Gear Pump Extruder Volume Control for Shear Heating
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Solution Overview
Problem
In gear pump extruding machines, excessive warming of viscous materials occurs due to shear stress from rotating screws, leading to potential vulcanization of unvulcanized rubber materials, which affects the quality of the extruded product.
Innovation Solution
The machine adjusts the pressure in the fluid communication channel by changing its volume using protrusive members and an actuator, rather than controlling the rotational speed of the screw, to regulate the extrusion rate and prevent excessive warming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the rotational speed of the screw is increased to adjust the extrusion rate, then the extrusion rate increases, but the viscous material is warmed excessively
Solution Approach 1:
The invention changes the control parameter from screw rotational speed to fluid communication channel volume. By adjusting the channel volume using protrusive members, the extrusion rate is controlled without increasing screw speed, thereby avoiding excessive warming of the viscous material while maintaining productivity
Solution Approach 2:
The invention introduces protrusive members as an intermediary mechanism between the control system and the extrusion process. These members adjust the fluid communication channel volume, which in turn controls the extrusion rate indirectly, preventing direct coupling between screw speed and extrusion rate that causes excessive warming
2Productivity
If the pressure on the inlet side of the gear pump is increased to control extrusion rate, then the extrusion rate adjusts, but the screw rotational speed must be controlled which causes warming
Solution Approach 1:
The invention makes the fluid communication channel volume dynamic and adjustable during operation. The protrusive members can move forward and rearward to change the channel volume in real-time, allowing flexible control of extrusion rate without the complexity of controlling screw rotational speed for pressure adjustment
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 approach maintains high-quality extruded products by avoiding excessive warming and allowing precise control over the extrusion rate without affecting the screw's rotational speed, thereby enhancing productivity and product quality.
Implementation Method 1
When the screw rotates, it exerts a shear stress on the viscous material, causing the viscous material to generate heat and to be plasticized
Implementation Method 2
the screw rotates, it exerts a shear stress on the viscous material, causing the viscous material to generate heat
Implementation Method 3
the pressure in the fluid communication channel that keeps the screw feeder and the gear pump in the fluid communication with each other, i.e., the pressure on the inlet side of the gear pump device, can be changed by changing the volume of the fluid communication channel
Data Source
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AI summary
A gear pump extruding machine for extruding a rubber material has a screw feeder 10, a gear pump 20 provided on an outlet side of the screw feeder 10, and a die 30 disposed on an outlet side of the gear pump 20. The gear pump extruding machine includes protrusive members p movable forward and rearward to protrude into a fluid communication channel S that keeps the screw feeder 10 and the gear pump 20 in fluid communication with each other, to thereby change the volume V of the fluid communication channel S. An actuator 45 is provided for moving the protrusive members p to protrude into the fluid communication channel S, and is controlled by a controller 50. The controller 50 controls the actuator 45 to move the protrusive members p forward and rearward to thereby change the volume V of the fluid communication channel S in order to set the pressure in the fluid communication channel S to a predetermined pressure depending on the rate at which the rubber material is extruded. When the volume V of the fluid communication channel S is changed, the rate at which the rubber material is extruded is adjusted to prevent the rubber material from being warmed excessively at all times.