Intelligent Configuration System for the Entire Production Line

Using an industrial control system based on Ethernet communication, the aluminum profile production line allows for automated distribution of multiple supporting parameters according to the mold process. For example, by inputting mold number 1 into the control system, the corresponding complete line data is automatically retrieved, ensuring effortless communication and information exchange among the equipment.

• Assigns the required billet temperature for the heating furnace
• Determines the necessary billet length for cutting operations using hot log shear or saw
• Allocates the required cooling method and data, including air cooling, water cooling, mist cooling, mist + air, water immersion, and standing waves for executing quenching operations
• Sets parameters for extrusion press such as extrusion speed, maximum pressure for each action, and billet container temperature to achieve energy-efficient extrusion
• Calculates the dimensions (length, width, height) of the profiles to automatically adjust the puller’s opening height. Also determines profile extrusion length to provide data signals for trimming excess lengths, cold bed processing, puller tension, and sawing speed
• Uses supporting parameters, puller data, and self-detection data from the cold bed to achieve fully automated straightening without manual intervention, including adjustments for required straightening tension
• Connects to the client’s ERP system to monitor the operational status of each extrusion production line in real time

On-line Energy-Saving System Algorithm

The system uses real-time energy-saving calculations to effectively reduce motor energy consumption.
For example, with the formula speed = flow/area, when the main cylinder is set to a speed of 5mm/s, the flow rate is 172L. The system automatically calculates the motor's rotational speed and adjusts it to 680 RPM.
The system also provides the following advantages:

• Motor pump: 1000 RPM, 250 displacement
• Main cylinder speed: 5 mm/s
• Main cylinder diameter: 820 mm
• Noise reduction by 20-50%
• Energy consumption reduction by 10-30%
• Lower oil temperatures and extended hydraulic pump lifespan
• Improved acceleration efficiency

Safety Leakage Self-Inspection System

Safety Shutdown
Using the Siemens self-test system, when there is an obvious hydraulic leak during the extrusion process, more than thirty detection points are recorded by level sensors for comparison with the actual, and the machine is shut down immediately to protect the safety of personnel and equipment.

Servo Motor Non-Demagnetization Solution

Traditional synchronous servo rotors rely on magnetic sheets attached to the rotor. When the temperature reaches a certain threshold, the magnetic sheets begin to demagnetize, reducing its power output. In contrast, we use Siemens asynchronous servo rotors, which generate magnetic fields through electric current. This design eliminates the need for magnetic sheets, ensuring permanent resistance to demagnetization and providing more stable and reliable power.

Servo Electromagnetic Scale

The stroke measuring system utilizes a self-developed electronic measurement system in collaboration with Siemens servo technology. This system ensures precise constant-speed or segmented-speed control, resulting in more stable aluminum extrusion quality. It also guarantees swift positioning and enhances the stability of the hydraulic oil circuit.

Advanced Die Alignment Mechanism

The die alignment mechanism ensures precise centering and adjusting the die position in the extrusion process, addressing the critical need for maintaining aluminum extrusion accuracy and consistency. Unlike traditional sliding mold cylinders, which can experience displacement over time due to internal leakage caused by damaged solenoid valves or seals, this advanced mechanism uses a specialized structural design to effectively prevent die misalignment, ensuring stable and accurate positioning throughout operation.

Shear Blade Lock Safety Barrier

The protection lock system uses a hydraulic cylinder pin for quick and precise positioning. This mechanism ensures that the shear blades remain stationary when not in use or during idle periods, effectively preventing accidental movements and ensuring safety.

Exclusive Exhaust Function

The positions of A and B in the original setup are displayed to illustrate their arrangement and functionality in the process.

The exclusive exhaust function features a patented design that significantly reduces non-extrusion time. Unlike traditional methods that require a two-step process, first opening A and then B, this innovative system completes the exhaust process in a single step by simply opening A. The exhaust action is performed without utilizing the liquid charging valve, ensuring greater efficiency and streamlined operation.

Intelligent Problem Diagnosis

The system provides precise issue detection through its control screen, which displays actionable prompts for each step of the extrusion press operation. When an issue arises, the specific problem is shown on the corresponding area of the screen, enabling maintenance or operational staff to quickly and accurately identify the source of the issue and address it effectively.

For example, if an operator attempts to move the sliding mold base out and it fails to respond, the system uses a closed-loop guidance mechanism to display step-by-step troubleshooting instructions, helping the operator systematically diagnose and resolve the issue efficiently.

Electrical Cabinet Temperature Control

• When the temperature is below 45°C, the air conditioning system activates, and the exhaust fan is turned off.
• When the temperature exceeds 45°C, the exhaust fan is activated.
• This system maintains consistent temperature control within the electrical cabinet, ensuring protection against dust and moisture.

Automatic Oil Residue Fine Filtration

• Eliminates the need to clean the oil tank by automatically collecting sludge and impurities through a fine filter, with a pressure gauge reminder for timely replacement.
• Prevents valve jamming, ensuring smooth and durable operation of all valves.
• Maintains unobstructed oil flow, reducing noise and vibration during operation.