Rubber/Silicone Extrusion Production Line: How to optimize to improve efficiency?

What efficiency bottlenecks exist in traditional extrusion production lines?

The efficiency bottlenecks in rubber/silica extrusion production line are mainly concentrated in three aspects. First, the parameter control accuracy is insufficient. The traditional control system has slow response to temperature, pressure, and extrusion speed, which can easily lead to product size fluctuations, and requires frequent shutdown and adjustment, reducing production efficiency. Second, the scrap rate is relatively high. Due to problems such as uneven plasticization of raw materials and unstable mold pressure, defects such as product surface roughness and excessive cross-sectional dimensions often occur, which increases raw material loss. Third, the degree of automation is low, data collection relies on manual recording, and it is impossible to monitor production status in real time. Untimely abnormal situations are discovered, which can easily cause batch quality problems, and the accuracy of manual adjustment parameters is difficult to ensure.

Which technology upgrades can break through the efficiency bottleneck?

The use of intelligent control and system optimization technology can effectively improve the efficiency of the extrusion production line. The core upgrade is to build a multi-parameter collaborative control system, which can quickly respond to parameter fluctuations in production through high-performance PLC (CPU processing speed ≥20MHz) and high-precision sensor network (accuracy ≤0.1%). In response to the temperature hysteresis problem, a feedforward + feedback composite control strategy can be adopted to predict temperature changes in advance and adjust to ensure uniform plasticization of raw materials. In addition, the introduction of real-time data analysis and automatic tuning systems can continuously optimize parameters through self-learning algorithms, reduce manual intervention, and set up an abnormal warning mechanism to promptly detect and deal with equipment failures or parameter deviations.

How to maintain optimized efficiency in daily operation?

The optimized production line needs to be maintained efficiently through scientific operation and maintenance. The first is regular equipment calibration, and the key components such as sensors, pressure gauges, temperature controllers are calibrated every month to ensure the accuracy of detection data. This is the basis for parameter control accuracy. The second is the control of raw material pretreatment. The raw materials need to be dried and screened to remove moisture and impurities, and avoid extrusion instability caused by raw material problems. In addition, it is necessary to establish an equipment maintenance ledger, regularly clean screws, molds and other components, check the lubricating status of the transmission system, and prevent performance degradation caused by equipment wear. At the same time, operators need to be familiar with the operating logic of the intelligent system, be able to accurately interpret data feedback, and cooperate with the system to conduct precise regulation.