Composite Pipe Tape Winding for Continuous Online Production
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Solution Overview
Problem
Existing methods for producing glass fiber reinforced tape polyethylene composite pipes face challenges in achieving continuous on-line production of inner pipe extrusion, glass fiber reinforced tape continuous winding, and outer-layer cladding, as they require shutting down the production line when the reinforcement material runs out and lack online replacement capabilities.
Innovation Solution
A continuous production device comprising a first extruder, inner pipe die, vacuum sizing box, cooling spray boxes, winding machines, heaters, an automatic tape replacing manipulator, outer pipe extruder, and cooling shaping dies, which allows for continuous production by automatically replacing tapes and fusing polyethylene layers, eliminating the need for vacuum sizing and enabling continuous winding and outer-layer cladding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fixed-length inner pipes are produced and reinforcement material is wound on them, then the pipe structure is formed, but the production line must be shut down when the reinforcement material runs out, preventing continuous production
Solution Approach 1:
The patent implements continuous production by enabling online replacement of the reinforcement material (glass fiber tape) during the winding process. The inner pipe is produced continuously by the extruder, and when the glass fiber tape on the first rolling drum is exhausted, a second roll of tape is automatically fed and connected without stopping the production line. This eliminates idle time and maintains continuous useful action throughout the manufacturing process.
Solution Approach 2:
The patent prepares the next roll of glass fiber tape in advance and positions it ready for automatic connection when the current roll is exhausted. The system includes a second rolling drum with a备用 (backup) roll of tape, and the connection mechanism is pre-positioned to facilitate seamless transition between rolls without interrupting the production flow.
2Productivity
If glass fiber reinforced tape is wound on the inner pipe, then the reinforcing layer is formed, but the tape cannot be replaced online, limiting production continuity
Solution Approach 1:
The patent employs an automatic tape replacement system where the machine itself performs the replacement operation without manual intervention. The connection device automatically connects the end of the exhausted tape with the beginning of the new tape, and the system self-regulates the tension and alignment during the transition, making the complex replacement process simple and automated.
Solution Approach 2:
The patent introduces a connection device as an intermediary mechanism between the exhausted tape and the new tape roll. This intermediary device facilitates the seamless connection by providing a controlled environment for joining the two tape ends, managing the tension and alignment automatically, and ensuring the transition is smooth and does not affect the quality of the reinforcing layer.
3Manufacturing precision
If vacuum sizing box is used for inner pipe sizing, then the pipe dimensions are controlled, but it creates layering issues and requires elimination for improved quality
Solution Approach 1:
The patent removes the vacuum sizing box from the production line entirely. Instead of using vacuum suction to size and dry the inner pipe, the system relies on the precision of the extrusion process itself and the subsequent winding process to maintain proper pipe dimensions. This extraction of the problematic vacuum sizing step eliminates the layering defects that occurred in the composite structure while maintaining manufacturing precision through alternative means.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables continuous on-line production of glass fiber reinforced tape polyethylene composite pipes with enhanced compression strength, reduced production costs, energy efficiency, and environmental friendliness, while preventing layering issues and allowing for recycling of production leftovers.
Implementation Method 1
a first extruder, an inner pipe die, a vacuum sizing box, a first cooling spray box
Implementation Method 2
a first extruder, an inner pipe die, a vacuum sizing box, a first cooling spray box, a first tractor, a first winding machine
Implementation Method 3
a first cooling spray box, a second cooling spray box
Implementation Method 4
a first heater, a second heater, an automatic tape replacing manipulator
Data Source
Figure 1~2
Figure 3
AI summary
The present invention belongs to the technical field of plastic pipes and, in particular, to a continuous production device and method for a glass fiber reinforced tape polyethylene composite pipe. The main structure of the production device comprises a first extruder, an inner pipe die, a vacuum sizing box, a first cooling spray box, a first tractor, a first winding machine, a first heater, a second winding machine, a second heater, an automatic tape replacing manipulator, an outer pipe extruder, an outer pipe extrusion die, an outer pipe cooling shaping die, a second cooling spray box, a second tractor, a meter counter, a fixed length cutting machine and finished pipe racks. The process of the production method totally comprises four steps: inner pipe extrusion molding, continuous winding of the composite tape, outer pipe extrusion cladding, and cutting and warehousing, thus realizing the continuous on-line production of the glass fiber reinforced tape polyethylene composite pipe. The production device is friendly to the user environment. The production method adopts a scientific and reasonable principle. The produced glass fiber reinforced tape polyethylene composite pipe has a high compression strength, thin pipe wall thickness, low production cost, energy saving and environmental friendliness.