DE102010040317A1 - Device for production of double-walled corrugated plastic pipes, has memory plate provided for reproducible assembly of extrusion tool so that adjustment of tool remains maintained during reinsertion of tool - Google Patents

Abstract

The device has an extruder (2) connected with a replaceable extrusion tool (3). The extrusion tool is adjustable with respect to a corrugated pipe machine (4) for generating of determined pipe diameter. A memory plate is provided for reproducible assembly of the extrusion tool so that adjustment of the tool remains maintained during reinsertion of the tool. The memory plate is firmly with the tool after completion of the adjustment of tool. An extruder terminal is provided between the extruder and a plastic supply pipe as a two-piece radial segment chucking flange. An independent claim is also included for a method for reduction of tool change times in a production device for corrugated plastic pipes.

Description

The invention relates to a production device for plastic corrugated pipes and in particular to a production device in which the tool change times are reduced during a dimensional change, that is to say when the diameter of the plastic corrugated pipe changes. Furthermore, the invention relates to an adapted extrusion tool and a method for reducing the tool change times in the dimensional change in such a production device.

Such a production device is used in particular for plastic composite pipes with corrugated outer tube and smooth, welded to the outer tube, inner tube. To produce a molded sleeve on such a plastic corrugated pipe or plastic composite pipe (double wall pipe) can also be used such a production device. As double-wall pipe here is a pipe product referred to, which consists of two walls in construction. A smooth inner wall is firmly connected to a corrugated outer tube. The corrugations of the outer tube are arranged transversely to the tube axis on the circumference of the tube. The smooth inner wall serves the optimal hydraulic drainage characteristic of the pipe system. The corrugated outer skin gives the double wall pipe the desired static properties for absorbing the earth pressure when installed under ground.

A production line of such a production facility comprises several components, some of which will be described in more detail below. Two or one extruder, also called extruder, plasticize the plastic and press it through an extrusion die. The extrusion die in turn is placed in front of a corrugated tube machine and serves to produce a plastic tube for the outer strand and at the same time further downstream of the production of a plastic tube for the inner strand. Depending on the spray head or pipe material, the plastic hoses are produced by an extruder or separately from two extruders.

The corrugated outer tube is then formed from the outer strand by shaping into shaped jaws. The molding is preferably accomplished by using vacuum in the profile of the mold jaws. The shaping can also be done by overpressure from the inside into the profile of the mold jaws. Combinations, such as vacuum from the outside and positive pressure from the inside, are also possible. With the help of a cooled calibration mandrel, the smooth inner wall of the plastic composite pipe is created by placing the inner strand. The residual heat, the two strands (the outer strand with the inner strand) are welded. Due to the predetermined gap between the Kalibrierdorn and the inner mold cavity both strands are held in shape and pressed until both wall thicknesses are welded together.

The corrugated pipe machine serves to move the mold jaws. In the molding area, a molding channel is formed by the mold jaws. The mold jaws are supplied to the mold channel on the upstream path (upstream side) and taken out on the downstream path (downstream side). The return of the mold jaws to the inlet by means of the so-called return path. In a chain machine, these are pushed back in a pushed closed compound (chain) to the inlet. For larger corrugated pipe machines, the return is dissolved in the return, d. H. The mold jaws are singulated and transported at higher speed back to the inlet. The principle of operation of such a machine is called the shuttle principle. By using special forming jaws special shapes such as inline joints, spigots, engravings, markings etc. can be produced on the final product pipe.

Changing the diameter or the nominal diameter of the corrugated pipe or plastic composite pipe to be produced is referred to as dimensional change. For the purpose of the dimensional change of the pipe size to be produced subsequently, dimensionally dependent components must be exchanged and settings changed on the components of the production line.

In known production facilities for producing a plastic corrugated pipe, a lower part or a base frame of a spray head rest remains in the production line. The base frame of the spray head rest is designed so that it can be used in all dimensions. The fine adjustment, ie the line alignment and the alignment of the center axis of the calibration and the spray head to the extrusion center is carried out so that the extrusion tool is placed with an upper part of the spray head rest on the base frame and screwed. The alignment then takes place on an adjustment mechanism of the base frame. The device of the spray head thus takes place on the base frame and takes place at each diameter or nominal diameter change again, the setting is not reproducible. The adjustment is made to align the plant components and later to keep the production process stable and accurate. The adjustment is required to compensate for assembly and manufacturing inaccuracies (tolerances) of the components. The disadvantage here is the time-consuming and time-consuming recurrent search of the optimal position setting on the adjustment. On top of that, the Adjustment complicated to use and are usually attached to hard to reach places.

Furthermore, forming jaws have to be searched, picked up and lifted in pairs one after the other with suitable hoisting gear on a transfer position (parking station). Afterwards, the new pairs of shaped jaws of different dimensions must be individually placed in a transfer position by crane and hoist. In this case, the mold jaw pair is released from a carrier plate of a Formbackentransportsystems and the newly used mold jaw pair fixed again on the support plate. As a result, the change of the mold jaws or the dimension inserts is time-consuming and labor-intensive. The necessary production shutdown takes a long time due to the many manual labor, and is subject to errors due to the time stress.

The object of the invention is thus a shortening of the tool change or set-up times with dimensional change and the associated reduction of non-productive production time, d. H. an increase in use. This in turn results in lower unit costs and higher productivity.

This object is achieved by the subject matters of the independent claims. Further embodiments of the invention form the dependent claims.

The production device for plastic corrugated pipes according to the invention comprises an extruder which can be connected to a replaceable extrusion tool. The extrusion tool comprises a spray head and a calibration mandrel for producing a specific pipe diameter. The extrusion tool is adjustable with respect to a corrugated tube machine with forming jaws to produce a given pipe diameter. The adjustment is made by a memory plate for reproducible assembly of the extrusion tool, so that the setting is maintained when re-inserting the extrusion tool.

Preferably, the memory disk is firmly connected after adjustment with the extrusion tool. Preferably, the extrusion tool with respect to its transverse positioning, its level and its rotation about its own axis can be adjusted and fixed. To position the extrusion tool together with the memory plate on the base frame, centering bolts can be provided on the base frame. In order to achieve a high reproducibility when assembling the extrusion tool together with the memory plate with the base frame, a precision fixation between the memory plate and the base frame can be provided.

It is also possible with targeted game afflicted prefixes between the memory disk and the base frame to allow a relatively coarse placement of the spray head including memory disk on the base frame. In order to finally position the spray head together with the memory plate on the base frame, end fixations can be provided between the memory plate and the base frame.

The extruder connection, that is, the adapter part between the extruder and the supply pipe, can be designed as a two-part radial-segment clamping flange by means of a segment design, which saves screws and thus expenditure of time when changing tools. During disassembly, the screws always remain on the clamping flange due to a so-called captive protection. By a "hinge", the two halves of the clamping flange are connected to each other, so that no separate parts (halves) are present. The integrated two-piece heating tape also remains on the flange surfaces, and does not need to be removed as usual when changing.

By using a so-called spray head heating station, the tool changing time can be further reduced. The spray head heating station is an additional electrical cabinet with integrated heating zones, which are adapted to the maximum number of heaters on the spray head. This spray head heating station allows the spray head to be brought to the starting temperature before and during the dimensional change and held before it is connected to the heating zones of the extruder.

Coded plug-in connections can ensure a mix-up-safe and fast connection of the heating power cables with associated temperature sensors.

Sockets can be brought together compactly on a busbar and possibly in a cable junction box. Tidy cable routing and simplified troubleshooting are additional benefits. There may be provided quick release on sealing devices of a post-cooling unit, to quickly adapt the post-cooling unit to a new dimension.

A transport frame can enable the safe lifting or transporting of the extrusion unit from the spray head and calibration mandrel. Furthermore, the slide over the spray nozzle and the calibration mandrel transport frame can serve the protection of the tool against damage. The extrusion unit can be connected by draw bolts instead of by screwing to the transport frame to further reduce the setup times.

To further accelerate the tool change process, a so-called console roller table can be attached to the end of a parking station of the corrugated pipe machine. The shaped jaws or the profile inserts can be moved out of the corrugated tube machine via this console roller table. This fact allows a good access situation for changing mold jaws, profile inserts and vacuum adapter plates. The tool change operation is further accelerated when an automated mold jaw storage system with a set-up station is provided for retrofitting the mold jaws during manufacture to reduce production loss through the mold jaw changing operation. In this case, gripper receptacles may be provided on the forming jaws to be gripped by a gripping system of a gantry robot, which transports the forming jaws between a transfer position and a storage system.

Exemplary embodiments of the invention are shown in the figures, in which:

1 shows a production device according to the prior art,

2 shows a production device according to the invention in the production position,

3 shows a production device according to the invention in the dimensional change position,

4a showing the memory disk in its spatial position between the extruder ports and the corrugated tube machine,

4b showing the memory plate in plan view,

4c showing the memory plate in cross section,

4d a cross section along the line AA of 4b shows,

4e a cross section along the line BB of 4b shows,

5a showing the automatic mold baking storage system in a 3D view,

5b the automatic mold baking storage system from the side shows

5c the automatic mold baking storage system from above shows

6a Form baking on a transfer table shows, and

6b shows the transfer area with scroll bars.

1 shows a production device according to the prior art. It includes two extruders from right to left 2 in an extrusion tool 3 lead. The extrusion tool 3 consists of a spray head and a calibration mandrel. The extrusion tool 3 follows a corrugated pipe machine 4 by a user 5 is controlled. The corrugated pipe machine 4 is an endless tube, which by a blow-off unit 6 , a cutting unit 7 and a besäumsäge 8th to be led. The individual tubes thus obtained are in the sleeve reinforcement unit 9 provided with a sleeve, and the finished plastic corrugated pipe is then through the pipe handling system 10 transported.

2 In contrast, shows a production device according to the invention in the production position. The corrugated pipe machine 4 is in a first position adjacent to the extrusion die 3 , With dashed lines is in 2 the corrugated pipe machine 4 also in the second position adjacent to a cross conveyor portal 13 shown. This second position serves the dimensional change of the mold jaws 11 , 3 shows the production device according to the invention only in the dimensional change position. In addition to the above-mentioned components of the prior art, FIGS 2 and 3 forming jaws 11 , a post-cooling unit 12 and the cross conveyor portal 13 with his robot 14 , Connected to this is the automatic mold baking storage system 15 with his set-up 16 ,

The post-cooling unit 12 serves to support cooling of the pipe, which ultimately leads to improved performance and the improvement of product quality. In the Nachkühleinheit is sprayed with z. B. cold water, the product additionally cooled. The length of the post-cooling unit 12 depends on the output and the wall thickness of the product. At the end of the post-cooling unit 12 The tube is dried by selective blowing with special nozzles. These nozzles can be designed both from individual nozzles as well as complete rings (annular gap nozzle). Normal blow-off and nozzle rings with venturi effect are possible. At the aftercooling unit 12 the pipe guides are brought to the required guiding position by means of adjusting levers. The sealing devices at the beginning and end of the post-cooling unit 12 are fastened by means of quick-releases. The blow-off unit 6 At the end of the Nachkühleinheit is adjusted to the new pipe diameter or the blow-off ring (annular gap nozzle) is exchanged.

4a shows the memory plate 20 in their spatial position. The memory plate 20 is located between a shell 22 one Spray head rest and a lower part of the spray head rest. The top 22 the spray head support may be part of the spray head or a separate part, while the lower part of the spray head support part of the base frame 23 or a separate part. Also possible is an additional height adapter for adaptation to very large pipe diameters.

4b and 4c shows the memory plate 20 in plan view and in cross section. 4d shows a cross section along the line AA of 4b , The reproducibility when assembling the shell 22 the spray head rest including memory disk 20 with the base frame 23 is achieved with the help of a precision fixation between the memory plate and the base frame. With the help of precision bolts a very high repeatability is achieved. The positioning on the flanges of the base frame 23 by means of special centering pins (final fixation). Hardened inserts prevent the setting of the bearing surfaces of the screws. There is no more adjustment effort when changing tools required.

The 4b to 4d show adjustment means 24 in the transverse direction (x-axis), adjustment means 25 in the height direction (y-axis) and adjustment means 26 in the direction of rotation about the axis of the memory disk 20 (Z-axis). Furthermore, retaining screws 27 for screwing between the upper part 22 the spray head support or the spray head and the memory disk 20 , Prefixes 29 and final fixations 30 shown. The final fixation 30 is in 4e , a cross section along the line BB of 4b , shown as a precision bolt with a ball fixation.

The device of the extrusion tool 3 takes place once per nominal width between the upper part 22 the spray head rest and the memory plate 20 , The height, the transverse positioning and the rotation about the Z-axis can be adjusted and fixed. The setting is on the memory disk 20 "Frozen". After initial setup, the memory disk remains 20 at the top 22 of the respective spray head. After this initial setup also the base frame 23 firmly screwed. The base frame 23 remains untouched after the first setting, the adjusting screws on the base frame 23 So never be misplaced.

When first setting up the extrusion tool 3 on the base frame 23 the calibrated spray head support is set the center (target extrusion height) of the extrusion height with the screws for adjusting the Z direction. After the adjustment, the screws for the adjustment of the Z-direction are countered, and thus fixed the height.

The system is characterized by a very high repeat accuracy (0.02 mm) with tools weighing tons. This is achieved z. B. by the combination of prone with targeted play prefixing 29 , which allow the relatively coarse placement of the extrusion die on the base frame. After placement, the retaining screws are easily brought to rest, then by means of Endfixierungen 30 to be brought into the exact position. After setting the final fixings 30 and the target position thus achieved, the retaining screws are tightened with torque.

forming jaws 11 or profile inserts are the molds for the production of the profiled wall of the corrugated pipe or the double wall pipe and are taken from a parent form. The stem shape is driven by toothed racks and driving flanks on the die back plate. The design as a mold jaw and not as a profile insert is mainly carried out on the largest nominal width. The words profile insert and mold baking are used here synonymously. A vacuum adapter plate is a control plate, which is always assigned according to the pipe profile the corresponding profile insert and is changed in the dimensional change with the profile insert. The vacuum adapter plate is on the back of the profile mold baking 11 arranged. The vacuum adapter plate controls the vacuum at the same time. Changing the profile inserts and the vacuum adapter plates always takes place in the same position. This transfer position is the so-called parking station. Parking station is the position at which a special pair of forming jaws (eg inline sleeve) is parked until it is needed again in the forming section. After exchanging the profile insert and the vacuum adapter plate on both mold halves (left and right), they are automatically inserted into the circulation as needed, and the next pair are provided on the transfer position. The profile inserts and the vacuum adapter plates are fastened by means of quick-releases.

5a shows the automatic mold baking storage system 15 in a 3D view. 5b shows the automatic mold baking storage system 15 from the side and 5c from above. The automatic mold baking storage system 15 with his set-up 16 Serves to accelerate the tool change process when converting the inserts or when exchanging the stem shape against the profile forming jaws during production. This results in a further reduction of the dimensional change process and thus a shortening production loss due to the Formbackenwechselvorgang. The automated mold baking storage system 15 is a linear loading system with a suitable number of storage locations. In this embodiment, the system has 22 Storage spaces to 20 To record mold halves. One or two parking spaces are required for the intermediate parking at the start of the tool change process. The stem molds and the profiled shaping jaws are equipped for this purpose with corresponding gripper receptacles to move from the gripper system of a gantry robot to the cross conveyor 13 and to be gripped by that of the storage system. The gantry robot is a single-arm robot, which can be displaced transversely on a driven axle. The axis with the guides is preferably mounted at the top so that the robotic arm is hanging overhead overhead. Of course, the arrangement can also be mounted on the ground. The gantry robot alternately engages the left and then the right mold jaws provided on the parking station or other transfer position (master mold or profile mold jaws or profile insert) around this then transversely to the storage system 15 to transport and place it there on the transfer table. At the transfer table is from the storage system 15 the parked there baking molds 11 picked up, and a form baking 11 provided with the new dimension there again. The gantry robot becomes the mold baking 11 now taken and at the previously removed point on the transfer position of the corrugating machine 4 turned off again. It is also conceivable to change only the profile inserts, equipped with appropriate receptacles for grippers, and appropriately designed storage spaces.

Another embodiment is a device without cross conveyor and storage system. As in 6a Shown are the mold jaws 11 (Parent mold or profile mold jaws or profile inserts) from the parking station to a transfer table 17 downstream (downstream) transported by a machine control and additional drive elements. After transporting the mold jaws 11 on the delivery table 17 There are either the mold jaws 11 exchanged or only the mold jaw inserts including the vacuum adapter plates. The mold jaw inserts to be used are taken from stackable storage pallets into which the removed mold jaw inserts are then deposited. When changing the entire mold jaws 11 These are usually stored and transported on standardized, so-called "Euro pallets". By preferably two-sided pivoting cranes can each have a pair of mold jaws 11 Alternatively, a second crane bridge to the crane system, which is necessary for changing the extrusion die, can be adapted and thereby parallel the extrusion die 3 and the mold jaws 11 change. After conversion, the mold jaw pair is transported back into the mold back chain and the next to be converted mold jaw pair is automatically by the machine control on the transfer table 17 transported. As in 6b shown is the handover table 17 equipped with heavy-duty roller rails and a hold-down system on which the mold jaws 11 after leaving the drive elements in the machine by hand in the change position can be brought. After the replacement or change of the mold jaws 11 These are brought by hand back into engagement with the drive elements of the machine and this promotes the mold jaws 11 after detecting a reference position back into the Formbackenkreislauf. It is also conceivable that the transport of the mold jaws 11 on the delivery table 17 or back into the machine by means of drive elements, which in the transfer table 17 are integrated and the mold jaws 11 on the one hand, when the drive elements in the machine release them or around the forming jaws 11 to supply the drive elements in the machine again.

Using the components described (clamping flange, memory disk, automated mold-jaw storage system) reduces the tool change time z. From 10 hours to 6 hours. Another tool change time reduction of z. B. 6 hours to 4.8 hours can be realized by the spray head heating station.

Claims (17)

Production device for plastic corrugated pipes, comprising an extruder ( 2 ) equipped with a replaceable extrusion tool ( 3 ) is connectable, wherein the extrusion tool ( 3 ) comprises a spray head and a Kalibrierdorn to produce a specific pipe diameter, and wherein the extrusion tool ( 3 ) in relation to a corrugated pipe machine ( 4 ) with molded jaws ( 11 ) is adjustable to produce a specific pipe diameter, and a memory disk ( 20 ) for reproducible assembly of the extrusion tool ( 3 ), so that the setting when re-inserting the extrusion tool ( 3 ) preserved. Production device according to claim 1, wherein the memory disk ( 20 ) after adjustment firmly with the extrusion tool ( 3 ) connected is. Production device according to claim 1 or 2, wherein the extrusion tool ( 3 ) can be adjusted and fixed with respect to its transverse positioning, its level and its rotation about its own axis. Production device according to one of the preceding claims, wherein a precision fixing between the memory disk ( 20 ) and the base frame ( 23 ) is provided to a high Reproducibility when assembling the spray head with memory disk ( 20 ) with the base frame ( 23 ) to reach. Production device according to one of the preceding claims, wherein centering pins on the base frame ( 23 ) are provided to the spray head including memory disk ( 20 ) on the base frame ( 23 ). Production device according to one of the preceding claims, wherein prefixes ( 29 ) between the memory disk ( 20 ) and the base frame ( 23 ) are provided, so that a relatively coarse placement of the spray head including memory disk ( 20 ) on the base frame ( 23 ). Production device according to the preceding claim, wherein final fixings ( 30 ) between the memory disk ( 20 ) and the base frame ( 23 ) are provided to the spray head including memory disk ( 20 ) finally on the base frame ( 23 ). Production device according to one of the preceding claims, wherein an extruder connection ( 21 ) between the extruder ( 2 ) and a plastic supply pipe is provided as a two-part radial-segment clamping flange in order to save screws and thus time required for dimensional change. Production device according to one of the preceding claims, wherein a spray head heating station is provided in order to bring and maintain the spray head before and during a dimensional change to operating temperature in order to further reduce the time required for dimension change. Production device according to one of the preceding claims, wherein coded plug-in connections are provided in order to allow confusion-proof and fast connection of heating power cables with associated temperature sensors. Production device according to one of the preceding claims, wherein a transport frame for the spray head and the Kalibrierdorn is provided to allow a safe lifting or transporting the spray head and the Kalibrierdorns and protection against damage. Production device according to one of the preceding claims, wherein a console roller table at the end of a parking station of the corrugated pipe machine ( 4 ) for moving the mold jaws ( 11 ) is provided, over which the mold jaws ( 11 ) from the corrugated pipe machine ( 4 ) to access when changing mold jaws ( 11 ) to improve. Production device according to one of the preceding claims, wherein an automated mold baking storage system ( 15 ) with a setup station ( 16 ) for converting the mold jaws ( 11 ) is provided during manufacture to reduce production loss due to the die jaw change operation. Production device according to the preceding claim, wherein gripper receptacles on the forming jaws ( 11 ) are provided to receive from a gripping system of a gantry robot ( 14 ), which grips the forming jaws ( 11 ) between a transfer position and the mold baking storage system ( 15 ). Production device according to one of the preceding claims, wherein quick releases on sealing devices of a post-cooling unit ( 12 ) are provided to the Nachkühleinheit ( 12 ) quickly adapt to a new dimension. Extrusion tool ( 3 ) with a spray head and a calibration mandrel for producing plastic corrugated pipes with a specific pipe diameter, wherein the extrusion tool ( 3 ) to a memory disk ( 20 ) for one-time adjustment of the extrusion tool ( 3 ) is mountable to a specific pipe diameter, so that the setting when changing the extrusion tool ( 3 ) and when reinstalling the extrusion tool ( 3 ) preserved. Method for reducing tool change times in a production facility for plastic corrugated pipes comprising an alignment step of an extrusion tool ( 3 ) to a corrugated pipe machine ( 4 ) with molded jaws ( 11 ) for producing a specific pipe diameter, wherein the alignment step via a memory disk ( 20 ), a fixing step in which the extrusion tool ( 3 ) firmly with the memory plate ( 20 ) is connected so that the plastic corrugated pipe can be made with the specific pipe diameter, and the extrusion tool ( 3 ) including memory disk ( 20 ) after the production of the base frame ( 23 ) can be lifted, and so that for re-production of plastic corrugated pipe with the specific pipe diameter, the extrusion tool ( 3 ) including memory disk ( 20 ) without the alignment and fixing step on the base frame ( 23 ) is placed.

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