Profile extrusion--manufacturing of preforms and straining with the integrated gear pump.Conventional, separately driven gear pumps A Gear pump uses the meshing of gears to pump fluid by displacement. They are one of the most common types of pumps for hydraulic fluid power applications. Gear pumps however are also widely used in chemical installations to pump fluid with a certain viscosity. have been developed to a high degree of sophistication so·phis·ti·cate v. so·phis·ti·cat·ed, so·phis·ti·cat·ing, so·phis·ti·cates v.tr. 1. To cause to become less natural, especially to make less naive and more worldly. 2. and have been used successfully in the rubber industry for several years. Gear pumps are commonly used in extrusion lines where high extrusion pressures and/or and/or conj. Used to indicate that either or both of the items connected by it are involved. Usage Note: And/or is widely used in legal and business writing. improvements of output rates are required. Because of the excellent plastification properties of single screw screw, simple machine consisting essentially of a solid cylinder, usually of metal, around which an inclined plane winds spirally, either clockwise or counterclockwise. rubber extruders, gear pumps cannot replace extruders for most applications. Gear pumps are designed for high volumetric volumetric /vol·u·met·ric/ (vol?u-met´rik) pertaining to or accompanied by measurement in volumes. vol·u·met·ric adj. Of or relating to measurement by volume. conveying capacities and can only be used within limits for plastification of rubber compounds. Therefore, rubber gear pumps are commonly used in combination with extruders. The design of the extruders, such as hot or cold feed design, is dependent on the process application. Despite the proven process advantages of such extruder gear pump combinations, the addition of a separately driven gear pump leads to considerably higher investment costs Those program costs required beyond the development phase to introduce into operational use a new capability; to procure initial, additional, or replacement equipment for operational forces; or to provide for major modifications of an existing capability. which are sometimes difficult to justify. Therefore, over the last few years, Berstorff intensely worked on the development of an integrated pump as an alternative solution to the conventional extruder gear pump systems. With this development, Berstorff designed a conveying device, integrated in the extruder barrel, featuring four planetary plan·e·tar·y adj. 1. Of, relating to, or resembling the physical or orbital characteristics of a planet or the planets. 2. a. gear spindles driven by the main spindle spindle: see spinning. A rotating shaft in a disk drive. In a fixed disk, the platters are attached to the spindle. In a removable disk, the spindle remains in the drive. Laptops use spindle designations to indicate the number of built-in drives. , firmly connected to the extruder screw (figure 1). [FIGURE 1 OMITTED] The pressure on the inlet inlet /in·let/ (-let) a means or route of entrance. pelvic inlet the upper limit of the pelvic cavity. thoracic inlet the elliptical opening at the summit of the thorax. side of the integrated gear pump ensures that the complete filling of the pump is provided by the single screw extruder. The pump itself is designed to generate the required discharge pressure Discharge pressure (also called high side pressure or head pressure) is the pressure generated on the output side of a gas compressor in a refrigeration or air conditioning system. , considerably reducing the load on the extruder. As a result, the temperature, pressure and conveying capability of the system is being drastically dras·tic adj. 1. Severe or radical in nature; extreme: the drastic measure of amputating the entire leg; drastic social change brought about by the French Revolution. 2. improved. Additionally, by using the integrated pump, the volumetric conveying properties are enhanced, leading to an accurate and uniform output rate. Advantages The advantages of the integrated gear pump can be summarized as follows: * Easy and proven feeding--continuous and reliable feeding of rubber slab (cold or hot) by using a rubber extruder with powered feed roll. * Modular screw design--for cold feed applications, the extruder part can be equipped with a pin-barrel section to increase the energy input into the compound to improve the homogenization homogenization (həmŏj'ənəzā`shən), process in which a mixture is made uniform throughout. Generally this procedure involves reducing the size of the particles of one component of the mixture and dispersing them evenly efficiency of the extruder. * Leakage LEAKAGE. The waste which has taken place in liquids, by their escaping out of the casks or vessels in which they were kept. By the act of March 2, 1799, s. 59, 1 Story's L. U. S, 625, it is provided that there be an allowance of two per cent for leakage, on the quantity which shall appear free extrusion--bearings of the inline gear pump are completely integrated in the barrel of the extruder, with no external leakage possible. Rubber leakage as often experienced with conventional gear pumps has been completely eliminated. * Reduced investment cost--compared to conventional extruder gear pump combinations, the total investment for an extruder with an integrated gear pump is significantly reduced, mostly due to the elimination of an additional pump drive and reduced process control requirements. * Easy operation--the unique design of the integrated gear pump allows the use of only one drive for the single screw extruder and the gear pump combined. This results in a very simple machine operation comparable to a standard single screw rubber extruder. * Reduced spare parts Spare parts, also referred to as Service Parts is a term used to indicate extra parts available and in proximity to the mechanical item, such as a automobile, boat, engine, for which they might be used. Spare parts are also called “spares. cost--by using the integrated pump, the pressure build-up build·up also build-up n. 1. The act or process of amassing or increasing: a military buildup; a buildup of tension during the strike. 2. of the extruder will be reduced and part of the equipment wear will be transferred from the extruder to the pump. Compared with conventional, separately driven rubber gear pumps, at comparable output capacity, the gear spindles of the inline pump can be manufactured at lower cost, and therefore can be offered at a lower, more attractive price. Fields of application Because of the processing advantages of extruders with integrated gear pumps, the new type of system can be used for applications in the technical rubber industry such as: * Compound straining--because of the volumetric conveying characteristics of the integrated gear pump, the machine is able to build up high pressures without excessive temperature increases. This makes the machine very useful for straining applications. * Continuous production of preforms--the use of a rotary Rotary can refer to:
* Profile extrusion--the extruder with integrated gear pump can be used for the production of high precision profiles. The compact design of the inline gear pump system, as shown in figure 3, must be considered as an additional advantage. The space requirement for the installation of an extruder with integrated gear pump is very small. [FIGURE 3 OMITTED]
Table 1--layout dimensions of extruder with integrated
gear pump
GE/IGP GE/IGP GE/IGP GE/IGP
45K 60K 90K 120K
A in mm 1,300 1,700 2,535 3,200
B in mm 700 940 1,020 1,300
C in mm 1,751 1,751 1,751 1,751
D in mm 1,100 1,100 1,100 1,100
Table 2--machine specifications of extruder with
integrated gear pump
Extruder type
GE 45K GE 60K
Screw [empty set], mm 45 60
Screw length, D * 5 5
Screw speed, rpm 105 80/100
Drive power, kW 10 22
Drive power, hp 15 30
Output range, kg/h. ** 40-65 90-120
Output range, lb./h. ** 90-140 200-260
Extruder type
GE 90K GE 120K
Screw [empty set], mm 90 120
Screw length, D * 5 5
Screw speed, rpm 55/68 44/57
Drive power, kW 55 90
Drive power, hp 75 125
Output range, kg/h. ** 315-420 540-720
Output range, lb./h. ** 700-950 1,200-
1,600
* Extruder with additional PIN section available for extrusion of
tough compounds.
** Depending on compound viscosity and pressure.
Pump type
IGP 45 IGP 60
Differential pressure, bar 350 350
Differential pressure, psi 5,076 5,076
Outlet pressure, bar 375 375
Outlet pressure, psi 5,440 5,440
Specific volume per rev., 32 64
[cm.sup.3]
Pump type
IGP 90 IGP 120
Differential pressure, bar 350 350
Differential pressure, psi 5,076 5,076
Outlet pressure, bar 375 375
Outlet pressure, psi 5,440 5,440
Specific volume per rev., 128 256
[cm.sup.3]
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