Extrusion - Crossheads Generation RX. made by ROSENDAHL

Transcription

1 Extrusion - Crossheads Generation RX made by ROSENDAHL Introduction RX Labeling RX Product Overview RX Centering Devices RX Tool Types RX Accessories RX Configuration RX Rheological Analysis RX Features & Benefits

2 Introduction: The Path of Polymers (optional) Rosendahl RX Crosshead

3 RX Insight Tip with cone or thread Distributor for outer skin or stripe Die Miller Main Distributor Body Prehead

4 RX Labeling e.g.: RX 45 F.1.1.T RX 110 M.1.0 RX...Rosendahl Crosshead (X-Head) 45...Max. Conductor diameter [mm] F.Fix centered M Manual centering V...Variabel (both F or M feasable) B...Ball Centering 1...One Layer 2...Two Layers 0...Prehead without extruder connection 1...Prehead with extruder connection for dummy, 2...Skin and stripe distributor Last position Options, additional Info: T...for oil Temperatur control units instead of heaterbands H...High temperature (Fluor material - Inconell) S...Special Design C...Special Tools P...Special Polymers (f.e. PBT,PA,...) E... PEEK (>300 C)

5 RX Product Overview: Data Table I...Insulation; S...Sheating; O...Optical Fiber Cables; C...Coaxial Cables; MC...Micro Coaxial Cables; L...LAN; SC...Solar Cables

6 RX Centering Devices: Fix or Manual fixed manual by 4 screws

7 RX Centering Devices: Variabel Combination of both alternatively: M manually centered F.fix centered Selction by bayonet-lock Position F Position M

8 RX Centering Devices: Ball Centering RX5 B.2.1 Adjusting screw Ball-centering easy leverage high precision calibration self sealing

9 RX5 B.2.1 ball centered double layer / one skin distributor plate for skin distributor outer layer adjusting screws for ball centering

10 RX Tool Types: Compression Tool: melt meets conductor under requested pressure Tube Tool: between die and tip melt gets first formed tubular and then covers to the conductor(s) (ev.vacuum needed) Semi Compression Tool: similar to tube tool but higher pressure onto conductor(s)

11 RX Tool Sets: Tips & Dies Tips with cone or thread cone cone thread thread

12 RX Tool Dimensions Standard Material: hardened steel Inserts if required: tungsten carbide or diamond insert

13 RX Tool Adapters for Existing Tools - on request Tip Tip Adapter Die Die Adapter Tip & Die supplied by customer

14 RX Tool Change: A unscrew die miller B press out die with melt C press (screw) out tip D Insert new tool set (tip & die) C Auxiliary Tool B A

15 RX Accessories: Bypass Systems Type RBP 15 M RBP.. Rosendahl-By-Pass diameter of feeding throat [mm] M... Manual drive P... Pneumaitc drive H... Hydraulic drive easy access RBP 15 M RX12

16 RX Accessories: Support / Trolley max.10kg max.150kg max.150kg Low Weight: max.350kg Heavy Duty: max.700kg fixed to frame fixed to basement fixed / not fixed to basement fixed / not fixed to basement

17 RX Accessories: Cleaning Disassembling Cleaning Set Tool Box standard equipment optional equipment

18 RX Production RX Crossheads: developed, designed and made by ROSENDAHL RX Crosshead Tools: made by ROSENDAHL for original RX-crossheads exception: tips with diamond inserts

19 RX Crosshead Quality Control Quality Assurance according to ISO Standard guarantees: highest performance at delivery quickest start-up best reproducibility ISO 9001:2008 CAQ of distributor QC on centricity test stand

20 RX Crosshead Configuration CUSTOMER`S DEMAND Application Product design Insulation material Product dimensions Line speed - Output... Min. max. Output/Material Min. - max. diameter of cables Layer concept (1/2...) Extruder size Adapter Crosshead Screws Bush Bypass Distributors Tools Checklist availableforcrossheadinquieries

21 Rheological Analysis Key-parameter: melt pressure melt flow velocity melt temperature melt stress and strain

22 RX Way to Performance Way of Trial & Error: Way of ROSENDAHL to customer s benefit: pressure temperature

23 RX Distributor Optimisation Common way to an improved distributor design: Simulation Trials by ROSENDAHL: several trials & errors lead to acceptable distribution Optimisation by R&D-Analysis enables perfect distributon at once Time and costs impacted result Saving time and material grants best performance

24 RX Dimensioning an Ideal Distributor critical areas with stagnation Min. Shear rate 0,156 s-1 poor surface quality & inhomogenities Min. Shear rate 0,218 s-1 residendce time 384 =>166 sec (43%)

25 RX Design for Coextrusion Wide range applicability regarding material combination and layer thickness Smooth velocity-profile at layer contact Stable layer interface High centricity within cable

26 RX Flow Analysis based Design (1) features: consideration of rheologic characteristics in polymer material enabling & ensuring: proper welding of seperated polymer mass flow efficient relaxation of polymer molecules low polymer volume in flow channels reduced residence time of polymer quick material / colour change stable temperature profile

27 RX Flow Analysis based Design (2) features: optimal melt pressure profile without peaks and dumps enabling: energy saving production reduced abrasion of equipment high production output area [m m 2] 200 melt velocity [mm/s ] pressure [bar] axial length [mm]

28 RX Flow Analysis based Design (3) features equal compression across the flow paths and constant melt velocity at the outlet zone prevents & avoids: Roughness / shark-skin on cable surface Break of melt flow Material aggregation Degradation of polymer Swelling of material at die outlet zig-zag phenomenon in coextrusion joint-lines (at confluence)

29 RX Crossheads General Benefits Supply of high performance key-components for extrusion lines developed & made by ROSENDAHL state of the art Rosendahl as a leading supplier of cable industry responds quickly to direct feedback from worldwide customers close cooperation of Rosendahl with leading material suppliers grants continuous upgrade of polymer data base for RX-design Benefit from comprehensive cable know-how at Rosendahl over 50 years

30 RX Crossheads fit for... all cable lines... performance... innovation... availability... quality... environment... retrofit... efficiency... challenge... fit for customers