6000 MM BIAXIAL GEOGRID PRODUCTION LINE

SATURN4105024

6000 MM BIAXIAL GEOGRID PRODUCTION LINE

1.General information

Raw Material PP, PE, master batch etc

Final Product Output 1200-1500kg/hr

Machine Color   Standard color:（Grey and Orange）

Final Product    

1.Product width: 6m

2.Sepcification: Biaxial

1.Equipment

3.1 Material Auto dosing and mixing system

Measure and feeding method: Gravimetric

Measure components:4

Suitable: diameter 3~5mm particles, temperature≤80℃

Mixing capacity: ≥2000kg/h

Material: parts that contacting material are stainless steel

Hopper volume: 300L*1pc

150L*3pcs

Mixing barrel volume: 80L

Mixing motor power: 1.5kW

3.2 Automatic loader 2 sets

It adopts spiral conveying feeding system, equipped with material level detection.

Loading capacity： 2000kg/h

Material: The contact parts with raw materials are all stainless steel.

3.3Single screw extruder 2 sets

Screw diameter: 160mm

L/D: 33:1

Main motor power: 355kW，frequency control

Screw speed: 0~72rpm

Extrusion capacity: about 800~900kg/h/set(PP)

Heating method: electric heating

Heater: cast Aluminum heater

Heating power: 168kW

Heating section number: 8 zones

Material of screw and barrel: 38CrMoAl, nitride treatment, hardening and

tempering

Temperature-sensing element: platinum resistance

Temperature controller accuracy: Fuji or RKC temperature controller, ±1℃

Main motor speed regulation controller： ABB controller

Screw type: special screw for polyolefin

Screw structure: barrier screw

Screw compress rate: not higher than 3.2

No need internal cooling for screw, water cooling for feeding section, water temperature3

should below 30℃.

3.4 Double channels screen exchanger

It adopts hydraulic screen exchanger to change the screen without stopping the machine.

3.5 Melt pump

500CC, 5~40 rpm, Delta inverter, equipped with one pressure meter and one

pressure sensor, to match the melt pump speed with extruder speed.

3.6 Coat-hanger type T-die

Sheet thickness: 1~10mm

Sheet width: 1800mm, can be adjusted

Die effective width: 1950mm

Die gap adjusting range: 1≤δ≤12mm, to produce different thickness product.

Flow passage expand angle: 174~176º

Heating method: electric heating

Heater: electric heating bar

Heating power: 36kW

Heating section number: 9 zones

Material: special mold steel

Adjustment method for die gap: damping block rough adjustment, bolt fine adjustment to ensure raw material extruded evenly

Material: special high grade steel

Equipped with one die head, lifting and dismantling device.

3.7 Five-roll calendar(L)

Frequency conversion motor and decelerator drive, domestic brand decelerator. Five-roll drives independently, helical grip structure, uniform heating, high-quality product.

Roll gap adjusting method: electric, mechanical locking

Roll surface heat treatment hardness: HRC≥55

Roll surface roughness: Ra0.025

Roll surface chrome-plating, plating thickness: 0.12~0.14mm

Felt wrapped roll diameter: ≥700mm

Five-roll effective length: 2100mm

Felt wrapped roll speed: 0~5m/min（50Hz） 4

Adjust distance between up and down felt wrapped roll: 0~40mm

Product width: ≤1800mm

Product thickness: 1~10mm

Total drive power: 7.8kW

Sheet accuracy: ±0.02mm

Temperature controller: It consists of five 3kW stainless steel two-stage pump and a booster pump, water temperature and pressure is adjusted automatically to meet different temperature requirement.

3.8 Haul-off, cooling, trimming cut device

3.8.1 Haul - off

Sheet haul-off is driven by one motor, double rubber rolls as a pair of haul-off roll. Passive rubber roll is driven by the cylinder, it can move up and down, hold down and loosen. Haul-off speed can be adjusted within a limit.

Haul-off speed: 0~5m/min

Roll diameter: 250mm

Roll effective length: 2100mm

Rubber roll displacement: 50mm

Motor power: 2.2 kW

Cylinder diameter: 160mm

Working pressure: P≤0.6MPa

3.8.2 Cooling

Sheet cooling method: natural cooling

Roll diameter: 80mm

Height from roll to ground: 1200mm

3.8.3 Trimming cut

It adopts fixed cutter, trimming cut width can be adjusted within a range.

3.8.4 Waste edge collecting in line

The waste edge is directly fed into the silent crusher, and the crushed material is directly transported to the automatic mixing system of the raw materials.

Crusher motor: 37kW

3.9 Punching device 5

Main motor adopts frequency conversion motor, advanced technology to ensure positioning accuracy of punching and material conveying synchronous. There are limiting device and press roller before punching and a pair of press roller after punch to make sure the sheet flat. It equips with a set of double-row punching needle mold.

Punching position accuracy: transverse ±0.02mm

longitudinal ±0.2mm

Working pressure: 315T (mechanical)

Working table effective area: 2250×800mm

Motor power: 37kW

Slide strokes: 80~100mm

Slide strokes Per Minute 65 times

Structure: closed type

3.10 Recycling device

Automatic collecting and conveyed to the auto dosing system.

3.11 Tension device

It is composed of multi-roll damping and conveying to meet different specifications’ requirement.

Conveying motor power: 1.5kW

Roll diameter: 300~400mm

Cylinder diameter: 125mm

3.12 Limiting device before longitudinal stretch

Limit width is adjustable to meet different requirement.

3.13 Longitudinal stretching device

Multi-roll and multi-point stretching are adopted to ensure stretching uniform and high-quality product. Longitudinal stretching is divided into 3 parts.

3.13.1 Preheating part

Preheating roll number: 6

Roll diameter: 400~500mm

Effective length: 1800mm

Drive method: gear drive

Speed range: 0~3.5m/min6

Drive source: Frequency conversion AC motor

Drive power: 11kW

3.13.2 Stretching part

It is composed of several stretching rolls.

Roll diameter: 300~390mm

Effective length: 1800mm

Drive method: gear drive

Speed range: 1~12m/min

Drive power: 45 kW

3.13.3 Back shaping and treatment part

It is composed of 6 drive rolls, roll is driven by motor, roll linear speed is matched with linear speed of the last stretching roll.

Roll diameter: 400~450mm

Effective length: 1800mm

Drive method: gear drive

Speed range: 1~12m/min

Three parts are fixed as a whole by two side plates, including oil pipeline system and multi-point lubrication device.

3.13.4 Others

Longitudinal stretching ratio: max 1:10, two groups drive, multi-point stretching

Roller surface temperature: automatically controlled and adjustable

Heating roller structure: suitable for heating with thermal oil or steam medium

Heating roll method: thermal oil or steam heating

Heat efficiency protect: sheet stretching in closed space

Bearing lubrication: The bearing seat is equipped with oil injection holes for cheap lubrication

3.14 Haul-off device

It is composed of motor, 3 drive rolls and 2 pressuring rolls.

Motor power: 7.5kW

Drive roll diameter: 350~400mm

Passive rubber roll diameter: 290mm 7

Effective width: 1400mm

Cylinder diameter: 160mm

Working pressure: 0.4~0.6MPa

Stroke: 75mm

3.15 Uniaxial product winder

It equipped with haul off and convey device for uniaxial product.

3.16 Transverse stretching device

3.16. 1 Technical parameters

1). Speed: 0~25m/min (25m/min, 50Hz）

2). Transverse tensile strength: ≥18000N/clip

3). Nominal width: 6300mm

4). Sheet thickness: 1~8mm

5). Oven length: 30m, total 12 sections, each section 2.5m.

6). Oven heating methods: Hot air by natural gas direct burning, heating, maximum temperature 200℃.

7). Stretching requirement: sheet 800~1900mm, stretched width 4000~6300mm.

8). Working face height: 1225mm

9). Width adjusting method: Transmission by long shaft and segment, each rail can be adjusted by clutch separately. There are max./min. width adjusting alarms. Adjust the width on-line manually, and add speed reducing device for convenient manual adjustment. Add gauges to display rail width of entry and exit.

10). Sheet clamp method: The clip is equipped with saw tooth-shape flat clip mouth, two clip mouths for each clip, interchangeable with each other, single surface clip mouth with saw tooth pattern, all of the clip mouth shims are the same height, the tolerance of which is less than ±0.1mm. Seller can supply sheet thickness 1.2, 1.8, 2, 2.3, 2.8, 3mm.

11). Chain and running method: Rolling bearing, rolling chain, running horizontally, pitch of the chain is 63.5mm, there is oil orifice on the bearing to fill high temperature lubrication grease.

12). Circulation fan: motor power 7.5~15kW. Speed≥20m/s. Accuracy≤10%

13). Lubricating method: Open-close device and rail lubricating adopts grease pump lubricate automatically, there are more than 8 oiling channel at head part, and also rear part. 8

3.16.2. Equipment

1). Guide part

It is composed of feeding roll, up-press roll and position guide part. Feeding roller is composed of three parallel roll. Up-press roll is composed of three driven roller, and lifting or pressing controlled by cylinder, pressing location is adjusted by hand wheel at the end of cylinder. Pneumatic components, pipes and cables are fixed and layout clean. Location guide components are respectively set at the front of roll one (one left, one right), between roll one and roll two(one left, one right), between roll 2 and roll 3( one left, one right). Front idler roller guides the sheet into the up and down press roller and the position (left or right) adjusted by hand wheel manually, adjustment amount is about 200mm one side. Front idler roller locates at the centre of the feeding roll, left and right symmetry, which meet the requirement for producing 4m to 6m geogrid.

2). Head part

For the head part, there is width adjusting device, which can adjust separately or generally, automatically or manually. The clip closing device adopts spring or spring plate to ensure the clip closing strength is enough and the clip won’t be damaged, the clip closing is accurate and reasonable, the max. clip closing strength is more than 300 kgf. The structure of the clip closing/open device is reasonable, which can avoid the abrasion and damage of the clip.

3). Rail part

The rail frame is made of ductile iron, one segment is basically 2.5m, it is fixed connected between the straight sections and hinged between the straight section and curved section, and the hinged connection can oscillate within a certain angle. The requirements for the shape and structure of the rail: the first 12.5m is preheating zone, the middle 12.5m is stretching zone, the final 5m is shaping zone. The width adjusting range for preheating zone is 800~1900mm, for shaping zone and cooling zone is 4000~6300mm, the width of the stretching zone can be changed with the change of preheating zone and forming zone. The working surface of rail adopts wear-resistant steel plate. And set some chip removal outlet at each corner. It adopts proper measures to fix the stretch part guide rail, the four hinge joints are covered by wear plate to avoid the moving noise. The rail thickness is not less than 15mm and add wear plate.

4). Chain-clip part

The chain-clip adopts rolling bearings, pure rolling structure, running horizontally, the chain pitch is 63.5mm, rolling bearing diameter is 47mm. The clip frame is manufactured by precise casting. There are 10 rolling bearings for each chain-clip, 8 pieces on both sides, one piece on the top, and one piece in the bottom. There is oil orifice on the bearing to fill 9

high temperature lubrication grease. The lower clip mouth is a plane with file shape, which can increase the friction, the upper clip mouth is sawtooth shape, equipped with self-lock spring. The clip and the adjusting shim can meet the application requirements of different thickness sheets (1~6mm, for different specification products). The raw material of the clip is ZG45, which is hard, impact resistant, abrasion resistant. The rolling wheel is hard enough, and easy for disassembling. The whole outer surfaces of the clip are planted with zinc.

5). Chain transmission part

The chain transmission adopts a main motor with reducer, drives the gearboxes on both sides by the spline shaft, then drives the chains on both sides. The main motor (namely the main transmission motor of the rear part) is AC frequency conversion motor, power is 55kW, controlled by inverter, equipped with brake. The chain is tensioned by hydraulic pressure, which is safe and reliable. The tensile strength for chain, rail and clip is designed for 18000kN.

6). Oven part

Equipped with ten pcs1.2~1.6*10^5 Kcal burner. The ovens are divided into three zones along the machine direction, the effective width of the preheating zone is 1900mm, the effective width of the forming zone is 6300mm, both width can be adjusted within a certain range. The height of inlet, outlet and inner oven ensures the clips go through safely. The clip mouth height is 1225mm from geogrid to floor. The oven adopts building block-type small circulation structure, there are two circulation fan motors for each oven, the power of one motor for preheating zone is 7.5kW, air flow amount is 13800m3/h; the power of one motor for stretching zone is 11kW, air flow amount is 17000m3/h ( two of the motors, the power is 15kW, air flow amount is 26000m3/h); the power of one motor for forming zone is 11kW (two of the motors, the power is 15kW). It adopts staggered arrangement between the segments of the ovens. One burner one temperature controller. The air blowing pipe is wedge pipe, staggered arrangement, air blowing mouth is small round hole, the resistance is big, and the air distribution is uniform. Cooling zone is air cooling, blow mouth adopts air knife type. There are thermal insulation plates in the inlet and outlet of the oven to reduce the heat loss. The temperature of each heat-exchange space can be controlled automatically. The temperature precision is ±2℃, the transverse temperature uniformity is ±3℃. The oven is equipped with thermocouple holes and lifting rings, and the stiffness of the oven can meet the requirements of lifting and is not easy to deform. The oven space and heat dissipation area is large, heating wind speed is high, temperature is uniform. There is self-lock protection device for the oven door, the alarm will start and stop the machine if the door is not closed completely. Add 3 no-material alarm devices in the oven in order to judge if the geogrid is broken or not. 10

The viewing windows of the ovens should be away from the nozzles, switches, etc, and seller provides drawing for exact distribution of the windows. The viewing windows of the ovens adopt double-layer tempered glass with good sealing; Add protection plates and handrails around the viewing windows; Add handrails and ladders around the ovens, painting yellow color. Add covers for the width adjusting lead-screws in the oven. Increase the oven roof thickness to 120mm, with reinforcing ribs. Use natural aluminum powder paint inside the oven, and grey polyurethane paint outside the oven.

7). Fume exhaust part

The burner is located at the bottom of the oven, and there is a self-circulating process (hot air) in the oven in each area, including the combustion chamber and hot air pipeline, etc.

The burner is located at the bottom of the two sides of the oven, and there is a (hot air) self-circulation process in each area of the oven, including the combustion chamber and hot air pipe. Burner connection size and combustion chamber should match. The fire protection material of the burner should be thicker, the thickness should not be less than 5mm, and the material is stainless steel. Three sets of exhaust pipes and fans are arranged at the top of the oven from section 2 to Section 9, with exhaust volume of 250m³/ 250,000 Kcal.

8). Rear part

The rear part consists of base seat, right/left gearbox, beam, main transmission frequency conversion motor(55kW) and transmission device, main transmission reducer, clip-open device, etc. The base seat is divided into three parts, Add security covers for width adjusting motor and main motor in the rear part.

9). Edge cutting device

Install a reducer rotating edge cutting device at the front of the traction and the shaping roller. Equipped with a dual station waste edge winding device.

3.17. Haul-off device

It adopts one couple rubber as haul-off roll, rubber roll as pressing roll, frequency conversion motor to drive, the pressing rolls are driven by cylinder, can move up and down.

Haul-off rubber roll diameter: 300mm

Effective length: 6200mm

Speed adjusting method: frequency conversion

Motor power: 11kW

Cylinder diameter: 160mm

Double-row chain Type 25.4 11

There are 3 shaping rail before haul-off device.

3.18 Online recycling of horizontal pulling waste edges

3.19 Accumulator

It adopts 50 m accumulator, to avoid uneven surface when changing winding roll.

3.20 Fixed length cutting device

It is composed of a couple of grip conveying rolls, they are static while shearing, after cutting they rotate quickly, so that the accumulated geogrid’s speed can match with the normal haul-off speed. Geogrid will be cut automatically when reaching the setting length.

Haul-off rubber roll diameter: 300mm

Effective length: 6200mm

Speed adjusting method: frequency conversion

Speed range: 0~20m/min

Haul-off motor power: 7.5kW

Cutting motor power: 2.2kW

3.21 Winding device

It adopts auto winding device, and roll discharging device.

Max winding width: 6000~6050mm, adjustable

Max winding diameter: 800mm

Rated torque: 150N•m

1. Production capacity

1200~1500kg/h.

1. Electrics

Temperature controller :

It adopts Delta products, accuracy ±1℃.

Frequency converter :

It adopts Delta.

The traction of oven chain, haul-off roll and waste edge shearing adopt inverter, stepless speed regulation.

Unit for length counting: cm; equipped with length counting alarm.

The operation panel of the oven contains buzzer, emergency stop, tracking speed button (Knob). 12

The outside dimension of the electric cabinet

Height 2000mm

Thickness 600mm