Releasable Cooling Plug for Pipe Extrusion Shutdown
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Solution Overview
Problem
In the manufacture of large diameter plastic pipe, sudden shutdowns of extrusion systems result in excess molten plastic adhering to mold blocks and cooling plugs, causing damage and significant labor and production losses due to the difficulty in stopping high-pressure plastic flow and the subsequent need for extensive disassembly.
Innovation Solution
A system with a releasably secured cooling plug, controlled by a release mechanism activated by sensors or manual switches, allows for automatic separation from the extrusion head during shutdowns, creating a void to receive excess plastic and simplify system restarts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a high capacity extruder is used to manufacture large diameter pipe, then sufficient plastic can be provided for forming the pipe, but sudden shutdown is difficult and excess plastic fills voids between mold blocks and cooling plug
Solution Approach 1:
The cooling plug is divided into two separate components: the cooling plug body and the release mechanism. The release mechanism can be activated to separate the cooling plug from the extrusion head, creating a void that prevents excess plastic from filling the gap between mold blocks and cooling plug during shutdown.
2Reliability
If the cooling plug is securely attached to the extrusion head, then stable cooling is maintained, but excess plastic adheres to the cooling plug and binds with mold blocks during shutdown
Solution Approach 1:
The attachment between the cooling plug and extrusion head is made dynamic through the release mechanism. Under normal operation, the cooling plug remains securely attached for stable cooling. During shutdown, the release mechanism can be activated to separate the cooling plug, preventing plastic adhesion and enabling easy restart.
3Manufacturing precision
If mold blocks are used to form the pipe shape, then the pipe cross section is defined, but excess plastic fills cavities between mold blocks and cooling plug causing damage and production losses
Solution Approach 1:
The release mechanism is pre-configured to separate the cooling plug from the extrusion head before excess plastic can fill the voids between mold blocks and cooling plug. This preliminary separation action prevents plastic adhesion and binds, eliminating the need for extensive disassembly and reducing production downtime.
Data Source
AI summary
The pipe molding system includes a separable cooling plug and an automatic procedure to alleviate problems associated with excess plastic continuing to extrude after a sudden shutdown of the extrusion system. The separable cooling plug and shutdown procedure includes accommodating any excess plastic in a created void between the cooling plug and the extruder. This arrangement simplifies removal of the excess plastic and reduces the time required to return the equipment to normal production. Preferably, a controller monitors operating conditions of the system and automatically releases the cooling plug based on the monitored operating conditions.