Step 1 Wear and tear
Wear of screw and barrel: After long-term use, the gap between screw and barrel will gradually increase. This will cause the plasticizing effect of the plastic to become worse, the extrusion amount is unstable, and the plastic may leak in the extrusion process, affecting the quality of the product. For example, the plastic pipe produced may have problems such as uneven wall thickness and rough surface.
Transmission parts wear: such as gear, chain, belt and other transmission parts after a long time of operation will appear wear, resulting in reduced transmission accuracy, may appear jumping teeth, slipping and other phenomena, affecting the speed stability of the screw, and then affect the stability of the extrusion process and product quality.
2. Fatigue and deformation
Fatigue of frame and support structure: the extruder will produce vibration and stress during operation, and the frame and support structure may have fatigue cracks or deformation under long-term action. This will affect the overall stability of the equipment, so that there is shaking during the extrusion process, affecting the dimensional accuracy and appearance quality of the product. For example, the flatness of plastic sheets may be affected.
Deformation of the heating and cooling system: the heating ring and cooling pipe may be deformed under the action of long-term thermal expansion and cold contraction, affecting the uniformity of the heating and cooling effect, thus affecting the plasticization and molding quality of plastics.
1. Aging and failure
Wire and cable aging: During the long-term use of the electrical line of the extruder, the insulation layer of the wire and cable may age and crack, resulting in an increased risk of electrical failures such as leakage and short circuit. This not only affects the normal operation of the device, but also poses a threat to the safety of the operator.
Aging of electrical components: contactors, relays, frequency converters and other electrical components will also age over time, resulting in poor contact, failure and other problems. For example, the inverter may appear output instability, frequency fluctuations and other phenomena, affecting the speed control of the screw, and then affecting the stability of the extrusion process and product quality.
2. The performance deteriorates
Motor performance decline: After long-term operation of the extruder's drive motor, winding insulation aging, bearing wear and other problems may occur, resulting in a decrease in the output power of the motor, unstable speed, serious heating and so on. This will affect the extrusion capacity and production efficiency of the extruder.
Control system accuracy reduction: With the aging of the electrical system, the control system of the extruder may have problems such as reduced accuracy and slow response speed. For example, the temperature control system may not accurately control the temperature of the cylinder, resulting in unstable plasticization of the plastic; The pressure control system may not accurately control the extrusion pressure, affecting the quality and dimensional accuracy of the product.
1. Extrusion volume decreases
Due to the aging of the extruder, the wear of the mechanical components and the deterioration of the performance of the electrical system will lead to a gradual reduction in the extrusion volume. This will extend the production cycle, reduce production efficiency and increase production costs. For example, a certain number of plastic pipes can be produced per hour, but with the aging of the extruder, the production efficiency may drop by 20% or more.
2. Increased energy consumption
Aging extruders consume more energy during operation. For example, a decrease in the efficiency of a motor can lead to an increase in power consumption; Increased heat loss in the heating system increases energy consumption. This will not only increase production costs, but also does not meet the requirements of energy conservation and environmental protection.
1. Quality is not stable
Aging of extruder will lead to unstable product quality and various defects. For example, plastic film may appear uneven in thickness, with bubbles or wrinkles on the surface; Plastic profiles may have dimensional deviation, bending deformation and other problems.
2. Scrap rate rises
Due to the aging of the extruder, the increase of equipment failure and the increase of uncertainty in the production process lead to the increase of scrap rate. This will waste raw materials and energy, increase production costs, and reduce the economic efficiency of enterprises.
