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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
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.
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[02] Roving Guide Stands.
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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
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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
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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.
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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.
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[10] Automatic Section Cutter.
Gripes Section to be cut .and Releases Just on Completion of Cutting Action, ending
Return of Cutter Motor Assembly at Home Position.
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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.
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Other Equipments:-
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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.
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.
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 ]
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:-
[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.
[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:-
Lubricate Guide Rods of Reciprocating Carriages using General Purpose Lubrication Oil 20W40
.
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.
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Automatic Section Cutter Operating Panel:
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 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:
▪ 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.
Recommended:
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
Page 22 of 22
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INSTRUCTION, OPERATION
&
MAINTENANCE MANUAL
Mat Slitter
Gearbox
with motor
(1) Lift Cutting Blade assembly UP (2) Remove Nut Bolt at right side.
Figure - 2
Slide the Roll guide pipe
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
(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
Figure - 9 Figure - 10
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 :::
OFF ON
pipe.
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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