How to effectively use upvc double wall corrugated pipe extrusion equipment

To effectively use the UPVC double-wall corrugated pipe extrusion equipment, it is necessary to pay attention to the equipment's operating procedures, material properties, process parameters, equipment maintenance and other aspects. The following are some key points to help improve production efficiency, ensure product quality, and ensure the long-term stable operation of the equipment:

1. Understand the composition and working principle of the equipment

UPVC double-wall corrugated pipe extrusion equipment usually consists of the following main parts:

Extruder: used to process the raw materials into a tube by heating and pressure.

Mold: used to control the shape of the pipe, especially the formation of the corrugated part. The mold of the double-wall corrugated pipe generally consists of two parts, the inner mold and the flat mold, which are used to form a smooth inner wall and corrugated outer wall.

Cooling system: After the pipe is extruded, it needs to be quickly cooled by a water tank or air cooling system to maintain the shape of the pipe.

Traction system: used to pull and stretch the already formed pipe to ensure that the outer diameter and wall thickness of the pipe are consistent.

Cutting system: Cut according to the length requirements of the product.

2. Choose the right raw material (UPVC)

Raw material selection: The selection of UPVC raw materials is very critical. High-quality UPVC particles or powders have good fluidity, thermal stability and formability.

Ingredient ratio: UPVC raw materials are often formulated with additives such as stabilizers, UV inhibitors, lubricants, etc. The formula should be adjusted according to different product requirements to ensure the quality and performance of the pipe.

3. Adjust appropriate process parameters

The parameters of the extrusion process include temperature, screw speed, pressure, traction speed, etc., which directly affect the quality and production efficiency of the pipe. Reasonable adjustment can ensure the smoothness, corrugation depth, wall thickness uniformity, etc. of the double-wall corrugated pipe. Common adjustment steps are as follows:

Temperature setting: Reasonable temperature control is crucial. Usually, the temperature during extrusion needs to be set according to the melting point and processing requirements of the material. The temperature range of the UPVC extrusion process is generally 170℃-210℃.

Screw speed: Too low screw speed may lead to insufficient output, and too high screw speed may cause excessive shearing, resulting in reduced product quality. It is usually necessary to adjust the screw speed according to production requirements and raw material properties.

Mold temperature control: The mold temperature should be stable between 150℃-180℃. Appropriate mold temperature can help the pipe form a better corrugation effect and ensure the appearance and structural strength of the product.

Pulling speed: The setting of the pulling speed should match the production speed of the extruder and the cooling effect of the pipe. Too fast pulling speed may cause the shape of the pipe to be unstable, and too slow may reduce production efficiency.

4. Optimize the cooling process

Water tank cooling: Double-wall corrugated pipes need to be cooled by water tanks, and the cooling water flow rate, temperature, and water entry method of the pipes need to be precisely controlled. Usually the water temperature of the water tank should be maintained at room temperature or slightly lower than room temperature.

Air cooling: For some thinner or smaller diameter pipes, auxiliary cooling may be required through an air cooling system to reduce product deformation.

5. Mold and corrugated structure design

Mold design: The mold design of double-wall corrugated pipes is very important and needs to be customized according to different pipe diameters, corrugation depths and other requirements. The design of the mold directly determines the corrugation shape and precision of the pipe.

Corrugation depth and spacing: The depth and spacing of the corrugation need to be adjusted according to production needs. Too deep corrugations will cause the pipe to be too thick and heavy, affecting transportation and installation; too shallow corrugations may affect the strength of the pipe.

Inner wall smoothness: The inner wall of the double-wall corrugated pipe needs to maintain good smoothness to ensure the flow of the pipe and reduce water flow resistance.

6. Product quality control

Outer diameter and wall thickness: The outer diameter and wall thickness of the pipe are controlled by adjusting the mold, pulling speed, etc., so that the product fluctuates within the standard range to ensure product consistency.

Tensile strength and strength: Check the tensile strength and pressure resistance of the pipe to ensure its stability in practical applications.

Check the corrugation depth: Ensure that the depth of each corrugation is consistent, and the corrugation shape is regular and meets the design requirements.

7. Equipment maintenance and care

The normal operation of the extrusion equipment requires regular maintenance and care:

Clean the screw and mold: After each replacement of raw materials or long-term use, the screw and mold need to be cleaned to prevent residues from affecting product quality.

Lubrication system: Ensure that the transmission part of the extruder is adequately lubricated to reduce equipment wear and energy consumption.

Check the cooling system: Check the water flow of the cooling system regularly to avoid blockage or failure of the water tank or air cooling system.

8. Automation and quality inspection

Modern UPVC double-wall corrugated pipe extrusion equipment is generally equipped with an automated control system, which can monitor the temperature, pressure, speed and other parameters in the production process in real time, and adjust the operating parameters through the PLC system. In addition, the equipment may also be equipped with an automatic detection system, such as inner and outer diameters, wall thickness, length and other detection devices to ensure that the produced pipes meet the standards.

Only by making full preparations in the above aspects can we improve production efficiency, reduce costs, ensure the quality stability of products, and effectively use UPVC double-wall corrugated pipe extrusion equipment.