Product Descriptions
Automatic Screw Element Removal Machine
Controlled, Safe, and Efficient Removal Technology for Twin Screw Extruders
Screw elements used in twin screw extruders can become jammed on the screw shaft due to high temperatures, process pressure, polymer residues, and long operating times. Carbonized materials, fillers, and process residues, in particular, can make it difficult to separate screw elements during maintenance.
Traditional methods such as hammering, heating, mechanical striking, or uncontrolled hydraulic force can lead to long maintenance times, intensive labor, and the risk of damage to screw elements and shafts. The inability to control the force applied by the operator also poses a risk to occupational safety.
The Automatic Screw Element Removal Machine is designed for the controlled removal of modular screw elements in twin screw extruders. Thanks to its hydraulic clamping system, servo-controlled removal position, and program-set removal pressure, it helps to perform maintenance operations more safely, quickly, and repeatably.
Automatic Screw Removal Technology
The system secures the screw assembly to be removed with adjustable hydraulic pliers. The program automatically matches the required removal pressure according to the application conditions, while the servo system manages the removal position in a controlled manner.
Thanks to this structure, the force is applied to the screw elements in a predetermined and controlled manner. This aims to reduce operator-dependent variations and uncontrolled mechanical interventions.
The automatic removal process basically consists of the following stages:
1. Placing the screw assembly on the machine
2. Adjusting the hydraulic pliers according to the screw diameter
3. Securely securing the screw assembly
4. Determining the removal position by the servo system
5. Matching the appropriate removal pressure by the program
6. Controlled separation of the screw elements
7. Advancing the removal position for the next screw element
The application procedure may vary depending on the screw geometry, element arrangement, and machine configuration.
Key Advantages
Automatic Removal Process
The program automatically matches the pressure required for removal. The servo-controlled positioning system helps to apply the force to the correct removal point.
This makes the removal of screw elements a more controlled and standardized process.
High Clamping Capacity
The adjustable hydraulic collet system offers a clamping force range of 0-50 tons. The strong clamping structure supports the controlled holding of the screw group during the removal process.
Removal Force Up to 15 Tons
The system provides an adjustable removal force between 0-15 tons. The controlled application of the removal force helps to adapt to different screw elements and process conditions.
Servo-Controlled Positioning
The servo system precisely controls the position of the removal mechanism on the screw group. This feature allows for sequential access to different screw elements and ensures the smooth progress of the process.
Wide Diameter Range
Adjustable hydraulic collets are suitable for clamping screw groups with diameters ranging from 30-100 mm. This allows various screw diameters used in different extruder models to be processed on the same machine.
Accessibility to Different Screw Lengths
The machine is designed for removing screw assemblies exceeding 500 mm in length. The suitability of screw dimensions must be verified during the project phase using technical drawings.
Faster Maintenance Process
Automatic pressure matching and servo positioning help reduce maintenance time compared to manual removal processes.
Shorter Removal Time:
* Reduces the time the extruder is out of production,
* Enables more efficient maintenance planning,
* Allows for faster screw cleaning and inspection processes,
* Reduces the workload of maintenance personnel.
Improved Occupational Safety
Removing screw elements using hammers, uncontrolled heating, or manual striking methods can pose risks to the operator. The automatic machine applies the removal force within a closed and controlled system.
The system is equipped with safety features such as operator protection, hydraulic pressure monitoring, and overpressure alarm. An alarm is triggered and the process is stopped if the set pressure limit is exceeded.
Protecting Screw Components
Controlled tightening, pressure, and positioning help reduce mechanical damage to screw components and screw shafts during removal.
Protecting the surfaces, connection areas, and geometries of reusable screw components is particularly important for maintenance costs.
Compatibility with Different Screw Models
The adjustable collet structure and servo-controlled movement system support the removal of screw groups of different diameters and lengths on the same equipment.
Final compatibility should be evaluated according to the following characteristics:
* Screw shaft diameter
* Total length of the screw group
* Screw component geometry
* Connection structure between shaft and element
* Spline or channel dimensions
* Arrangement of screw elements
* Clamping level
* Estimated force required for disassembly
Robust Industrial Construction
The machine is designed to withstand the demanding working conditions of extrusion maintenance areas.
Chrome-Plated Work Surface
The chrome plating used on the work table helps to increase the surface's resistance to wear and corrosion. This feature provides a more resistant work surface to moisture, water, and process residues that may be encountered in maintenance environments.
Waterproof and Explosion-Protected LED Lighting
The work area uses fully enclosed, waterproof, and explosion-proof LED lighting. This ensures adequate illumination of the disassembly area and allows the operator to monitor the process more easily.
Durable Bearing System
NSK brand bearings are used in the head and rear bearing units. This structure contributes to the stable operation of the moving mechanisms and the system's suitability for long-term industrial use.
Applications
The Automatic Screw Element Removal Machine can be used in the maintenance of process equipment using modular screw elements, primarily twin-screw extruders.
Main application areas:
* Plastic compound production
* Masterbatch production
* Filled plastic compounds
* Engineering plastics
* Polymer modification
* Powder coating production
* Cable compounds
* HFFR and halogen-free cable compounds
* Bioplastic and recycling applications
* Chemical and additive production
* Laboratory and production type twin-screw extruders
* Process machines with modular screw elements
* Extruder maintenance and service centers
The machine's compatibility with a specific screw system must be verified by examining the screw dimensions and connection geometry.
Contributions to the Maintenance Process
Regular removal of screw elements is important for cleaning, wear control, and changing the process configuration.
The automatic disassembly system facilitates the following maintenance operations:
* Separation of screw elements for cleaning
* Identification of worn elements
* Replacement of damaged elements
* Rearrangement of screw configuration
* Inspection of kneading and conveying elements
* Inspection of shaft and spline surfaces
* Creation of a new screw arrangement according to the production recipe
* Shortening of periodic maintenance intervals
Benefits for Businesses
The Automatic Screw Element Disassembly Machine offers the following operational advantages:
* Reduction of the need for manual disassembly
* Faster separation of screw elements
* Shortening of maintenance and production downtime
* Controlled application of disassembly force
* Reduction of operator-dependent process variations
* Reduction of the risk of damage to screw elements and shafts
* Ability to process different screw diameters in the same system
* Reduction of the physical workload of maintenance personnel
* Improvement of occupational safety
* Standardization of maintenance processes
* Increased possibility of reusing screw elements
* Increased extruder utilization rate
Technical Specifications
Device name | Automatic Screw Element Removal Machine
Purpose | Removal of modular screw elements
Machine dimensions | 3680 × 800 × 1500 mm
Hydraulic collet clamping force | 0-50 tons, adjustable
Hydraulic collet clamping range | Ø30-100 mm, adjustable
Maximum removal force | 0-15 tons
Suitable screw length | Over 500 mm
Hydraulic system power | 6 kW
Total installed power | 30 kW
Electrical supply | 380 V / 50 Hz
Machine weight | 3.8 tons
Position control | Servo controlled
Pressure control | Automatic matching according to program
Technical values are based on the manufacturer's standard machine information. Final dimensions and configuration must be verified according to the project and screw specifications.
Application-Specific Technical Assessment
To ensure the machine is prepared with the correct configuration, the technical specifications of the screw assembly to be disassembled must be evaluated beforehand.
It is recommended to share the following information for the technical study:
* Extruder brand and model
* Screw diameter
* Total length of the screw assembly
* Technical drawing of the screw shaft
* Spline or channel geometry
* Technical drawings of the screw elements
* Screw element arrangement
* Material of the shaft and screw elements
* Disassembly frequency
* Processed polymers and additives
* Clamping status of the elements
* Existing disassembly method
* Desired automation and safety options
* Loading and unloading equipment requirements
Polmak Plastik provides support in evaluating the technical data, checking the compatibility of the machine with the screw assembly, and determining the appropriate system configuration.
