압출 다이 문제 해결 가이드: 전기 구역 및 히터
때로는 가장 체계적인 작업조차도 광범위한 문제 해결이 필요한 예상치 못한 생산 시작 문제에 직면할 수 있습니다. 문제를 정의하고, 가능한 원인을 분류한 다음 해결책을 개발하는 체계적인 접근 방식을 사용하면 주사위 시스템을 성공적으로 온라인으로 가져올 수 있습니다.
현장에서의 서비스 및 기술 지원 경험을 통해 설정 문제의 몇 가지 일반적인 원인을 파악하여 문제 해결 프로세스를 신속하게 추진하는 데 도움이 되었습니다.
히터 점검
다이 및/또는 피드블록을 생산 라인에 다시 설치할 때마다 히터를 확인하는 것이 중요합니다. 장비가 최근에 보관소에서 꺼내졌거나, 최근에 수리되었거나, 예방적 유지 관리 이벤트를 위해 단순히 가동이 중단된 경우에 해당합니다.
설치 과정을 완료하기 전에 히터를 점검하면 히터가 제대로 가열되고 있는지 확인할 수 있으며 생산을 시작할 때 추가 문제가 발생하지 않도록 할 수 있습니다.
히터를 점검할 때는 다이 또는 피드블록과 함께 제공된 전기 도면에 포함된 정보를 참조하세요. 전기 도면에는 구역의 개수, 각 구역에 있는 히터의 수, 각 구역 히터의 와트수가 표시됩니다.
Example Electrical Drawing
- In this example drawing, we see the zones for the flex and non-flex bodies of an extrusion die (highlighted in orange). Each zone is labeled, for a total of 10.
- This diagram also shows that the end zones (1, 5, 6, and 10) have fewer heaters than the center zones (highlighted in green). This also means that these zones have a reduced number of total watts.
- Finally, at the center of the drawing (highlighted in blue), we see the pin designations, beginning on the left.
This information will be important to note as you begin checking heaters.
Once you’ve reviewed the information in your electrical drawing, you may begin testing the heater by checking the ohms in each zone using a multimeter, reading across the corresponding pins. We will use the information from the drawing above as an example, so Zone 1 is across from Pins 1 and 2.
First, we need to calculate the total number of ohms (Ω), using Ohm’s Law, in Zone 1:
Ohm’s Law: Ohms = Voltage (V) x Voltage (V) ÷ Watts (W)
240 V x 240 V = 57,600 Total Voltage
3 Heaters x 500 W Each = 1,500 Total Watts
57,600 ÷ 1,500 W = 38.4 Ω (± 10%)
The number of heaters differs for each zone in this die, so we will need to complete a similar exercise to find the total number of ohms for Zone 2, as well as any other zones with a different number of heaters:
Ohm’s Law: Ohms = Voltage (V) x Voltage (V) ÷ Watts (W)
240 V x 240 V = 57,600 Total Voltage
4 Heaters x 500 W Each = 2,000 Total Watts
57,600 ÷ 2,000 W = 28.8 Ω (± 10%)
Using an ohmmeter, check the value of the corresponding pins for each zone. If the measurements differ from the calculated value, then you’ll need to check each individual heater within the zone as there may be an issue. To do this, you will need to calculate the heater ohms (Ω) of the individual heater:
Ohm’s Law: Ohms = Voltage (V) x Voltage (V) ÷ Watts (W)
240 V x 240 V = 57,600 Total Voltage
Divide the Total Voltage by the Heater’s Wattage (500 W)
57,600 ÷ 500 W = 115.2 Ω (± 10%)
If your heater ohm reading differs from this value, verify that the installed heater has the correct voltage and wattage required (this information is engraved on the heater). If this information is correct, then the heater may be bad and should be replaced.
Checking Electrical Connections to the Die System Zones
Whether you are installing a brand-new die or feedblock, or one that’s been recently refurbished or pulled from storage, it’s important to ensure that all electrical components are in the proper position to function correctly. This process can be completed in a relatively short time and saves a lot of frustration later during start-up.
This procedure should be completed when your die or feedblock is at an ambient temperature. Starting from one end of the die, begin turning power on to one zone at a time. Once the temperature begins to climb for the activated zone (approximately 10°F), turn the power back off and move to the next zone to repeat the process.
While simple, this process ensures two things. First, you are confirming that the correct zone is heating once power is applied. Second, you are confirming that each thermocouple is installed in the correct location.
If you notice that a different zone is heating when power is applied, then there could be an issue related to wiring or thermocouple placement. If a zone does not turn on, check if there is a solid-state relay that needs to be replaced, if there is a fuse blown in the control panel, or if there is a loose or broken wire.
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