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Gear extruders

Initial feedback from leading North American automotive weather stripping suppliers is said to indicate that the company's gear extruders have shown dramatic reductions in scrap rates, and are providing $80,000 to $100,000 in cost savings per month, according to the manufacturer. The reduced scrap rates, cost savings and quality control provided by these machines are said to make them ideal for manufacturing Class A rubber products. Used independently or in tandem with a single screw extruder, the gear extruder strains rubber prior to extrusion and removes impurities through 140- to 180-mesh screens. The filtered strips can then be fed into the primary extruder, eliminating the need for screening during the extrusion process. The removal of screens on the primary extruder and use of filtered material lowers extruder pressure, reduces temperature and increases output, according to the company. There is said to be less down time because the extruder can be run continuously without stopping to change screens. Prescreening the rubber also is said to eliminate costs related to quality control, allowing for higher quality part production and reduced scrap from defective parts. The gear extruder is available in three sizes, including 70 mm, 120 mm and 150 mm. Standard features include a two-roll feeder for single of multiple strip feeding, a hydraulic head clamp, three zones of temperature control, a touch screen PLC control, 100 mm, 300 mm and 370 mm screen diameters, respectively, dual head capability and feed strip detectors. The machines can be operated in a number of configurations, including as a gear pump on the front of the primary extruder to enhance extrusion stability. (Davis-Standard)

Circle 100 on card

On-demand rotary cutter

The Simple-Servo on-demand rotary cutter features velocity servo controls said to offer higher accuracy and easier operator control at lower cost than microprocessor-controlled servo cutters. For rotary cutting applications, simpler velocity controls are said to have proven superior to microprocessor controls. PLCs are said to be more costly and delicate than velocity controls, and require software and programming which the company's controls do not. As for accuracy, microprocessor controls must run a scan loop, which can affect the repeatability of the cutting cycle, which is not the case with velocity controls which require no process time, according to the company. Velocity controls are also said to otter a simpler interface. The operator enters the cut length into a counter, eliminating the need to program a PLC, and the keypad with which to do it. Rotary cutting is said to be a basic function that does not require the broad capabilities and associated complexities of a front end microprocessor. With digitally controlled servos, the drive as well as the motor may require replacement due to program incompatibilities. With a velocity-controlled system, only the motor would need replacement. (G.F. Goodman & Son)

Circle 101 on card

Tire identification/stripping

The Print-A-Mark Stripe-It prints a continuous bright stripe on fabric, film, wire and extruded tread stock without disturbing the aesthetics of the product, or the mess associated with conventional striping methods, according to the company. By applying a consistent, precise mark, the Stripe-It is said to reduce ink consumption and spillage onto the product, saving the user money. The company has found a 30% decrease in ink consumption by using the Stripe-It and their striping inks compared to other conventional systems. The company is said to offer the user a wide selection of striping heads, from single and double heads in widths from 1/16" to 1/2". The mounting bracket holds a one or four-liter bottle of ink equipped with a special cap and striping head that mounts over the line. With no tools required, the unit is said to easily adjust for tread thickness to consistently apply stripes in a variety of colors and widths. The Quickset Model 3045 is a machine developed mainly for the tire manufacturing industry. The machine can be manufactured to emboss or deboss serial number tags or tins that are used in the mold where the tire is vulcanized. The tags than allow the numbers to be molded into the sidewall of the tire, according to the company. (Matthews International)

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Extrusion systems

Three extrusion systems have been introduced by the company. The ZE Ultra Torque twin-screw extruder is best suited for the compounding of today's complex resins, while providing high throughput, and easy maintenance and operation. The ZE Ultra Glide series of laboratory and high rate, small lot production machines are designed for the varying needs of today's color masterbatch producers who need to respond more quickly to customers, according to the company. The Compex multi-process compounder is specially designed for low-torque compounding applications, allowing the precise mixing technology that is necessary for the new generation of powder coatings, toners and other heat- and shear-sensitive compounding applications, according to the manufacturer. (Berstorff)

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Sheet roll cutter

The EconoSheeter is said to be an economical air-operated scissor shear sheeter that cuts a wide variety of roll material, from corrugated to foam, rubber, textiles, nonwovens and vinyl. The sheeter is capable of operating stand-alone or in-line as part of a custom designed system. (Contech)

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Redesigned rotating union

The Rotherm Series 200 Olympic rotating union has been redesigned to offer a broader range of sizes for transferring steam or hot water in or out of calenders, mixers and mills. The design construction and performance superiority of Rotherm rotating pressure joints are said to continue in the Olympic product. Designed for long-term, maintenance-free operation, the body is manufactured of aluminum or stainless steel. Two sealed ball bearing assemblies are said to assure clean running surfaces and never require lubrication. The high-density carbon seal is self-aligning. The Series 200 Olympic rotating union is designed for applications that require higher speeds, such as hydraulic applications and the transfer of coolants. They feature speeds up to 3,600 rpm, hydraulic pressures up to 1,000 psi, pneumatic pressures up to 75 psi and temperatures up to 500 [degrees] F, according to the manufacturer. (Bristol Machine & Engineering)

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Injection molding technology

GCP gas counterpressure technology is available on the company's Next Wave, Modular and Universal lines of injection molding machinery. This technology allows for enhanced communication between machinery components, leading to increased efficiency and many other benefits, according to the company. In addition to injection molding, the GCP technology is said to have proven successful with other processes, including structural foam, gas assist, coinjection and PIM (powder injection molding). The GCP process allows for real-time communication between the internal melt pressure (IMP) in the mold cavity and a machine's hydraulic system. It relies on a pre-pressurized system, usually at 200 psi, from the injection nozzle to the mold cavities. Signals from nozzle and cavity transducers combine to generate a single, rather than a double, process variable which automatically controls any pressure changes (injection, pack or hold) to maintain a static IMP. The resultant benefit of this capability is said to be the ability to produce parts with excellent surface finishes and reduced sinks, warpage and cycle times. The GCP technology is custom programmed into the HPM CMD4500 IMM control system. (HPM)

Circle 106 on card

Traverse winding system

The Model MS 103 PMC is said to exemplify the state-of-the-art in traverse winding. This particular dual spindle design was created to solve several problems in winding continuous lengths of a difficult profile product. Both spindles operate through a common dancer system to minimize change over from full to empty spool. Additionally, the machine incorporates the Accu-Wind computer control system to manage all the machine functions and winding patterns into a closely supervised and controlled system. (Progressive Machine)

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