Extrusion.

Extrusion

A truly vast array of new extrusion equipment was represented at this year's NPE. In blown film, new auto-profile die technology was unveiled. In sheet, there was ample evidence of an evolution toward greater versatility and control in roll stack designs. New suppliers in all extrusion categories, high-output extrusion lines for pipes and profiles, and sophisticated controls with vivid "object-oriented" displays were also on hand.

BLOWN FILM DEVELOPMENTS

In addition to an all-new HDPE blown film line with rotating die (see PT, March '91, p. 13), Reifenhauser Film Systems, Peabody, Mass., introduced a new generation of its automatic die, called Reicoflex II. Only one model of this die has yet been built in Germany. The first Reicoflex models had piezoelectric actuators located around the die circumference, which expanded and contracted on an electrical signal to selectively deform the die lip. This system had the disadvantages of being expensive, having limited range of movement, and losing control if power was lost to the system. Reicoflex II has a lower-cost actuator system consisting of small servo drives operating through a gearbox and turning a cam "pusher" against a rod that contacts the die. Each servomotor turns 180 [degrees] in 7400 steps for very fine control (18 steps per micron of movement). Total lip-deflection range is now 400 microns.

The new die, suitable for any type of PE extrusion, reportedly has run at [+ or -]1.5% gauge control. Demonstration of its capabilities appears in the accompanying histograms of a 2-mil LDPE lab run in Germany. Four corrections made at 15-min intervals after startup brought 95% (equal to [+ or -] 2 standard deviations) of all gauge measurements at 132 points around the bubble circumference from [+ or -]3.61% or [+ or -]2.71 microns initially to [+ or -] 1.26% or [+ or -] 0.95 microns.

The company is currently quoting on three Reicoflex II retrofits to conventional non-Reifenhauser dies from 18 to 28 in. Package prices for these three systems, involving replacing the upper die assembly and adding a scanning gauge and standalone Reicoflex II microprocessor controller (386-type) are in the range of $200,000-250,000.

As an intermediate level of technology between conventional dies and Reicoflex II, Reifenhauser is offering a patented approach of using a ring-shaped heat pipe to even out temperature around the die circumference.

A similar device, called Positive Heat Transfer, is being employed by Future Design, Brampton, Ont., together with heat-pipe manufacturer Acrolab Instrument Ltd. of Windsor, Ont. (see PT, Jan. '91, p. 74). Future Design showed its new Saturn II dual-lip air ring for HMW-HDPE. What's new is a nonadjustable forming cone; primary and secondary air flows are controlled by an external vernier adjustment located above the chamber assembly.

A Mexican company, Maquinaria Plastics Equipment Co., represented here by Aaron Equipment Co., Bensonville, Ill., is introducing blown film lines for the first time in the U.S. Maquinaria's product line includes blown film systems for HDPE and LDPE. Demonstrated at the show was an HDPE blown film line including a 1 3/4-in. diam. extruder with a 2.5-in. die and a maximum output of 44 lb/hr. Price, including takeoff, is about $40,000.

Macro Engineering & Technology Inc., Mississauga, Ont., displayed its new D9 air ring, which holds the bubble by venturi effect at three points instead of two. This allows putting 50% more air through the ring for 20-30% higher outputs, Macro says. Blowup ratios from 1:1 to 5:1 can be used on the same ring, which is aimed at low-stalk processes.

A new-generation internal bubble-cooling system was on hand from Sano Corp., Passaic, N.J. (see PT, June '91, p. 43). A key feature of System III IBC is its use of situation-based algorithms that are adaptive to the situation presented to the IBC. The system monitors and trends a number of key inputs to "learn" the environmental conditions in which it is operating. Among the conditions for which System III will make adjustment without operator assistance are exhaust duct changes, ambient air changes, and bubble blowouts. Price for the electronics package is $20,000, with additional cost for mechanical components.

Addex Inc., Boston, introduced the Griffin cooling system, an external bubble-cooling device that is said to increase output and reduce gauge variations by controlling ambient air. Production tests running 3-mil LLDPE have shown increased outputs by as much as 30%, according to the company.

Addex also displayed a newly designed oscillating hauloff, called the Gauge Band Randomizer. The GBR, a horizontal-type assembly, is said to differ in major respects from its competition. One distinction is that the turning device is suspended from the outside rather than hung from a spindle in the middle of the tower. The GBR's idler rolls and turning bars are mounted into rings that turn on each other, reportedly a more stable arrangement that is said to avoid wrinkling. The elimination of the center spindle is also said to prevent web wandering. Its height requirements are claimed to be less than other horizontal-type hauloffs (28 in. vs. 6-10 ft), because the drive assembly, driven from the outside by chain and sprocket, replaces gearing normally located at the center in other units.

A compact (120 x 84 in.), three-layer coextrusion blown film line for the meat-packaging industry was introduced by Polysystem International, Inc., Mississauga, Ont. The complete system costs about $290,000.

An unusual film coextrusion demonstration was provided by Alpine American Corp., Natick, Mass., which sandwiched a mixture of PP and recycled post-consumer HDPE between two layers of colored virgin HMW-HDPE (see PT, July '91, p. 11). The two skin layers each constituted 30% of the structure, which was 0.65 mil thick, though Alpine reportedly has run it as thin as 0.5 mil. The core layer (40% of the total) ranged from 30% virgin PP + 10% post-consumer recycled (PCR) HDPE to 15% PP + 20% PCR + 5% virgin HDPE. Alpine says it has run as much as 50% PP, which adds significant extra tear strength and puncture resistance to the structure. This highly unusual example of long-stalk extrusion of PP used a special grade of PP developed by Himont Inc., Wilmington, Del. (see Materials section), specifically for air-quenched film processes. The inclusion of PP reportedly does not decrease output: throughput rate at the show was 320 ft/min, or around 440 lb/hr, from a 160-mm die (22.4 lb/in. of die circumference).

SHEET AND CAST FILM NEWS

Two of the new sheet lines displayed were reported here earlier: HPM's horizontal stack and Sano's new vertical model (see PT, Dec. '89, p. 15 and PT, July '91, p. 72, respectively). Both are indicative of a trend in roll-stack designs toward greater versatility and control.

One of the most versatile models shown was the new Acculayer Versaflex stack from NRM-Steelastic Inc., Akron, Ohio. The lower two rolls of the stack are normally at a 45 [degrees] angle, though they can be lowered to a true horizontal configuration, while the top roll can move 135 [degrees] from vertical to horizontal. The top roll can also be skewed on-the-fly. The conveyor also adjusts in/out and up/down relative to the cooling/polishing rolls. The three rolls have individual brushless d-c drives without speed reducers--gears can cause "chatter" marks, the company says. Cost is 50% more than a conventional stack, but it reportedly is competitive with horizontal sheet lines.

Battenfeld Gloucester Engineering Co., Gloucester, Mass., showed some new enhancements to its 45 [degrees] -angled Model 2000 Slant Stack. Originally developed for glazing-quality sheet, the unit's application range has been broadened to include thick polyolefin sheet and thin films. It now has a dual drive with independent roll drives for low-speed processing of glazing, and a chain drive on all rolls for higher-speed, general-purpose extrusion. Versatility is provided by the motorized top roll, which is infinitely adjustable on-the-fly, and the ability to cool the first three conveying rolls, the first one of which is movable up or down.

Welex Inc., Blue Bell, Pa., has added closed-loop roll-gap positioning via ultralinear potentiometer to its new offset upstack design. The latter has the bottom two rolls set at a 45 [degrees] angle, whereas the top and middle roll are in a conventional vertical arrangement. This line is aimed at producing thick, optical-quality sheet from low-viscosity PETG resin. It has individual brushless d-c roll drives, capable of providing high torque at low speed, plus four Moog servovalves for hydraulic roll positioning. The roll gap can be set from Welex's new touchscreen (see below).

Welex also put new features on a five-roll stack for thin-gauge coextruded PP sheet. The whole stack has a motorized up/down adjustment to facilitate control of the bank of material at the first nip. A new air-knife arrangement holds thin PP sheet against the cooling roll, and a new rotary slitting system (from Tidland Corp., Camas, Wash.) provides a cleaner cut than razor slitting.

Reifenhauser-Van Dorn, Peabody, Mass., has upgraded its optical sheet line with a new, more rugged saw. The company recently sold a line to run both PC and acrylic glazing, which is said to be unusual, but in this case was made possible by a screw design that represents a "good compromise" in ability to run both resins. In cast film, the company has a new agreement to supply bi-axial orientation lines in cooperation with DMT SA of France. That 18-month-old company will supply all downstream components of the line after the die.

McNeil Akron Inc., Akron, Ohio, is entering the U.S. market for sheet lines with systems from parent company Repiquet of France.

PIPE, PROFILES, TUBING

Cincinnati Milacron Plastics Machinery Systems, Cincinnati, had new developments for pipe, siding, and windows at NPE. For pipe, Milacron has completed its HP Designs series (previously including 55 and 80 mm) with a CM92HP screw and barrel that reportedly runs C-900 and C-905 pipe at over 2500 lb/hr (and siding at over 2000 lb/hr). It has a larger diameter and deeper flights in the feed zone and a special metering-section design for better pumping efficiency, providing more uniform wall thickness and pipe appearance.

For siding, Milacron introduced a "Spacemaker" over-and-under dual-extruder setup for capstock coextrusion. While such an arrangement has frequently been used for single-screw coextrusion, it's a bit unusual to see two twin-screws in that position. In this case, a CM55HP was mounted over a CM80HP on a sled that can be adjusted to angles up to 40 [degrees], with 5 in. of front-to-back adjustment relative to the coex feedblock. The new Dow-patent Milacron feedblock reportedly has been proven to give [+ or -] 1-mil capstock uniformity across the panel at rates up to 1500 lb/hr. The system uses a new, compact Milacron EXc microprocessor control with backlit LCD screen.

Milacron reports that a new screw design providing good results over a broad output range from 150 to 600 lb/hr is now enabling its CM65 (65-mm) conical twin-screw to find rapid acceptance in window profiles. Those outputs span both single- and dual-sash extrusion. The CM65 was shown with a new VT3/4ND vacuum calibration table designed for higher rates.

In addition, Milacron says it has responded to requests from window and siding manufacturers with newly offered replacement screws and barrels for imported German and Austrian 100-mm parallel and 60- or 62-mm conical twin-screws.

New twin-screw models for rigid PVC and some innovative downstream equipment from Krauss-Maffei Corp., Florence, Ky., are worth noting. These included a new 130-mm parallel twin-screw said to be capable of producing 2300 lb/hr of pipe. However, it was displayed in combination with a conical 60-mm twin-screw as part of a new siding line that's guaranteed for 1600-1800 lb/hr output. It comes with a new trapizoidal die design with a wide entrance channel to provide lower shear heating. New downstream equipment includes a pair of embossing rolls on a turret that permits changing woodgrain patterns easily.

There are no cooling rolls; the pre-sizer is cooled instead. Sizing tools include a screw adjustment of the undercut to compensate for wear, micrometer side-to-side "bow control" to keep the profile straight, and simple water-level control via a slide gate to keep hands dry. The water tank with all tooling can be lifted off the supporting table as a unit to permit changeovers without requiring realignment the next time that tooling is reinstalled. A wheel-type puller has all wheels directly shaft driven with no chains or sprockets, providing uniform speed with no slippage, according to the company.

American Maplan Corp., McPherson, Kan., showed two new parallel twin-screw extruder sizes: a 108-mm with new, higher-thrust gearbox, capable of 1700 lb/hr or more; and an 88-mm for 1000 lb/hr. In addition, a new-generation window calibration line -- all U.S.-made--includes a number of features to make it easier to service and operate. The belt puller has quick-change cleats and air control that permits balancing the pressure from front to back.

A new siding line from Maplan included a rotary embossing turret that permits changes between four different embossing rolls in 6 sec. A complete set of four rolls can be changed quickly by disconnecting the water hoses and lifting off the rolls as a unit. Also shown was a new-generation sheet die designed for high-volume inventory.

Samples of window profiles incorporating in-house scrap in targeted areas of the extruded piece were shown by Actual Plastics Technology Corp., Philadelphia. The tooling, known as the Rempex system, fits onto the die plate. The regrind can be deposited in areas of the profile that are not as affected by quality criteria such as color, surface finish, or tolerance. This added control permits the use of lower grade regrind than could be used if the regrind were blended with the virgin material. Cost varies with the complexity of the profile and type of material, but generally it adds about 30% to the cost of the tooling, according to the company.

The UC series of pipe corrugators from Unicor GmbH (represented here by A.I.M. International, Macon, Ga.), features a new intensive spray-cooling system on its UC pipe corrugators. The new system, available on corrugators producing pipe to 9.85 in., directly cools metal plates with an intensive water spray. Cooling capacity is said to be increased by 25% over the previous generation, with no additional cost.

A new Calcromsave calibrator for rigid profiles was shown by Mario Calagni & Co., srl (represented by Plastic Consultants International, Dix Hills, N.Y.).

EXTRUDERS, SCREWS, PUMPS

Merritt Extruder Corp., Wallingford, Conn., recently formed by former executives of Sterling Extruder (see PT, July '91, p. 86), exhibited an example of its new extruder line. Standard features are said to include an unusually quiet gearbox; spiral-grooved feed throat with integral water cooling; bolted--not strapped--heaters, which reportedly won't move with thermal expansion and shear off thermocouples; a barrel support that permits axial thermal expansion; new quick-release die-head clamp (which stays open on its own); and new barrier screw design with both variable pitch and variable depth. Although Merritt is pursuing a wide range of applications, in blown film it's concentrating on HDPE, offering 2-and 2 3/4-in. extruders and takeoffs with rotating nip. For reclaim, Merritt offers a unitized system with extruder, screen-changer, pelletizer and pellet dryer on a single base.

Akron Extruders, Inc., Canal Fulton, Ohio, showed its new Auto/Tilt 150, a 1 1/2-in., 24:1 pedestal-mounted coextruder. The roller base has hydraulic and electrical lift and tilt mechanisms, which are controlled from the cabinet. Price is around $30,000. Akron can also build them up to 2-in. diam.

Coming soon from Akron is a 1-in., 24:1 cart-mounted extruder for sophisticated lab work.

In gear pumps, Normag Corp., Hickory, N.C., showed two new models for high-volume operations. One is the PCP Polymer Compounding Pump for use with large twin-screw extruders (10,000-40,000 lb/hr). It comes with such features as steam or oil-heated jackets, explosion-proof drives, and feed-forward pressure-control loops to vary pump speed to control die pressure. Also new is the PRP Polymer Reactor Pump for direct conveyance to a pelletizer after a reactor. This is a new market area for Normag, and the pumps have stainless-steel construction and high-pressure (4000-5000 psi) capacity to permit high throughputs of high-viscosity materials.

Zenith Pumps Div. of Parker Hannifin Corp., Sanford, N.C., introduced the PEP-II series of Polymer Extrusion Pumps, which now incorporate as standard various features that had been provided on custom-built pumps. New gear tooth and bearing designs and one-piece drive shaft and gear are all said to contribute to reduced wear and 5-10% lower energy consumption. Prices have also dropped 5-10%, thanks to changes such as offering bolt-on heating plates with cast-in elements or cooling jackets as standard options. New controls are also more economical by virtue of combining two zones of temperature and pressure in one controller.

HPM Corp., Mount Gilead, Ohio, reports that it is in the final stages of testing two new screw designs. One is a Triple Wave version of its Double Wave barrier screw, said to be especially well suited to LLDPE. The novel, patented Zig-Zag Screw (see photo) reportedly offers "dramatically improved dispersion." Overall, initial results indicate 5% to 20% improvements in mixing, melt-temperature control, and pressure control with these new designs.

WINDERS, CUTTERS, PULLERS

Western Polymer Div. of John Brown Inc., which has moved its headquarters from Newark, Calif., to sister company Egan Machinery's offices in Somerville, N.J., is now for the first time building its own center/surface winders. Features include contact-roll pressure control.

A high-speed, positive cutoff, surface-type contact winder was introduced by Kuhne GmbH (represented by O/K International, Wayland, Mass.). The new winder was developed for high speeds in excess of 393 ft/min for thin-gauge HMW-HDPE. Price is $60,000.

Macro also has a new surface winder that's said to be unusual for having a swing-out roll shaft to eliminate shaft handling. A load/unload attachment for the winder makes it fully automatic. In addition, Macro has upgraded its 60-in.-diam. turret center winder with auto-cutoff in both directions and the ability to wind at up to 2500 ft/min.

ER-WE-PA, Marietta, Ga., is offering a new patented center/surface "cascade winder" with no turrets. Designed for sensitive stretch or embossed films, it reportedly can change and splice rolls automatically every 2 min, totally scrapless. Use of glue has been eliminated, and end-of-roll scrap eliminated along with the turrets, since loss of tension typically occurs when turning the turrets. A lay-on auxiliary backup roll moves into position against the finished roll at the time of roll change, while the primary lay-on roll starts winding against a new core, which has automatically indexed into position. Speeds can be to 1312 ft/min.

Killion Extruders, Inc., Cedar Grove, N.J., introduced two new profile and tubing cutters. One is a table-top mini puller/cutter for tiny medical catheter tubing of 1/8-in. diam. or less (see photo). It has separate electric servo drives on the puller and cutter. The belt puller is the primary puller, not just a feed assist. It's designed not to flatten the tubing when operating at 500 ft/min and costs $30,000.

For rigid profiles, Killion has a new 180-SR rugged clutch/brake on-demand cutter guaranteed to give 300 cuts/min with [+ or -] 5-mil accuracy.

From Conair Gatto, Hauppauge, N.Y., new flexible medical tubing cutters have a very sensitive, tensionless dancer to prevent stretching, and highly accurate d-c driven feed assist. They come with either vacuum clutch/brake or new a-c servodriven cutters. The latter has the blade mounted directly on the motor shaft. Improved control software is said to provide more reliable and accurate cutting than ever. A conventional cutter costs $13,500 and the servo type $17,000-18,000.

For larger, rigid profiles, such as some window lineals, microchip-carrier tubes, and also elastomeric profiles, Conair Gatto has new 4- and 6-in. heavy-duty on-demand cutters. These use a large guillotine instead of a saw. The curved blade has a protruding triangular point along its edge. This point first hits and penetrates the part, after which the curved blade slices the profile in two directions as it descends. Price is around $18,000.

Conair Gatto also announced the first major redesign in 20 years of its up-cut traveling saw. Controls are now above the table at eye level rather than down below. Two cylinders instead of one are used for clamping and cutting, providing better adjustment of clamping relative to blade speed. And new d-c solenoids are said to give faster response. A short-stroke cylinder is said to provide rapid acceleration from a dead-stop position, after which a longer-stroke cylinder takes over. Price is about $13,000.

A number of downstream introductions were on hand from Versa Machinery Co., Somerville, N.J. A new version of a small cutter/feed system, the Minicutter II, includes a standard batch piece counter with auto-stop, by which the machine will cut a designated number of pieces and turn itself off. It has a cutting capacity to 0.625 in. and will cut up to 150 cuts per minute. Also on hand was a Model 50 series cutter/feeder, which attaches the knife to the flywheel, and uses a servo feed system to eliminate variation and simplify setup. Versa also showed a low-tension winder for tubing that can maintain values as low as 1 oz.

CONTROLS AND GAUGES

One technological advance that was hard to miss was several spiffy examples of touchscreen graphics with vivid 3-D effects and "object-oriented" displays designed for intuitive comprehension with a minimum of reading. We have previously reported on the new IQ Series of controls and rugged CRT interfaces for extrusion and other processes from Buhl Automatic Inc., Guelph, Ont. (see PT, April '91, p. 15). A touchscreen and small PLC called the IQ Block were shown configured for gravimetric hopper control and gear-pump control by Luwa Corp., Charlotte, N.C., Buhl's parent company.

High-quality touchscreen graphics were also evident on Welex Inc.'s latest version of its Ultima II sheet-line control. Starting from a line overview schematic (see PT, May '91, p. 80), showing each major piece of equipment and key process parameters associated with it, the operator touches any piece of equipment, and the next screen "zooms" in on that component and its associated setpoints and other data. A diagnostic display of simulated status LED's duplicates what would be seen if the control cabinet were opened up. Trend charts for any variable in the system can be selected by touching a menu. Hitting a simulated "key" on the touchscreen permits instant expansion or contraction of the time span of the trend chart, or a change in the sampling interval.

Davis-Standard Div. of Crompton & Knowles Corp., Pawcatuck, Conn., unveiled its Epic II control for extrusion and blow molding (see PT, June '91, p. 128). It has vivid, easy-to-understand touchscreen graphics that are custom-configured to look like the user's actual line setup. Epic II is an "open" system based on industry-standard components. It integrates a touchscreen, Texas Instruments PLC and Intel 386-type PC with floppy disk drive and Ethernet card for networking. Unlike the Epic I, which was just a supervisory control, this is a full machine control (including Davis-Standard's dual-sensor temperature control and parison control for blow molding). Yet it's available at dramatically reduced cost--around $30,000 vs. $85,000 for Epic I. The touchscreen provides SPC/SQC and real-time and historical trending. Alarm windows pop up automatically, regardless of what display is on the screen, and the operator can move from one control function to another without having to return to an overview screen.

Battenfeld Gloucester demonstrated a new Panelview touchscreen control for its Model 1008 dual-turret center winder. Displays have been simplified to show only the data and input "keys" required for that function. Features include digital display of tension and of turret position in degrees, and the ability to adjust turret and lay-on roll alignment without requiring adjustment of mechanical cams to interchange between 3- and 6-in. diam. winding shafts. On-screen diagnostics of the Allen-Bradley PLC makes troubleshooting much easier, and the system can also be calibrated on-screen.

Three new gauging and control products for flat webs were introduced by Aeonic KGS, Inc., Billerica, Mass. The net effect of these products is to expand its CIMline system range at both the high and low end. To begin with, CIMstart is a new low-cost gauging and control package for relatively low-throughput lines, aimed largely at sheet extruders. It offers the standard CIMline touchscreen operator station with 19-in. color-graphic screen and the usual CIMline displays (scanner, profile, control, recipe, alarms, and trends), together with PC or DEC VAX computer, screw- or hauloff-speed control capability, and a scanning frame with a single basis-weight sensor from Aeonic's standard line--all for a system package of $75,000-90,000. This basic system is fully upgradable in the field with optional modules to bring it up to the full capability of standard CIMline systems costing $200,000 or more. These options include computer redundancy, auto-die profile control, integration with other devices like temperature controllers or PLCs, and multiple sensors.

At the high end, Aeonic KGS introduced a new integrated total line control capability, offering single-source responsibility with components from different companies within the Eurotherm International group. These include the Aeonic KGS gauging and control system, Eurotherm EM-2 temperature control, and SSD drive controls. The only non-Eurotherm component is an Allen-Bradley PLC5 for controlling materials feed to the extruder and sequencing and interlocking for startup and shutdown. Additional features include "one window into the process" instead of several, a single plantwide information database (accessible by PC terminals throughout the plant), and process schematics.

In addition, Aeonic KGS has a new standalone gauging package aimed at OEMs, called Smartsight. It consists of a scanner, basis-weight sensor, and built-in single-board PC that coordinates the overall operation of the scanner. The scanner controller is itself controlled by the OEM's process-control system via Allen-Bradley Data Highway Plus protocol. The "smart" scanner/sensor package sends back measurement data in engineering units to the OEM line control. That eliminates inaccuracies from interpretation of sensor analog data by the central computer. Price is in the range of $45,000-55,000.

New computer software and hardware for high-end flat-web gauging and process control were introduced by Measurex Corp., Cupertino, Calif. Integrated line control (ILC) and "one window into the process" is the concept behind new SuperVision 2002 UT, which contains supervisory control, temperature control, PLC, and gauging in one package. (For the PLC functions, Measurex is now marketing the UniLogic 90-70, built by GE Fanuc.) Not only are all alarms and other data collected in one interface and database, but the control software has also been made much faster. For example, this permits resolving the web profile into 0.25-in. "slices" while scanning at 10 in./sec. And MD variation analysis (separating MD from TD variation) can now be performed independently on each slice, rather than on an entire scan. The same is true of dynamic filtering--i.e., the adaptive control can self-adjust the level of signal-to-noise filtering independently for each slice.

Measurex's second major new product is CIMbase Data Management Application Software for its Vision 2002 Network System. CIMbase combines automatic, real-time data collection and analysis with a large-volume historical or archival database to permit comparisons or "overlays" of what's happening now with what has happened over long periods of past production.

Measurex describes this as highlevel management software for plantwide data integration, permitting flow of data to and from multiple terminals and input devices (including barcode readers). Perhaps its most important application is the Quality Manager for SPC/SQC, with on-line control charting, exception reporting and alarming, plus integration with the historical database.

Measurex also has a new "Turbo" enhancement (standard on new systems and retrofittable to others) for its auto-die control software, which is said to provide faster startups and product changeovers.

Fisher Controls International, Inc., Austin, Texas, had two new CIM products for extrusion plants. One is a new software module for the Allen-Bradley Pyramind Integrator that permits much faster integration of applications running on Allen-Bradley programmable controllers with process information generated by Fisher Provox process-control systems on a Provoxplus data highway. Also, Fisher has a new software module for its Data Historian high-speed data archiving and SPC/SQC package. Data Historian Event initiates event-driven, start/stop data collection and statistical analysis. An end-of-roll report would be a typical example.

Ohmart Corp., Cincinnati, introduced the ConceptOne, reportedly an extraordinarily powerful and flexible gauging package for flat webs for a moderate price--less than $40,000 for a package including a single beta sensor, two displays, and printer. The ConceptOne has a "smart" scanning frame with two Intel 16-bit microprocessors, one for the scanner and one for processing measurement data at rates of 20,000 samples/sec. The frame uses what are said to be maintenance-free linear bearings and a single timing belt for upper and lower heads.

One of the displays is a four-line vacuum-fluorescent digital display of average and last-scan thickness, which can be located up to 50 ft from the frame. The other is a 32-bit Intel 486 workstation with IBM OS/2 multi-tasking operating system, 14- or 19-in. color-graphic screen, and touchscreen, mouse or keyboard interface. All screens are user-defined and are object-oriented rather than text-oriented for quick comprehension.

Software features include closed-loop control, full SPC on 400 data points across the profile, roll archiving, recipe storage, and availability of different languages at the touch of a key. A modem for 24-hr remote "hotline" diagnostics is standard.

LFE Corp., Clinton, Mass., showed what it claims is a step forward in laser caliper technology. These noncontact sensors measure the true thickness of a web, rather than inferring it from mass-density data, as do nuclear gauges. LFE uses two laser heads, one above and one below the sheet. Each finds the distance of the near surface of the web from the sensor, according to the angle of reflectance of the infrared laser beam. From the known distance between the sensors it's possible to calculate the web thickness. Accuracy is said to be [+ or -] 0.1 mil over a range of 0-500 mils. LFE has paired a laser caliper with a nuclear sensor to provide simultaneous weight, thickness and density profiles of PS foam sheet.

LFE gives three reasons why its new caliper is superior to past laser systems. First, laser sensors are known to be temperature-sensitive. LFE therefore uses fans to stabilize the temperature in the heads. Thus, they reportedly can measure near webs at up to 200-300 F without losing accuracy.

Second, the sensor's measuring "window" inevitably gets dirty; so the sensor reads a stationary reference standard at the side of the web to recalibrate itself at specified intervals.

Third, laser caliper readings are affected by color and surface finish of the product being measured. So each system is factory calibrated using samples of the products to be run (only one thickness sample per product is required). When running, the operator keys in a product designation on the LFE Profitmaster 4x4 computer to call up that calibration standard. Typical gauging system cost is $80,000-90,000 with a mid-range computer. However, LFE also offers a lower cost ($10,000 less) version for applications where it is acceptable to touch one side of the web. Such systems use one laser sensor and a reference "shoe" or roll contacting the web on the other side.

A blown film gauge that not only measures thickness variations but also interprets them and identifies the probable cause of gauge variations was on hand from Octagon Process Technology GmbH (Addex Inc., Boston). The Gauge Profile Analyzer (GPA) achieves this through the use of artificial intelligence, which is based on the assumption that all thickness variations on the circumference of the bubble are symmetrical and appear as superimposed sinusoidal waves. Each potential source of gauge irregularities appears as a sort of imprint, or particular number of sinusoidal waves, on the CRT. The AI presents the variations on a bar graph on which the height of the bar represents the relative degree of the deformation. These are matched against equipment design details to give a good indication of the probable cause of the thickness variation.

NDC Systems, Monrovia, Calif., has revamped its whole line of gauging and control systems for blown and cast film, sheet and pipe. New tabletop display consoles have a 7-in. monochrome CRT display of thickness profiles coordinated with diebolt locations, instead of the former LED readout without diebolt references.

For blown film, the new Model 103T can also show a layflat display of thickness profile with diebolt reference. New features also include SPC/SQC, histograms and trend displays, MD trend charting, selectable diebolt average-thickness display, complete roll and shift report, dynamic roll-weight compensation (which retroactively corrects gauge measurements according to the actual finished roll weight), and ability to link up a printer/plotter and remote monitor. With all this, control and gauging is still available for blown film at under $20,000.

For more elaborate quality analysis of flat films, NDC's new Model 8000 floor-standing console system has a 32-bit computer and 19-in. color touchscreen. The latter provides a wide variety of charts, streak detection, auto-die control (standard), zone displays, "quick-start" display, and host-computer link. Split-screen display permits simultaneous display of a full web profile. Price range of the Model 8000 is around $75,000.

The Model 4100T pipe gauging and control system has similar display features and a gamma backscatter gauge with a gimbal counterbalance to ensure that the sensor stays in contact with the pipe surface. It costs around $50,000. A scanning sheet gauging/control system costs less than $40,000.

Contrologic, Blue Bell, Pa., introduced a fine-diameter version of its single-axis (Si 1025) and dual-axis (Si 2025) non-contact O.D. gauges. The dual-axis gauge has a range of 0.003 in. to 0.5 in. and an accuracy of [+ or -] 0.00005 in. while the material is in process, with no averaging required.

"Smart" Gravimetric Supervisor for complex extrusion lines was introduced by Luwa Corp., Charlotte, N.C. Based on Luwa's Smarthopper System (see PT, Aug. '91, p. 21), the package is said to feature sophisticated yet easy-to-use gravimetric extrusion control for up to six main extruders, with up to five-ingredient, on-line proportioning capability per extruder.

Also introduced was a Multi-Smarthopper System, in which three Smarthoppers are linked together into one compact unit to sit on top of an extruder. Cost of a complete Multi-Smarthopper system to handle two additional ingredients plus line control is about $35,000.

PHOTO : A highly versatile sheet line from NRM-Steelastic can alter the angle of the bottom two rolls from vertical to horizontal, while the top roll moves 135 [degrees].

PHOTO : Cincinnati Milacron's Spacemaker puts one twin-screw on top of another (with a variable-angle lifting device) for siding coextrusion.

PHOTO : Two new siding lines allow quick changing among multiple embossing rolls on a turret. Krauss-Maffei's (left) has two rolls. American Maplan's (below) has four.

PHOTO : Rempex tooling from Actual Plastics directs in-house scrap to areas of profiles that are less affected by certain quality criteria. Pictured is a sample of a window profile.

PHOTO : HPM Corp. claims improved mixing, temperature and pressure stability, and output with two new screws: the "Zig-Zag" screw at left and Triple Wave screw behind it at right.

PHOTO : Two new "mini" puller/cutters for tiny medical tubing--Killion's above and Versa's at left.

PHOTO : Attractive touchscreen graphics are the "new look" in several control systems such as this EPIC-II from Davis-Standard/HES.