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Extruder
The extruder is the heart of the machine. It consists of a hopper, a screw, and a barrel. The PVC resin pellets are fed into the hopper. As the screw rotates inside the barrel, it conveys the material forward while applying heat and pressure. The screw's design, such as its pitch and flight depth, is crucial for proper plasticization and extrusion. For example, a screw with a variable pitch can better handle the PVC material's melting characteristics and ensure a more uniform melt flow.
The barrel is heated using heating elements, usually electrical heaters. The temperature control of the barrel is essential as different PVC formulations require specific temperature profiles for optimal extrusion. The temperature range typically varies from 160 - 190°C for PVC extrusion.
Mold and Corrugation Unit
The mold is designed to shape the extruded PVC into a corrugated form. It has a complex structure with cavities and ridges that give the pipe its characteristic corrugated shape. The corrugation unit works in conjunction with the mold. It uses a set of rollers or other forming mechanisms to create the corrugations on the extruded pipe. The rollers can have different profiles to produce corrugations of various shapes and sizes. For instance, for a circular - corrugated pipe, the rollers are designed to form a series of circular indentations and protrusions.
Vacuum Calibration System
This system is used to ensure the accurate sizing and shape of the corrugated pipe. A vacuum is applied to the outer surface of the extruded pipe as it passes through the calibration unit. The vacuum helps to draw the pipe against the calibration sleeves or dies, which have the exact dimensions of the desired finished pipe. This process also helps to cool the pipe slightly and improve its dimensional stability.
Cooling Tanks
After the vacuum calibration, the pipe enters the cooling tanks. These tanks are filled with water or other cooling media. The corrugated pipe is cooled gradually to solidify the PVC completely. The cooling process is carefully controlled to avoid warping or distortion of the corrugated structure. The length and number of cooling tanks can vary depending on the production speed and pipe diameter. For example, for larger - diameter pipes, longer cooling times and more extensive cooling tank arrangements may be required.
Traction Unit
The traction unit pulls the corrugated pipe through the various stages of the production process at a constant speed. It usually consists of multiple pairs of rubber - or polyurethane - coated rollers. The traction force is adjustable to match the extrusion speed and ensure a smooth and continuous production process. The rollers' grip on the corrugated surface of the pipe is designed to prevent slipping and damage to the pipe.
Cutting Device
The cutting device is used to cut the continuous corrugated pipe into the desired lengths. It can be a saw - type cutter or a hot - wire cutter. The cutting operation is usually controlled by a length - measuring sensor or a programmed control system. For example, if the desired pipe length is set to 6 meters, the cutting device will activate when the pipe has reached that length.
Extrusion Capacity
The extrusion capacity of the machine is usually measured in kilograms per hour (kg/h). It can range from a few tens of kilograms per hour for small - scale machines to several hundred kilograms per hour for large - scale industrial models. For example, a medium - sized PVC corrugated pipe extrusion machine may have an extrusion capacity of around 100 - 150 kg/h.
Pipe Diameter Range
The machine can produce corrugated pipes with a wide range of diameters. The minimum diameter can be as small as 50 mm, and the maximum diameter can reach up to 1000 mm or more, depending on the machine's design and capabilities.
Corrugation Pitch and Depth
The corrugation pitch (the distance between two adjacent corrugations) and depth can be adjusted according to the specific requirements of the application. The pitch can range from a few millimeters to several centimeters, and the depth can vary from a few millimeters to more than a centimeter. For example, in a drainage application, the corrugation pitch may be around 30 - 50 mm and the depth around 5 - 10 mm.
Production Speed
The production speed is measured in meters per minute (m/min). It can range from a slow speed of about 1 - 2 m/min for pipes with complex corrugation patterns or large diameters to a relatively fast speed of 10 - 15 m/min for simpler corrugation and smaller - diameter pipes.
Drainage Systems
PVC corrugated pipes are widely used in municipal and building drainage systems. Their corrugated structure provides good flexibility, allowing them to be laid in curved or uneven terrains. They can also handle a large volume of water flow due to their relatively large internal diameter and smooth inner surface.
Cable Protection
These pipes are used to protect electrical cables and communication lines. The corrugated outer surface provides additional mechanical protection against external impacts, and the pipes can be easily installed underground or in conduit systems.
Agricultural Irrigation
In agricultural settings, PVC corrugated pipes are used for irrigation. They can be used to transport water from a water source to the fields. The flexibility of the pipes allows for easy installation and adjustment in the field, and their durability ensures a long - term service life.
Extruder
The extruder is the heart of the machine. It consists of a hopper, a screw, and a barrel. The PVC resin pellets are fed into the hopper. As the screw rotates inside the barrel, it conveys the material forward while applying heat and pressure. The screw's design, such as its pitch and flight depth, is crucial for proper plasticization and extrusion. For example, a screw with a variable pitch can better handle the PVC material's melting characteristics and ensure a more uniform melt flow.
The barrel is heated using heating elements, usually electrical heaters. The temperature control of the barrel is essential as different PVC formulations require specific temperature profiles for optimal extrusion. The temperature range typically varies from 160 - 190°C for PVC extrusion.
Mold and Corrugation Unit
The mold is designed to shape the extruded PVC into a corrugated form. It has a complex structure with cavities and ridges that give the pipe its characteristic corrugated shape. The corrugation unit works in conjunction with the mold. It uses a set of rollers or other forming mechanisms to create the corrugations on the extruded pipe. The rollers can have different profiles to produce corrugations of various shapes and sizes. For instance, for a circular - corrugated pipe, the rollers are designed to form a series of circular indentations and protrusions.
Vacuum Calibration System
This system is used to ensure the accurate sizing and shape of the corrugated pipe. A vacuum is applied to the outer surface of the extruded pipe as it passes through the calibration unit. The vacuum helps to draw the pipe against the calibration sleeves or dies, which have the exact dimensions of the desired finished pipe. This process also helps to cool the pipe slightly and improve its dimensional stability.
Cooling Tanks
After the vacuum calibration, the pipe enters the cooling tanks. These tanks are filled with water or other cooling media. The corrugated pipe is cooled gradually to solidify the PVC completely. The cooling process is carefully controlled to avoid warping or distortion of the corrugated structure. The length and number of cooling tanks can vary depending on the production speed and pipe diameter. For example, for larger - diameter pipes, longer cooling times and more extensive cooling tank arrangements may be required.
Traction Unit
The traction unit pulls the corrugated pipe through the various stages of the production process at a constant speed. It usually consists of multiple pairs of rubber - or polyurethane - coated rollers. The traction force is adjustable to match the extrusion speed and ensure a smooth and continuous production process. The rollers' grip on the corrugated surface of the pipe is designed to prevent slipping and damage to the pipe.
Cutting Device
The cutting device is used to cut the continuous corrugated pipe into the desired lengths. It can be a saw - type cutter or a hot - wire cutter. The cutting operation is usually controlled by a length - measuring sensor or a programmed control system. For example, if the desired pipe length is set to 6 meters, the cutting device will activate when the pipe has reached that length.
Extrusion Capacity
The extrusion capacity of the machine is usually measured in kilograms per hour (kg/h). It can range from a few tens of kilograms per hour for small - scale machines to several hundred kilograms per hour for large - scale industrial models. For example, a medium - sized PVC corrugated pipe extrusion machine may have an extrusion capacity of around 100 - 150 kg/h.
Pipe Diameter Range
The machine can produce corrugated pipes with a wide range of diameters. The minimum diameter can be as small as 50 mm, and the maximum diameter can reach up to 1000 mm or more, depending on the machine's design and capabilities.
Corrugation Pitch and Depth
The corrugation pitch (the distance between two adjacent corrugations) and depth can be adjusted according to the specific requirements of the application. The pitch can range from a few millimeters to several centimeters, and the depth can vary from a few millimeters to more than a centimeter. For example, in a drainage application, the corrugation pitch may be around 30 - 50 mm and the depth around 5 - 10 mm.
Production Speed
The production speed is measured in meters per minute (m/min). It can range from a slow speed of about 1 - 2 m/min for pipes with complex corrugation patterns or large diameters to a relatively fast speed of 10 - 15 m/min for simpler corrugation and smaller - diameter pipes.
Drainage Systems
PVC corrugated pipes are widely used in municipal and building drainage systems. Their corrugated structure provides good flexibility, allowing them to be laid in curved or uneven terrains. They can also handle a large volume of water flow due to their relatively large internal diameter and smooth inner surface.
Cable Protection
These pipes are used to protect electrical cables and communication lines. The corrugated outer surface provides additional mechanical protection against external impacts, and the pipes can be easily installed underground or in conduit systems.
Agricultural Irrigation
In agricultural settings, PVC corrugated pipes are used for irrigation. They can be used to transport water from a water source to the fields. The flexibility of the pipes allows for easy installation and adjustment in the field, and their durability ensures a long - term service life.
