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INSTRUCTION, OPERATION

&
MAINTENANCE MANUAL

PULTRUSION MACHINE
Model No. AIHP-HGR-12

Plot No.: 1907, Phase-II, G.I.D.C., Industrial Estate, CHHATRAL, Dist: Gandhinagar, Gujarat (INDIA), Pin: 382729
Phone: +91 2764 234017 | Fax: +91 2764 232498 | Mobile: +91 9825286770
Email: info@ashirvadind.com | Website: www.ashirvadind.com
Description & Instruction Manual
For Pultrusion Machine

Machine Part Description:-

[01] Glass Roving / Creel Stand.

For Storing and Arranging Glass Roving Creels Required for Pultrusion
Of Different Sections having varying Cross Sectional Area and Profile Shapes. Creels may be of
Pultrusion Roving, Tax 2400, Tax 4400 or Tax 4800, Depending up on Constructional
Requirement of Process.
Normally This Crels are Available in Approx. Overall dimensions as: 270mm Dia.x 270mm
Height. Weighing 18 Kegs. Each.
Each Roving Should be Guided using Ceramic Bushes for Proper Orientation and easy un
winding during Pulling Process.

Approximate overall dimension: Length Width Height


3700mm 800mm 2200mm

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[02] Roving Guide Stands.

Out Going Ravings from Creel Stands, Requires to be grouped in 2.3.4


For Reducing Area as it travels towards Resin Impregnation Bath and Pultrusion Performs. This
can be achieved in Single or Double Stage Area Reduction by Different Guide Stands, As per
Requirement...
Ceramic Bushes may be adopted for this Purpose.

Approximate overall dimension: Length Width Height


2000mm 1000-1600mm 2100mm

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[03] Stand for Mat Roll

Fabricated form structural steel like, channel, angle or pipe Suitable arrangement for holding
6 Nos. of Mat Rolls

Approximate overall dimensions: Length Width Height


1200mm 1100mm 2100mm

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[04] Perform Guide Stand

Fabricated form structural steel like, channel, angle or pipe With arrangement to attach these
at the end of die bed

Approximate overall dimension: Length Width Height


1000mm 1000mm 300mm

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[05] Resin Impregnation Bath.

S.S. Resin Impregnation Bath is used to get Wetting Dry Glass roving and Matt Reinforcement
system adopted for pulling Required Section. Dry Glass by Dipping inside Req. Grade of Resin
Mix (Compound by proper Formulation) gets impregnated and follows further Perform Guides
for
Creating Performs as per Pultrusion die Profile...
Normally Bath Size are Selected in reference to Section size & Volume.
Separate Baths are used to pull Two Different Sections in Individual Grippers.
Performs made of HMHD Sheets, By Drilling Holes or Slots similar to Shape of Sections, but
with Little Enlarged Size are placed between Resin Bath and Die Bed. Entry of Holes and Slots
must be Given Proper Chamfer Radius for Smooth Movement of Wet Glass System.

Approximate overall dimension: Length Width Height


950mm 400mm 650mm

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[06] Die Bed.

Die Bed is Consisting of Number of Heavy Duty Base Tube Rollers, Equally spaced Longitudinal
to Pulling Direction. Pultrusion Die of Different Width and Length can be clamped by 6 Nos .of
M20 Studes.Keeping Space for Suitable electrical Heaters.
Bottom Rollers wherever required can be dismantled for Accommodating electrical Heaters at
Bottom Surface of Die.
Complete die bed Height can be adjusted by for side guide Slotes, and Movement by for nos
of Jack Screws.

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[07] Electrical Panel.

This Panel contains all electrical Contactors, Relays, Power Supplies, MCB for Heater &
Motor Protection. Connection Terminals. & Major Operating Components.

[5A] This Portion of electrical Panel Contains Temperature Controllers, Plug Socket Units for
Electrical Heaters. On –off Switches and Thermocouple connectors for heating Control
Sensors. PID Temperature Controllers can be configured according to Practical
Parameters required for different Application. This portion of Panel is facing towards
Die Bed to facilitate ease of Heater Connection as well as Observation of Set and
Actual Temps from Die Side. Specific Catalogue of Temperature Controller is attached
in Machine Manuel.

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[08] Hydraulic Pulling Stations.

These two Stations are Main Responsible part of the Machine for Generating Reciprocating
Movement along with Desired Gripping force to
Facilitate Desired Pultrusion Action.
Two Moving Tables are Reciprocating by Means of Individual Hydraulic Cylinders, at Desired
/Set Speed by Means of Hydraulic Oil Flow Control Valve. This Action is achieved from Remote
Panel by means of Suitable Synchronous Geared Motors. Speed of Individual Tables are
Displayed on Front Operating Panel in Terms of mm /Mni. Or Desired Scale .Feedback of
Travel Speed is generated by Encoder & Programmable Counters.
Both End Limits as well as Parallel Movement commands are Adjustable by means of
Adjusting 6 Nos of Inductive Proximities, of PNP/NO Type.
2 Nos .of Grippers Actuating by Means of Pneumatic Cylinders holds Section under Pulling
Cycle. Gripping Action can be controlled by means of Solenoid Valves. Pneumatic Air Pressure
of 6-7 Kg/Sq.Cm is Require3d for Proper Griping.

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[09] Hydraulic Power Pack.

Hydraulic Power Pack consisting of Two Nos of 3.0 H.P. Motors, Hydraulic Pumps, Directional
control Valves, Pressure Relief Valves. Pressure Gauges and Required Accessories. Pulling
Capacity of Pulling Tables can be adjusted by Changing Hydraulic Pressure of the System.
Suitable Heat exchanger has been provided for Cooling of Oil.

Enklo 68 Oil is recommended for Hydraulic System adopted in this Machine.


Recommended Maximum Pressure ig Gauge is: 110 Kg/Sq.Cm. for Desired Maximum
Output Force.

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[10] Automatic Section Cutter.

Automatic Section Cutter consisting of pneumatically operated Table, and


Cutter motor

Assembly. Electrodeposited Diamond Cutter is adopted for Cutting GRP Pultruded


Sections. This Cutter Actuates from Remote Photoelectric Sensor, Adjusted as per
cutting Length Desired. Cutter can operate in Manuel Mode also by Simply Actuating
One Push button for Desired Cutting Action. Whenever Desired .4 Nos of PneumaticCylinders

Gripes Section to be cut .and Releases Just on Completion of Cutting Action, ending
Return of Cutter Motor Assembly at Home Position.

Pneumatic Air Pressure of 6-7 Kg/Sq.cm should be maintained for Perfect


Operating of Section Cutter.

Approximate overall dimension: Length Width Height


1750mm 1850mm 1700mm

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[11] Section Conveying Roller Table.

Roller Table at the End of Pultrusion Machine, is used for conveying Cut,
Or Continuous Sections Coming out of Pultrusion Machine.

Approximate overall dimension: Length Width Height


3000mm 900mm 875mm

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Other Equipments:-

[12] Glass Matt Slitter.


Suitable for Slitting Glass Matt Roll in to Required Width for Different Section
Requirement. Cutting Action achieved by means of Rotating Matt Roll and Stationery
Cutter Blade. Steeples Speed variation of Cutting can be Generated using A.C.
Frequency Drive Provided with Cutter.

Suitable for Mat Roll up to Ø 400 mm X 1600 mm


Slitting width / Blade position adjustment by manual
Mat Roll mounting spindle movement by suitable geared reduction drive & inverter drive for
achieving
required spindle speed
Electric requirement: 0.75 kW.

Approximate overall dimension: Length Width Height


3000mm 1000mm 1000mm

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CONTROL PANEL:-

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SAFETY INSTRUCTION FOR OPERATION.

Do not Put Direct Hand or any Portion of Body near Puller Clamping Position. During
Machine in working condition.

Do not keep hand in area of Cutting blade Movement of Automatic Section Cutter.
Avoid attempt to attain any working part while Buzzer /Flesher indication is on during
Section Cutting Operation.

Avoid Direct Touch by putting hand over Heated Die on Die Clamping Station. As temp Of 145
-175 Deg. C. May Burn Contact portion.
While any adjustment of Heater Keep Suitable Hand Gloze in working hands.
While attaining Heaters, it is advisable to put off first Respective Heater Zone form
Heater Panel.

Suitable Dust Collection at Section Cutter May be Used in Place of Installation.


In Case of Operating with Specific Resins /Materials suitable fume extraction should
Be installed at place of Such Emission.

Do not open /Dismantle any Hydraulic Fittings /Tubes while machine is Working, as
Hydraulic Pressure may harm to exposed Part.

Do not continue / operate in case of Material Locking in side die, as heavy slippage
May Result in Machine working with abnormal jerks’. Avoid this by Opening Die and
Releasing Material for Smooth Starting of Process.

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INSTALLATION INSTRUCTION.

Lift Machine form Bottom of Base Frame, and in Weight Balancing Position. Put Lifting Belts
Near Marked Position.
Use Lifting Capacity no less than 6000Kg for safe handling of Maine Puller and Machine
Assembly.

Lay –out may be used to keep Required Space between each Equipment and Acc. Of the
Machine.
Machine Mounting Pads are provided with Machine, and same should be kept in Position
before Lowering Machine in Position /Floor of Installation.

Leveling may be Achieved by adjustment of Machine Mounting Pads. In Case of Major Floor
Diff. Suitable Arrangement may be Made to Level the Machine.

Assemble other Acc. Like Creel Stands, Glass Roving and Mat Roll Stands and Section
Conveying Roller Tables as per Inst. /Guide provided.

Connect Compressed Air line to Main FRL Unit of the Machine. Assuring Mini.4-5CFM@6
Kg/Sq.Cm Dry Air supply input.

Connect Machine Mail electrical Panel with Supply Source of 3 Phase + Neutral and Industrial
Earthling.
Supply Line of capacity Mini. 3 Phase, 380-430V A.C .50HZ, 63Amp/Phase. + Neutral
+Industrial Earthling.

Cooling Water line with Flow rate of 40 -45 LPM and inlet temp 20-22Deg.C may be connected
to Hydraulic Power Pack Heat Exchanger.

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INSTRUCTION FOR MACHINE OPERATING:-

Power ON Mains MCB. Ensure all Three Phase Indicators are OK.

Turn ON switch for VOLT/AMP. Meter, It will Indicate Voltage, Amps., and Frequency of
Three Phase Power Source.

Ensure that main Air supply to FRL unit is between 4 - 5.5 Kg/Cm².

Power ON all MCB’s for Heater Supply, Motor Supply, and Controls.

Plug in Temperature Sensor Wire in related socket [ Ex. TC-1 ---- TC-6 ]

Turn ON Selector switch for required Temperature Controller / Heater Zone, RED Color
display [PV] is an Actual Temperature of related Thermocouple, and GREEN display
indicates set value [SV] of required zone temperature.

Insert required Heater Plug in related Socket [ Ex. H-1 ----- H-6 ]

Wait till required set Temperature for different zone has been achieved.

Ensure that MCB for motors is ON.

Start motor for Puller A & B by pushing on PUMP MOTOR Push buttons, indicated on
Operating Panel.

Select AUTO/MANUAL mode for running the machine by selector switch on Operating
Panel.

Turn ON Display Selector Switch, this will start display for Speed Indication of Puller A &
B.

Push on FORWARD Push button for respective Puller A or Puller B, this action will start
Puller Table movement in forward direction, we can return Puller by pushing push button
for RETURN [ if operating mode MANUAL is selected ]

If selection is in AUTO then respective Puller will move in FORWARD direction and before
end of the stroke will START another Puller in FORWARD direction, from the end of stroke
limit Puller will return to HOME position and will wait for next cycle to be continued by
PLC.

Observe reading of Puller Speed in MM/MIN. for both Puller A & B and ensure that
Operating Speed is very near to desired / decided / required Pulling Speed for Starting
Production, if this speed is higher or lower, adjust this by SPEED increase ▲ or decrease
▼ Push button

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[ This can be adjusted by rotating Knob over Flow Control Valve in Clockwise and anti
clockwise direction also by manually ]

If Pulling speed and Temperature for different zone is ok then turn ON selector switches
for GRIP-A and GRIP-B, check selector switch for GRIP LINE – 1 and GRIP LINE – 2 is on
turn ON position ]

Allow pulling bar to activate pulling action for the process.

PURGING [ momentary standstill status ] can be achieved by Inching PRUGING Push


button, OFF time for PURGING can be adjusted by selecting decimal time on a timer fixed
on contactor panel

In any sudden stop required EMEGENCY STOP Push button may be use, but ensure that
for restarting the machine EMERGENCY STOP button has been released.

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START UP PROCEDURE FOR PRODUCTION:-

Basic Sequence of Starting Pultrusion Machine is as explained under,

[01] Calculating Required Quantity of Glass roving as well as Reinforcement


System consisting of various types of woven Roving, Stitch Matt, and Surface Matt is
required.

Normally Glass content varies between 70 -85% by weight.


Accordingly Creel Stand should contain required roving Creel.
And Reinforcement System should be guided from Ceramic Bushes.

[02] Pass Reinforcement form Resin Bath and Perform Guides. Near Die.

[03] Clamp die over Die Table by Means of Proper Clamping bolts.

[04] Insert Thermocouple Sensing Probes in Die, at pre determined locations for
Observation and Control of Temperature at Different zone of Die

[05] Set Desired Temp for Heating of Pultrusion Die. Normally in Curing Zone
Ranging between 145 – 155 C° depending up on Resin Composition and type of
Additives.

[06] Allow Die under Uniform Hating and Temp Stability at set points.

[07] Pour Resin Mix inside Resin Impregnation Bath

[08] Set required Gripping Pressure on pultruded section as high as not to crush section &
as low as not to slippage of section while carriage table is moving using Pressure
By adjustment of Pressure Switch & Pressure Relief Valve on Clamping Power Pack.

[09] Hold Pulling Bar /flat in Puller Gripper in such a manner that after initial travel of first
carriage same can be hold in second Carriage Gripping System.

[10] Start Pulling Manually, By Tying up Glass roving and Reinforcement in Pulling Hook at
the end of Pulling Bar. Till Cured Section comes Out of Pultrusion Die. And allow it to
continue till Direct Gripping in Second Carriage

[11] After Gripping Pultruded Section in Second Carriage, Machine can be put in Auto
Mode of operation, which wills Pull Section Continuously by Cyclic Operation of Both
the Carriages.

While Continuous pulling this way constant Observation should be made for Out
Coming Section, whether it is fully cured or not? And any correction in Pulling Speed or
Die Temperature should be applied.

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[12] Set Photo Sensor on Roller Table at Desired Reference Length to Cut in Auto Cutter,
and Put Cutter in Auto Operating Mode.

[13] Observe continuously that Compressed Air at 6-7 Kg/Sq.Cm is Available for Proper
Operation of Grippers as well as Cutter.

[14] Dust Collector should remain on if Auto Cutter is in Operation. To avoid fine Glass
Particles coming out of Cutting Area.

[15] Roving Dryer of Infra Red Bulbs, May be Used in Excessive Moist Atmosphere to
eliminate Moisture Contamination during Curing Process.

Warning:

Do not use different height sections to avoid misalignment of Moving Gripping Plate as shown
in Figure-1. Use appropriate fixtures to accommodate the height difference between 2
different height sections.

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MAINTENANCE INSTRUCTIONS:-

Follow Maintenance of Individual Components as per Furnished Original Manufacturers


Catalogue.

Besides This Following Points are Important.

Lubricate Guide Rods of Reciprocating Carriages using General Purpose Lubrication Oil 20W40
.

Apply Lubrication Oil to Gripper Hinge Pins Once Every Day.

Remove Collected Water from FRL Unit of Machine and Cutter to Avoid Moist Air Entering in
Pneumatic Cylinders and Valves.

Add Lub., Oil in Lubricator Bowl of FRL unit and Adjust Lubricant Rate by Adjusting Flow
Regulator.

Hydraulic Oil Level in Tank Should be Observed Periodically .and if required Enklo -46, Oil May
be added as per Requirement.

Suction Oil Filters of Pumps may be cleaned after every 2500 Hrs. of Working.

All Guide Ways of Automatic Section Cutter May be Lubricated Daily using 20W40 Lubricating
Oil.

No Maintenance is recommended for components like, Hydraulic Pump, Pressure Relief Valve,
Flow Control Valves and Pressure Gauges.

Gripper Studs should be checked regularly,

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Automatic Section Cutter Operating Panel:

Automatic Section Cutter Operating Instruction:

Power ON Cutter MCB

Ensure Air pressure on regulator are between 3 – 4 Kg/Cm2

Release EMERGENCY STOP button if it is active

Push ON push button for activating PLC

Select AUTO/MANUAL cycle from selector switch

If in MANUAL selection push MANUAL push button to active one cutting cycle
If in AUTO selection actuation of Photo sensor by presence of Section will activate one
cutting cycle

Adjust Clamping Cylinder Proximity according to Clamping height

Adjust Table end Proximity position as per required trolley travel during cutting

In case of any cycle disturbance reset the cycle by pressing CYCLE RESET push button

Emergency Stop can be achieved by pushing EMERGENCY STOP push button in case of
any sudden stoppage required

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Utility:

Electrical Power Required:

▪ Connected Load 6.0 Kw. For Hydraulic and Section Cutter

▪ For Mold Heating 6 Nos. of Heater Connections each of having capacity 16 Amp. With
230VAC Supply.

▪ Compressed Air for Gripper mechanism and section cutter, 6-8 CFM @ 60 PSI.

▪ Oil Heat exchanger cooling water circulation @ approximately 30-35 LPM.


With inlet water temperature 22-24 C°.

Recommended:

▪ Hydraulic Oil ------------------------------------------- Enklo 68


▪ Lubricating Oil ----------------------------------------- SAE 42W40
▪ Pneumatic Cylinder / Valve lubricating oil ----- ISO VG32 / Servo System 32 /
TQA ATF Type A

ASHIRVAD INDUSTRIES
Plot No. 1907. Phase-II, GIDC, Industrial Estate,
Chhatral – 382729, Dist: Gandhinagar,
Gujarat – INDIA.
Tel.: +91 2764 234017 Fax.: +91 2764 232498
Email : info@ashirvadind.com
Website : www.ashirvadind.com

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INSTRUCTION, OPERATION
&
MAINTENANCE MANUAL

Mat Slitter

Plot No. 1907, Phase-II, G.I.D.C., Industrial Estate, Chhatral – 382729


Dist: Gandhinagar , Gujarat, INDIA Tel: +91 2764 234017 Fax: +91 2764 232498
Email: info@ashirvadind.com, ashirvadind@hotmail.com
Visit us: www.ashirvadind.com , www.pultrusionmachine.co.in
TM

Mat Slitter Operating Instructions


Figure - 1
End flange for mat slitter

Unscrew the Nut bolt

Mat Roll guide pipe

Gearbox
with motor
(1) Lift Cutting Blade assembly UP (2) Remove Nut Bolt at right side.

Figure - 2
Slide the Roll guide pipe

(3) Slide the Roll Guide Pipe towards left side

Figure - 3 Lift the


Loosen bolt & guide pipe
remove End Flange

End Flange

(4) Now remove the Roll Guide Pipe from stand (5) Loosen the Bolt of End Flange & remove one Flange

Figure - 4
First insert mat roll & after Paper core tube of mat roll Mat Roll
insert End flange

(6) Insert the Mat Roll with paper cone in the pipe (7) Place End flange as shown in figure 5 & Tight the bolt

Figure - 5
Paper core tube of mat roll Mat Roll

Contd.....
::: 2 of 3 :::

Figure - 6

Place the Roll guide pipe


with Mat

(8) Place back the Roll Guide pipe with mat roll to Slitter stand

Figure - 7

(9) Slide the Roll Guide to right & align to the Hole at right side on both pipes.

Figure - 8
Align Pipe through hole &
Screw the Nut bolt

(10) Secure the bolt in aligned holes in pipes

Figure - 9 Figure - 10

Handle for moving


cutting blade slide
(at back side)

Adjust Blade
Cutting Blade Down Limit Bolt
Mat Roll

Set required cutting width using Handle as shown in fig. 10 & lower the Cutting Blade on mat roll.
Now Start the Motor using Start / Stop Switch over AC Drive. Set required Cutting Speed using POT on AC Drive.
When Mat roll is cut, Stop the motor.

Note : Adjust the Blade Down Limit Bolt to set the lowest down position of Blade so that the
Paper core tube of mat roll is not cut only Mat roll is cut.
Contd.....
::: 3 of 3 :::

Control Panel Operation :

MAINS POWER :- MCB for Main power supply.

MOTOR :- Rotary switch to Start or Stop Motor.

SPEED :- Potentiometer knob for setting cutting


speed in AC drive. Clockwise rotation increases
cutting speed. (Min. Frequency is 20 Hz - 58 RPM &
DISPLAY
Max. Frequency is 60 Hz - 167 RPM)

DISPLAY :- LED display Shows Set speed in RPM.

While running, when cutting blade cuts mat roll &


reaches to core of roll, there is a Safety limit switch
which activates & stops the motor & damage to blade /
MAIN POWER

OFF ON
pipe.

Note : The password for AC Drive is 225. Parameters


+
SPEED MOTOR are accessible after providing the password only.

Front Control Panel

TM

Plot No. 1907, Phase II, G.I.D.C. Indl. Estate, Chhatral - 382729. Gujarat, INDIA. Website : www.ashirvadind.com
PHONE : (F) +91 - 2764 - 234017 TELE-FAX : (F) +91 - 2764 - 232498 e-mail : ashirvadind@hotmail.com
Welcome Screen
1

Home Screen
2
Home Screen
3
For machine operating condition.
Clamping Pressure Display Screen
4
For edit set value of clamping pressure.
By clicking on 'LOG IN' button password screen
screen will
will appear.
appear.
Enter password '1458' for editing require change.

By Clicking here
Calibrition screen
will open.
* only use for
initial settings.

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