCE 1952."— Presentation transcript:
ALWAYS IN THE FOREFRONT IN EXTRUSION SYSTEM SINCE 1952
Aluminium Middle East 2013 Innovation Podium HIGH RELIABILITY AND EFFICIENCY ALUMINIUM EXTRUSION PLANTS Author : Giulia Bertoli – Sales Manager OMAV S.p.A. Italy
Facility sqm Employees 180 people Turnover mln euro Products press feeding line handling systems aging oven die cleaning equipments aluminium foudries heat treatment furnaces OMAV
PRE-ASSEMBLY AS A QUALITY TEST QUALITY ASSURANCE
THE ELECTRICAL & SOFTWARE DEPARTMENT This section of our company is dedicated to planning and designing the electrical project, prepare and complete all the wiring on board of the machines. We make safety and reliability our prime objectives and use the latest technology to ensure that our machines meet all electrical safety standards and customer’s requirements.
OMAV has focused on the standardization of middle size extrusion lines for logs of diameters 7” (177,8 mm) – 8” (203,4 mm) – 9” (228,6 mm) in order to be more competitive and to be able to reach a 99% AVAILABILITY for the press feeding line and 99% for the handling system line. EAP - EQUIPMENT AVAILABILIY PERCENTAGE (Available time – Downtime time) x 100% Available time HIGH AVAILABILITY AND HIGH EFFICIENCY EXTRUSION LINE
7” EXTRUSION LINE – STD CONCEPT LOG STORAGE TABLE LOG PUSHER LOG FURNACE HOT LOG SHEAR AIR COOLING SYSTEM HAND OFF PULLER WITH SAW ON BOARD STRETCHER HEADSTOCKSTRETCHER TAILSTOCK PROFILE STACKER COLD SAW AGING OVEN
SECTION OF THE PLANT 7” EXTRUSION PLANT – STD CONCEPT
MAIN TECHNICAL FEATURES PRODUCTIVITY OF THE LINE1.000 kg/h LOG DIAMETER7” LOG FURNACE PRODUCTION2.450 kg/h – 36 b/h LOG FURNACE LENGTH12,3 m HOT LOG SHEAR80 Ton MAX PROFILE WEIGHT8 kg/m PROFILE DIMENSIONheight = 150 mm; width = 350 mm QUENCH UNIT6 m with air cooling 6 m water spray cooling - 120m3/h water consumption LATERAL DOUBLE PULLER WITH SAW ON BOARD 20 kg kg pulling force STRETCHER FINGERS TYPE50 Mton FINAL CUT SAW7.500 mm 7” EXTRUSION LINE – MAIN DATA
LOG FURNACE LOG FURNACE PRODUCTIVITY 2450 kg/h 35 b/h ENERGY CONSUMPTION from 180 kcal/kg to 220 kcal/kg ± 10% for 2450 kg/h at 400°C
REDUCTION OF HEAT DISPERSION New concept of door for the log entry and exit Thermocouple gate LOG FURNACE
BETTER MAINTENANCE Movable external protection Thermocouple on the top of the furnace Increasing of rollers mean-life of 30% thanks to better alloy and new design. LOG FURNACE
HIGH INSULATION First layer faced to the burners made in refractory concrete Second layer made with insulating material in ceramic fiber BIGGER HEAT EXCHANGER to reach 300° C air temperature. CONTINUOUS REGULATION of the COMBUSTION RATIO in function of the temperature of the combustion air.
HOT LOG SHEAR MAIN FEATURES Horizontal shearing. Movable knives to facilitate the introduction of the log into the shear body reducing the log deformation (8%) and to avoid blisters on the profiles. Optimization of the cycle through a software that allows to use the pre-cut billets without changing the tools. Reduction of the shearing time thanks to the system of auto -measurement of the log. Shearing cycle of 40 sec. Special cycle for hard alloy and pre cut billets.
HOT LOG SAW MAIN FEATURES OMAV has engineered and built hot log saws up to 14”. In case of hard alloys the cutting temperature is more than 500°C. A double blade system in case of logs with diameter more than 335 mm to reduce the chips. Controlled lubrication system with nebulized spray directly on the blade teeth. Control of the cutting speed. No need of cooling the blade. Aspiration system to suck the smokes due to blade lubrication.
OMAV engineers and builds different cooling systems according to the customers’ requirements. OMAV offers different solutions for these types of cooling systems: Intensive air cooling Water spray and water wave Water wave, water spray and air in the same quench COOLING SYSTEMS - GENERAL
AIR COOLING The cooling occurs from the top through air channel with suitable slot nozzles near the profiles and from the bottom with air channel. The hood is fed by a fan dedicated controlled by frequency converter and butterfly valve. AIR COOLING FOR LIGHT PROFILES
This configuration gives the maximum flexibility on the cooling regulation of the tunnel, allowing to adjust any deformations of the profiles due to the asymmetric shape. All the valves, ON/OFF and the proportional ones, are controlled by the PLC, it is possible to choose a cooling configuration, according to the profile shape, to put in the PLC memory and to recall the wanted configuration in case of using the same die. COOLING SYSTEMS
OMAV has engineered and built pullers up to 4000 kg (8800 lbs) pulling force. In 2002 OMAV introduced a revolutionary puller system with a rack and pinion drive system. The drive motor is installed directly on board on the puller carriage. The movement occurs thorough a rack and pinion system (helical-toothed). Power supply by contact rails or power track DOUBLE PULLER
Key Advantages Smooth and precise movement of the puller carriage with no surface damage to the profiles (vibrations, die marks). Significantly lower power requirement for the drive motor due to elimination of power transmission elements (chains, cables) DOUBLE PULLER
DOUBLE PULLER INSTALLED POWER MAIN DATA OMAV PULLER TRADITIONAL PULLER WITH TRANSMISSION BY CHAIN OMAV’s PULLER WITH TRANSMISSION BY RACK-PINION AND MOTOR ON BOARD Pulling force200 kg Max Extrusion speed80 m/min Max Return speed200 m/min INSTALLED POWER27 KW11 KW
STRETCHER The movement is provided by powered wheels. Jaw with fingers for a better gripping of the profile and equipped with a common hole to lock together all fingers in case of solid bar. Stretching drive through hydraulic cylinder. Positioning of the tailstock by an absolute encoder or laser photocell. The positioning of the tailstock is locked by a proper anchoring pin. The scraps are 500 mm long each part (headstock and tailstock) but it can change according to different types of profiles.
COLD SAW QUALITY Cutting surfaces completely smooth High cutting precision Optimization of the cycle with a scrap handling RELIABILITY Hard sharps according to the type of alloy Increase of number of cuts per blade Reduction of the noise during the cutting phase thanks to silencer blade EFFICIENCY High performance system for chips evacuation, that are sucked from three points, upper lower and lateral position. 95 % chips aspiration Cutting cycle of 30 sec
OMAV SAW GAUGE TABLE - LATERAL Lateral moveable gauge travels on lateral guides. Movement through AC motor and frequency converter acting through a pinion gear and rack mounted on the frame. Locking brake actuated by air-oil pressure booster, clamps the gauge stop firmly in position.
OMAV AUTOMATIC PROFILE STACKER TYPE: Overhead stacker with 3-axis, with brushless motors and semi- automatic feeding system of spacers. SPACER DISTRIBUTOR: This is a semi-automatic station for spacer feeding. The spacers must be placed manually by the operator inside of a collection box under which are installed the pickup devices. Automatically then the spacers are picked up and sent to feeding position under the stacker. MAIN FEATURES HIGH STACKING PRECISION HIGH QUALITY PRODUCT KEPT THROUGH ALL THE CYCLE HIGH CYCLE TIME – 30 sec without spacers 35 sec with spacers distribution system HIGH AVAILABILITY
OMAV is always focusing on the satisfaction of his customers and wants to be even more close to them. For this reason we believe that is strategic to have a well organized after sales office. We have a unit in OMAV with dedicated people who follow up the customers from the starting project up to the after sales. Then we have established two other units: OMAV FOSHAN for our Chinese customers OMAV NORTH AMERICA for the American market, with dedicated people on the service and after sales. We believe that the results that we have already reached will be a beginning for even better long-term results with the main objectives to satisfy our customers. OMAV’s CHALLENGE FOR THE FUTURE
THANK YOU FOR YOUR ATTENTION We are available for any questions or any additional information