Continuous Lead Sheathing Extruder Type YQL100/5
1. Application
The continuous lead sheathing extruder typeYQL100/5 is designed
with innovation to compound lead sheath over small cables or
mineral cables, which is integrated with the advanced experience in
the domestic and abroad same kind of machine
The machine performs continuous extrusion of lead with the vertical
rotation of a screw to transit the lead upward, which is able to
ensure equal thickness of lead on the longitudinal line of the lead
pipe. Due to the strict control of temperature on each part, the
extruding pressure and temperature can remain constant so that it
is possible to keep the difference in lead thickness within a
minimum.
As the melting & holding pot and the liquefied lead conveyed are
enclosed, vaporization from lead can be greatly reduced. Therefore
this extruder basically does not cause pollution to the
environment.
This extruder is light in weight, and involves low labor intensity
in operation, and takes a comparatively small area.
The extruder extrudes pure lead or alloy lead, and the ideal
composition of alloy lead is as follows:
| m | | |
| 2.1 | Pure lead | Pb-99.99% |
| 2.2 | Lead-antimony alloy | Sb-0.3-0.4% |
| 2.3 | Lead-stannum-antimony alloy | Sn-0.4%; Sb-0.2% |
| 2.4 | Lead-antimony-copper alloy | Sb-0.4%; Cu-0.04% |
| 2.5 | Lead-stannum-cadmium alloy | Sn-0.2%; Cd-0.075% |
3. 3.1.
| Cable diameter | ф6mm～ф36(46)mm |
| Diameter after sheathed lead |
OD ф8mm～ф40(50)mm |
| Main motor of extruder | 55kw(DC)
|
| Heating power for extruding barrel | 18kw |
| Heating power of die stock | 16kw |
| Heating power of Ω pipe | 3kw |
| Heating power of 10T pot | 103kw |
| Power of other auxiliary pumps | ～10kw |
Total power | ～195kw(excluding pay-off & take-up) |
Power source | AC380V 50Hz |
P/O & T/U | Φ800～Φ2000mm or as per demanders require(optional item |
3.2
Lead composition | (r/min) Screw speed (rpm) | (kg/min) Extruded output (kg/min) |
Pure lead | 5～12 | 9～12 |
Soft alloy lead | 5～10 | 6～9 |
Thickness of lead layer: | 0.8mm～2mm | |
Max. outlet linear speed | ≤60m/min (MAX) | |
Water consumption | 5T/h | |
Occupied area | 42m2(L*W:7m*6m)
| |
3.3 5T/h
3.3.Internal water circulating consumption: 5T/h
4. Composition
| Loading unit with rollers | 1set |
10-ton purifying & holding pot |
1set |
Ω lead pipe |
1 pcs |
1 main extruding machine type YQL100/5 | 1set (including gear box, die stock, extruding barrel) |
| Gear lubricant oil system |
1set |
| Internal water circulating system |
1set |
| Rear cooling water system | 1set |
| Flow controller | 1set |
| Electrical control system(including full automatic auxiliary
system) | 1set |
5. Features for Main Composition
5. 1. Loading Unit with Rollers
5. 1.1. It conveys raw material with side transfer, driven by
motor, it is convenient for storing the lead ingot and easy for
operator, which reduce the labor strength, moreover it is equipped
with the clips for lead ingot.
5.1.2. The skid for inlet lead ingot is fixed on the slanting
support frame so that lead ingot can easily slip into the pot.
5.2
Capacity of melting pot | 10 t |
Work temperature | 360～380℃
|
Heating power | 102KW
|
Structure of melting pot |
Specially welded |
Thickness of insulation material | 100mm
|
zones divided in pot |
Melting zone, stirring & refining zone and holding zone |
To open the pot cover | By cylinder |
5.4. ΩPipe
It is used to transfer lead between the melting pot and the
purifying & holding pot, and between the purifying and holding pot
and the extruding machine.
The lead transfer pipe is shaped like Ω Because it expands due to
heating while the molten lead is heated in the holding pot and lead
transfer pipe .
Material of Ω pipe is molded with seamless steel tube with good
quality and without crack lines; at external Ω pipe is wrapped with
the special heaters for heating, which has equal and good heat
conductivity, moreover, the heating unit is not easily damaged,
meanwhile at two ends of Ω pipe are mounted two temperature
checking points, in which temperature checking thermal couples are
set
On top of Ω pipe is mounted an additional manual temperature
checking point to revise temperature
At the lead inlet entry to the host extruding machine, there is a
stearic container so that it can satisfy processing requirements
that cleans up the impurity etc. in the pipe during production
5.5
| Description | Parameter |
Nominal dia. of extruding screw | Φ100mm |
Screw rotating speed | 5～15rpm |
Extruding capacity | 9～12kg/min |
Main motor for extruder | 55kW(DC) |
Small die stock | Φ8-40(50)mm |
Work temperature for extruding barrel | 300～330℃ |
Work temperature for die stock | ～ 290℃ |
Gear box of extruder is of horizontal structure with leakage proof
treatment, motor is connected with spiral bevel gear, the other
gears is forged with alloy steel and cast steel and manufactured
with fine finish rolling
Extruding screw conveys the lead vertically, which reduces effects
of lead layer gravity
Axial die adjusting and die unloading at the entry of die are from
the electric hydraulic station, which is convenient to adjust the
thickness of lead layer and replace the die stock and die tip.
Equality of thickness of lead pipe is achieved with the 4 screws to
adjust the die cover.
At the exit of die is mounted a special spraying unit to supply for
the cooling and crystallization of lead layer.
5.6.Gear Lubricant Oil System
The gear box is oil stored tank, its whole structure for the
machine is reasonable and compact.
The lubricant oil line consists of oil pump, filter, dual coolers,
pressure gauge, etc. additionally is mounted pressure relay to
supervise the lubricant oil line so that it can automatically alarm
due to lack of oil. It saves maintenance time and ensures to resume
production because of oil supply by pump
Lubricant oil enters into the gear box in 5 lines and spray
lubricant oil on contact points of gears and each bearing
5.7.Internal Water circulating & Cooling System
Internal cooling water tank for the machine is under the ground ,
that is , it is at the bottom of host machine, consists of cooling
water pump, safety valve, level controller, 8m2 heat exchanger , etc. which is to cooling each section of
extruding barrel .
Clean soft water is pumped in from the entry of water tank(the
water hardness is less than 4～5°dh, advise to use the distilled
water )
On water tank is mounted level display meter for checking the water
level in it, additionally equipped with the temperature sensor,
flow regulator, pressure relay for supervising the internal cooling
water system, it will automatically alarm due to surpassing set
temperature or lack of water.
It saves maintenance time and ensure to resume production because
of water supply by pump.
Soft water in water tank is transmitted to the upper, middle, lower
heating zones of extruding barrel in 3 lines so that it can adjust
the temperature of extruded lead, and its flow can be adjusted
through valve according to the work state, and cooling water can be
recycled for use after it is out of machine body and back to water
tank
External cooling water supply for the machine is filtered drink
water, which is provided by users, and its flow is 5t/h,
temperature is less than 25℃, pressure is 0.3Mpa. After being
filter, the external cooling water enters into the plate type heat
exchanger to exchange heat with internal recycling cooling water,
in addition it goes through the gear oil cooler, rear cooling unit,
water cooling jacket of die stock for cooling.
5.8.Rear Water Cooling System
It consists of cooling water spraying pipe and subsequent spraying
pipe for stainless steel laundry , which can make the second
cooling for the crystallization of lead layer and crystallized lead
sheath at the exit of die.
At the rear of laundry is mounted air compressed wiper to dry the
surface of lead sheath.
5.9. Flow Controller (including full automatic auxiliary system)
The cooling water pumped out of the bottom of the machine enters
into the extruding barrel in 3 lines through 3 glass rotameters in
coordination with the heaters, inlet water is adjusted by manual
which can control the process temperature of extruding barrel.
Flow meter is equipped with the valve for adjustment, and on it
water flow on each cooling point of machine can be read.
Proportional valve for full automatic auxiliary system is Siemens,
China
5.10 Electrical Control System
Touch screen exchanges data in dual ways through PLC, controls and
monitors the system via PLC process. Output of PLC is transmitted
to each speed regulator to control and monitor status of each
device to carry out control in computer.
Power source |
380V,50Hz |
Total installed capacity |
195KVA(excluding pay-off & take-up, etc.) |
Speed regulator for DC motor |
SSD 591 series, Parker |
Temperature controller |
RKC, Japan |
General low voltage device |
within 63A Schneider, France |
PLC |
S7-1200 series , Siemens, China |
Touch screen |
“WEINVIEW”10`` color |
Display on Touch screen |
1.main machine and auxiliary devices 2.Temperature of each heating zone and set status 3.Automatic proportional valve and set status 4.Heating faults and motor faults 5.Illustrated pictures for each heating zone for watching easily
and directly 6.Cooling water temperature and liquefied lead level 7.Shift for auxiliary pumps
|
Display on recorder(equipped with printer port to collect the data) | 1.Current of main machine and diagram of rotary speed 2.Temperature diagrams of upward, middle and below extruding barrel 3.Linear diagram(signal from spooling dancer) 4.Diagram of Upward, middle and below automatic proportional valve 5.Oil temperature diagram of gear box |
Alarm |
Abnormal control of main motor, low pressure or over temperature of
lubricant oil |
Control of feeding material for pot |
Automatically open feeding motor after liquefied lead alarm |
Electrical control cabinet |
Fully closed structure similar to Rittal, equipped with air
condition to ensure the cleanness in cabinet and normal work of
system |
| Heating for omega pipe | Adopt jumping heating method to ensure normal work |
Heating die stock |
Divide into three zones to ensure easy operation |
5.11. Operation Direction
It’s up to users
5.12. Machine’s Color
Do as per color panel from users
6. Machine’s Protection
We design sealing systems for the holding pot and liquefied lead
transfer pipe considering some oxidation due to low lead molten
point, meanwhile strictly control and supervise the heating
temperature, eliminate lead vaporization and proliferation
For the melting pot, users can mount exhaust unit and water cooling
spraying unit by themselves so that it’s safe to exhaust
7. Items Provided by Users
7.1. Machine’s foundation construction, pipelines project, raw
material for production, necessary tools, measuring apparatus ,
equipments and auxiliary material for installation.
7.2. Water , electricity, and air supply and their pipelines for
connection for the line
7.3. Circulating water pipeline for flow meter cabinet to inlet
points and supply points of machine
7.4. Water circulating supply and water pipeline for cooler , die
stock and stainless laundry(5m3/h, 0.4Mpa, water temperature less than25℃)
7.5. Workshop electricity net and cables to machine’s electrical
cabinet, wires and cables to connect between cabinet and each
control point and among electrical cabinet
Seller supplies the specification of cables
7.6. Air supply and air pipeline to machine’s air inlet points, air
consumption is about 12m3/h
7.7. Exhaust unit and water spraying cooling unit for melting pot
so that it can safely exhaust.
option for customers
630/1600 Gantry travel active pay-off(including tension adjustor )
| Bobbin dia. | Φ630～Φ1600mm |
| Applicable bobbin width | 475～1180mm |
| Bobbin load | 4T |
| Applicable cable dia. | ≤40mm |
| Pay-off speed | 80m/min |
| Pay-off motor | 5.5kwAC motor |
| Motor for travel | 1.1kw |
| Motor for lift/fall | 0.75kw 2sets |
| Motor for clamping | Y90S-6-0.75kw |
800/2000 Gantry travel-on-rail take-up & traversing (including
tension adjustor )
| Bobbin dia. | Φ800～Φ2000mm |
| Applicable bobbin width | 600～1500mm |
| Bobbin load | 6T |
| Applicable cable dia. | Φ5～50mm |
| Spooling speed | 80m/min |
| Spooling motor | 5.5AC motor |
| Traversing motor | 0.75kw |
| Motor for lift/fall | 0.75kw 2sets |
| Motor for clamping | 0.75kw |
