Continuous Lead Extruding Machine (JQL-150/5)

JQL-150/5 Continuous Lead Extruding MachineYQL-150/5 type continuous lead extruder is designed to meet the requirement of the development of cable and hose industry, which is used to extrude lead protection layer of cross-linked polyethylene insulation submarine power cable and vulcanize the lead coating of tuber tube. The external diameter of the lead coating is 30mm to 130mm. 1. CompositionJQL type continuous Lead Extruder is mainly composed of:1.1 Main machine of 150/5 type lead extruder       1 set1.2 Box type 18T lead melting furnace             1 set1.3 Box type 10T refining and holding furnace         1 set1.4 Die seat 30~130mm                       1 set1.5 Lead ingot conveying and feeding system         1 set1.6 Ω lead conveying tube                        2 pieces1.7 Gear oil lubrication system                     1 set1.8 Inner circulation cooling water system           1 set1.9 Posterior cooling water system                  1 set1.10 Flow rate controller                          1 set1.11 Guide roller stand for inlet and outlet wire and cable    1 set1.12 Electrical control system                       1 set1.13 3150 pay off device                           1 set1.14 3500 take up and traversing device                1 set2. Conditions of usage2.1 Pure lead                        Pb-99.99%2.2 Pb-Sb alloy                   Sb-0.3-0.4%2.3 Pb-Sn-Sb alloy                       Sn-0.4%; Sb-0.2%2.4 Pb-Sb-Cu alloy                   Sb-0.4%; Cu-0.04%2.5 Pb-Sn-Cd alloy                   Sn-0.2%; Cd-0.075%3. Technical specification3.1 Cladding diameter           Φ30~Φ130mm3.2 Extrusion output           Ingredients of leadRotation speed of screw(r/min)Output(kg/min)Pure lead5~1518~30Soft alloy lead5~1215~25Hard alloy lead5~913~20Thickness of lead layer1.2mm~5mm3.3 Water consumption of inner circulation     6-8t/h4. Features of main components4.1 Lead ingot conveying raceway4.1.1 The lead ingot is send to the feeding platform by crane, which will facilitate the placement of the lead ingot and operation of workers, as well as reduce the labor intensity.4.1.2 The raceway for inlet ingot is fixed on a inclined bracket, which will make the lead ingot slip into furnace easily.4.2 18T lead melting furnace4.2.1 Furnace capacity             18T4.2.2 Working temperature         360~380ºC4.2.3 Heating power               141kw4.3 10T refining and holding furnaceThe performance and structure of 10T refining and holding furnace are same with that of 18T furnace. According to the different trial requirement, it can be used to be lead melting furnace. The furnace is separated to be two chambers, one refining chamber and one holding chamber. The furnace also adopts electrical heating, the total heating power is 100kw. The temperature of lead liquid is about 380ºC.4.4 Ω lead conveying tubeLead conveying tube is used to link the liquid lead among lead melting furnace, holding furnace and main machine. While conveying the liquid lead, The metal lead conveying tube will expand because of the heat while heating the lead melting and holing furnace as well as lead conveying tube, which will make the conveying tube to be Ω shape.The material of lead conveying tube is superior seamless steel tube which is made by bending the mould without any crack. Dedicated brasses heater with good heat transfer effect is used to heat outside the conveying tube. The heating components are not easily to be damaged. Meanwhile, two temperature measuring points with separate temperature measuring thermocouple are set at both ends of the conveying tube. Another manual temperature measuring point is set at the top of the conveying tube, which is used to check the temperature measuring.Stearic acid container is equipped at the lead inlet of the machine body, which can meet the requirement of normal production process.4.5 Main machine of 150/5 type lead extruderNominal dia. of screw                  Φ150mmRotation speed of screw                 5-15rpmExtruding output                       8-30kg/minMain motor               110kw (DC, Xi'an Xima or Shanghai Xingyang)Working temperature of screw cylinder       300~330ºCWorking temperature of die holder           about 290ºCThe liquid lead is guided to extrusion container from lead melting furnace through conveying tube, and then extruded to be finished products by die holder. The temperature of the liquid lead in every area will keep in a constant and predetermined value. The temperature can be controlled within a range of ±3ºC. The bigger difference of the liquid lead in extruding process, the big variation on thickness of the lead tube may have. Generally, each 10ºC difference may lead to 0.1mm variation on thickness of the lead tube. Because of the constant rotation speed set according to requirement and constant temperature of liquid lead, the pressure in extruding process is also constant, which can guarantee the thickness of the lead protection layer to be uniform.The body of extruding machine is horizontal structure, which is made anti-seepage treatment. Electrical transmission adopts spiral bevel gear to switch in, other gears adopt alloy steel forging and casting steel material with roll finishing.The extruding screw adopts vertical placed way to convey lead material, which can eliminate the effect of the lead layer gravity.The axial adjustable die and discharging die adopt electric hydraulic station, making it easily to adjust thickness of the lead layer and replace die core of the die holder.The wall thickness of lead tube is uniform, adopting four bolts to adjust through cap ring of the adjusting die. At the outlet end of the die installs a spray system for cooling and crystallizing of extruding lead layer.  Screw and screw cylinder adopt superior heat mould steel material (Level one flaw detection). Screw is grinding processed by imitation mould, polished by electric grease, and treated by plating hard chromium on surface. The cold plug inner screw cylinder is treated by special sealing (security techniques), which can prevent cracking effectively. Diversion channel of inner sleeve of the screw cylinder adopts CNC cutting technology to process, making the current guiding uniform.  Die holder also adopts superior heat mould steel material (Level one flaw detection). Diversion cavity is processed by four-axis CNC machining center whose dimension is accurate and surface is smooth.Provide two sets of die core moulds for test-run. (Consumers will provide the specification for the test-run wire.)4.6 Gear oil lubrication systemMaking the gear box body to be oil storage tank, structural arrangement of the whole machine is compact and reasonable.  The oil lubrication loop is composed of oil pump, filter, double cooler, pressure gauge, etc. In addition, it is equipped with flow transducer and pressure switch to monitor the oil lubrication system. While being short of oil, it will alarm automatically. Supplying oil with pump can save maintenance time and guarantee quick production recovery.4.7 Inner circulation cooling water system  The inner cooling water system is composed of water pump, safety valve, liquid level controller, 10m2 heat exchanger and so on, which is used to cool screw cylinder sections. Clean soft water is input through inlet of the water tank ( water hardness is no more than 4~5°dh, suggesting consumer to use distilled water). Water tank is equipped with liquid level indicator gauge to check the water level of it. In addition, it is equipped with temperature transducer, flow regulator and pressure switch to monitor inner circulation cooling water system. While being short of water and overheated, it will alarm automatically. Supplying oil with pump can save maintenance time and guarantee quick production recovery.Soft water in water tank is delivered to the upper, middle and bottom heating zone through three pipelines to adjust temperature of the extruding lead. The flow can be adjusted by valve according to the working condition. The cooling water will flow back to the water tank after it going outside the machine body for cycle use.  External cooling water adopts filtered tap water provided by consumer's factory. The water flow rate is 30t/h, water temperature is no more than 25ºC and the water pressure is 0.3Mpa. The external cooling water after flitting will enter into plate type heat exchanger for heat exchanging with inner circulation cooling water. In addition, it will cool the gear oil cooler, posterior cooling device and die holder separately by heat exchanger through their water cooling jackets.4.8 Posterior cooling water systemIt is mainly composed of water cooling nozzle inside the die holder and spray pipe of the subsequent stainless steel water trough, used in cooling and crystallizing of the lead layer at the outlet mould and secondary cooling of lead sheath after crystallization.  At the back end of trough equips compressed air drying unit for drying the surface of lead sheath.4.9 Guide roller stand for inlet and outlet wire and cable  It is a single wheel wire guiding stand of plastic material as nylon whose height can be adjusted, using in lifting the inlet and outlet die holders to prevent scratch and damage of cables.4.10 Flow rate controllerThe cooling water drawing from water tank at the bottom of the machine will enter into the extruding screw cylinder in three passes through three glass Rota meters. Coordinating with heater and adjusting water inflow, it can control the temperature of extruding technology. The Rota meters are with adjustable valves. The water flow rate of every cooling point on the machine body can be indicated on the Rota meters.4.11 Electric control system  The system adopts three phase five wire system. The power voltage is 380V, 50Hz, while the single phase control voltage is 220V.  Total heating power         about 220kw  Total capacity             330KVA (excluding take up and traversing stand)  DC motor speed adjusting   Siemens 6RA-80 series DC speed adjusting device  PLC control              Siemens S7-200 seriesThe touching screen adopts "WEINVIEW" color screen which can indicate, set and control the temperature parameters of every section, operation parameter of the equipment as well as working status. The processing temperature of die holder and screw cylinder is controlled by sections. The set valve of temperature of every section can be set on the touching screen.4.12 the manufacturer of main components for mechanical and electrical parts4.12.1 Bearings: products of Ha'erbin, Wafangdian and Luoyang4.12.2 Motors: China famous products4.12.3 DC driver: Siemens 6RA-80 series DC speed adjusting device4.12.4 PLC: Siemens S7-200 series products4.12.5 Touching screen: WEINVIEW-10.4 inches industrial color touching screen4.12.6 Thermometer: Japan RKC product4.12.7 Low-pressure electrical apparatus below 32A adopts Siemens products, above 32A adopts Zhengtai or other China famous brands.        4.13 3150 pay off device4.14 PN1600/3500 travelling type take up and traversing stand5. Equipment protection Because of the low melting point and being of certain oxidability of lead, the machine adopts closed system for lead melting and holding furnace as well as liquid lead conveying tube, meanwhile, monitor and control strictly on heating temperature to prevent the emergence and spread of lead steam.  Consumer can equip exhaust device and water spraying unit for melting furnace to realize safe exhausting.6. Consumer provided parts6.1 Equipment foundation, pipeline and wire projects, production raw material, common tools and measuring implements, equipment and auxiliary material for installation6.2 Water, electricity and gas supply for the machine and connecting line6.3 Circulation loop from flow rate meter cabinet to access point and water supply point of the equipment6.4 circulating water supply and its pipeline for cooler, die holder and non-ferrous steel trough (30m3/h, 0.4Mpa, water temperature is no more than 25ºC)6.5 Cable from power grid of workshop to electrical control cabinet of the equipment, connecting wire and cable from electrical control cabinet to every control point of the equipment, connecting wire and cable of connection inside the cabinet. (Seller will provide cable specification table.)6.6 Gas consumption of the machine is about 12m3/h, consumer will provide connecting line between gas source and gas inlet point of the equipment.6.7 Exhaust device and water spraying unit of melting furnace to realize safe exhausting.