Aluminium Composite Pipe Extrusion

Templet Deutschland
Battenfeld Extrusionstechnik

November 9th, 2005

 Aluminium composite pipe extrusion

Overview

Ø Pipe characteristics
Ø Extrusion line
Ø Demonstration data
Ø Summary

R.Mickley 1 November 2005

 Aluminium composite pipe extrusion

Pipe structure

Pipe dimension 16 x 2,1

Nominal dimensions [mm] Total pipe

Outside diameter 16,0
Wallthickness 2,1
Layer construction
Inliner PE-Xb 1,00
Inner adhesive 0,10
Aluminium 0,30
Outer adhesive 0,10
Outer layer PE-Xb 0,60

R.Mickley 2 November 2005

 Aluminium composite pipe extrusion

Pipe Features

• Quick installation
• Resistant to corrosion
• Shapeable and form stable
• Perfect gas-tightness
• No electrical conductivity

R.Mickley 3 November 2005

 Aluminium composite pipe extrusion

Application fields

• Operating range
- Pressure up to 10 bar
- Temperature up to 95°C
• Sanitary hot and cold water
• Pipes for radiator heating
• Pipes for compressed air
• Technical pipes for machine
engineering and automotive
industry
• Distribution of gas in
construction

R.Mickley 4 November 2005

 Aluminium composite pipe extrusion

Ø Pipe characteristics
Ø Extrusion line
• General line lay-out
• Production of inner layer
• Adhesive co-extrusion
• Aluminium treatment
• Aluminium forming and welding
• Adhesive and outer layer coating
• Control system
Ø Demonstration data
Ø Summary

R.Mickley 5 November 2005

 Aluminium composite pipe extrusion

General line lay-out

U-shape installation

S-shape installation

R.Mickley 6 November 2005

 Aluminium composite pipe extrusion

Production of inner layer

R.Mickley 7 November 2005

 Aluminium composite pipe extrusion

Single screw extruder and dosing station

• BEX 1-60-30B
- Grooved feeding section
- Barrier screw design
- Direct drive
- Motor capacity: 124 kW
- Throughput max. 150–180 kg/h

• DOS-3
- 3-Component dosing
- One main- and two side components
- Continuous weighing system

R.Mickley 8 November 2005

 Aluminium composite pipe extrusion

Battenfeld single screw extruders for PE-Xb

Screw Motor Screw Guarantee

diameter capacity speed throughput PE-Xb
[mm] [kW] [1/min] [kg/h]
45 75 350 90 - 110
60 124 250 150 - 180
75 170 190 200 - 250

• Optional shear elements • Optimized barrier zone

R.Mickley 9 November 2005

 Aluminium composite pipe extrusion

Die head

• PE-X 50/200
- Spider design
- Pipe o.d. 10-50 mm

R.Mickley 10 November 2005

 Aluminium composite pipe extrusion

Vacuum tank and calibration sleeve

• V2-63 VA
- Twin chamber design
- Total length 9130 mm

• Disc calibration
- Discs made from stainless
steel

R.Mickley 11 November 2005

 Aluminium composite pipe extrusion

Production of inner layer

• Ultrasonic measuring chamber

- USM 63/C-8

• Cooling length
- CB 63 VA
- Length 5900 mm

• Pipe drying unit

- KTR 60
• Diameter measuring system 1
• Belt haul-off 1
- P 100 BV E
- Electrical adjustment of upper
belt

R.Mickley 12 November 2005

 Aluminium composite pipe extrusion

Adhesive co-extrusion

• Co-extruder E 25.0 x 25D

- Screw diameter 25 mm
- Continuous weighing system

• Die head E 45-BN 10

- Single layer coating
- Vacuum system

• Diameter measuring system 2

R.Mickley 13 November 2005

 Aluminium composite pipe extrusion

Ø Pipe characteristics
Ø Extrusion line
• General line lay-out
• Production of inner layer
• Adhesive co-extrusion
• Aluminium treatment
• Aluminium forming and welding
• Adhesive and outer layer coating
• Control system
Ø Demonstration data
Ø Summary

R.Mickley 14 November 2005

 Aluminium composite pipe extrusion

Aluminium treatment

R.Mickley 15 November 2005

 Aluminium composite pipe extrusion

Aluminium treatment

• Aluminium tape uncoiler

- Dual system
- Two AC motor drives
- Left- / right direction run
- Rotary angle 180°
- Strip sensor and break system

R.Mickley 16 November 2005

 Aluminium composite pipe extrusion

Aluminium treatment

• Cross welding machine

- 75° cut
- TIG - welding
- Automatic height adjustment
for electrode
- Clamping unit

R.Mickley 17 November 2005

 Aluminium composite pipe extrusion

Aluminium treatment

• Accumulator for AL - tape

- Looping tower principle
- Upper cross beam movable
- Capacity 120m
- Break and dancer at inlet side

R.Mickley 18 November 2005

 Aluminium composite pipe extrusion

Aluminium treatment

• Strip brushing station • S - drive

- 4 Brushes - AC motor 3 kW
- Dust exhausting - Dancer

R.Mickley 19 November 2005

 Aluminium composite pipe extrusion

Ø Pipe characteristics
Ø Extrusion line
• General line lay-out
• Production of inner layer
• Adhesive co-extrusion
• Aluminium treatment
• Aluminium forming and welding
• Adhesive and outer layer coating
• Control system
Ø Demonstration data
Ø Summary

R.Mickley 20 November 2005

 Aluminium composite pipe extrusion

Aluminium forming and welding

R.Mickley 21 November 2005

 Aluminium composite pipe extrusion

Aluminium forming and welding

• Strip levelling station

- Reduction of tension
- Central adjustment of upper
part with display

R.Mickley 22 November 2005

 Aluminium composite pipe extrusion

Aluminium forming and welding

• Edge trim • Scrap winder

- Adjustable knife heads - Laying device
- Digital display of width - Collapsible core
- Range 35 – 125 mm

R.Mickley 23 November 2005

 Aluminium composite pipe extrusion

Aluminium forming and welding

• Forming station
- Fast change
- Compact design

R.Mickley 24 November 2005

 Aluminium composite pipe extrusion

Aluminium forming and welding

• TIG - Welding station

- AC / DC welding system
- 320 Amp at 100%
- Electronic control via monitor
- Camera to control the arc

R.Mickley 25 November 2005

 Aluminium composite pipe extrusion

Aluminium forming and welding

• Belt haul-off 2

• Weld seam control system

“EDDYCHECK”

R.Mickley 26 November 2005

 Aluminium composite pipe extrusion

Aluminium forming and welding

• Aluminum calibrating station

- Hydraulic adjustment
- Central and independent
adjustment
- Fast change

R.Mickley 27 November 2005

 Aluminium composite pipe extrusion

Aluminium forming and welding

• Heating station • Diameter measuring system 3

- Medium frequency
generator
- Medium frequency 10 kHz
- Medium power 60 kW

R.Mickley 28 November 2005

 Aluminium composite pipe extrusion

Ø Pipe characteristics
Ø Extrusion line
• General line lay-out
• Production of inner layer
• Adhesive co-extrusion
• Aluminium treatment
• Aluminium forming and welding
• Adhesive and outer layer coating
• Control system
Ø Demonstration data
Ø Summary

R.Mickley 29 November 2005

 Aluminium composite pipe extrusion

Adhesive and outer layer coating

R.Mickley 30 November 2005

 Aluminium composite pipe extrusion

Adhesive and outer layer coating

•Co-extruder E 25.0 x 25D

- Screw diameter 25 mm
- Continuous weighing system
•BEX 1-45-30B
- Grooved feeding section
- Barrier screw design
- Direct drive
- Motor capacity 61 kW
- Throughput max. 90 – 110 kg/h
• DOS-3
- 3-Component dosing
- Continuous weighing system

•Die head E 40-HN 20

- Two layer coating

R.Mickley 31 November 2005

 Aluminium composite pipe extrusion

Adhesive and outer layer coating

• Cooling section K63-VA - 9m

• Pipe drying unit
• Diameter measuring system 4
• Belt haul-off 3
• Pipe cutter

R.Mickley 32 November 2005

 Aluminium composite pipe extrusion

Adhesive and outer layer coating

•Automatic coiler
- Speed up to 40 m/min

R.Mickley 33 November 2005

 Aluminium composite pipe extrusion

Ø Pipe characteristics
Ø Extrusion line
• General line lay-out
• Production of inner layer
• Adhesive co-extrusion
• Aluminium treatment
• Aluminium forming and welding
• Adhesive and outer layer coating
• Control system
Ø Demonstration data
Ø Summary

R.Mickley 34 November 2005

 Aluminium composite pipe extrusion

Control components

Terminal 1

Terminal 2

R.Mickley 35 November 2005

 Aluminium composite pipe extrusion

Multi-terminal operating concepts

• Software with client-server

technology for more than one
independent operating device

• All terminals can have ...

- Different screen pages
displayed at the same time
- Individual privileges for
access and actions
- Specific purposes (operation,
service, data collection ...)

• Application examples:
- Additional operator panels in
a long or complex line
- Visualisation of several linked
BMCtouch extruders on one
central service computer

R.Mickley 36 November 2005

 Aluminium composite pipe extrusion

Ø Pipe characteristics
Ø Extrusion line
Ø Demonstration data
Ø Summary

R.Mickley 37 November 2005

 Aluminium composite pipe extrusion

Line set - up

Total line length app. 83 m

Dimension range 14- 40 mm
Total line capacity up to 40 m/min

R.Mickley 38 November 2005

 Aluminium composite pipe extrusion

Demonstration data

• Material type PE-Xb

• Inner layer
Material grade Silon, Taborex TA 1134 HD
Catalyst Silon, Taborex TA 2120 HD, natural
Process aid Silon, Taboradd 23-08350
• Adhesive DSM, Yparex OH 50
• Aluminium EN 3003
• Adhesive DSM, Yparex OH 50
• Outer layer
Material grade Silon, Taborex TA 1134 HD
Catalyst Silon, Taborex TA 2330 HD, white
Process aid Silon, Taboradd 23-08350

R.Mickley 39 November 2005

 Aluminium composite pipe extrusion

Demonstration data

Layer Thickness Throughput

[mm] [kg/h]
Inliner PE-Xb 1,00 72,0
Inner adhesive 0,10 7,3
Aluminium 0,30
Outer adhesive 0,10 7,3
Outer layer PE-Xb 0,60 45,0
Total 2,10 132

Line speed 30 m/min

R.Mickley 40 November 2005

 Aluminium composite pipe extrusion

Ø Pipe characteristics
Ø Extrusion line
Ø Demonstration data
Ø Summary

R.Mickley 41 November 2005

 Aluminium composite pipe extrusion

Advantages

• High performance line speed

• Safe and reliable production
• Easy operation
• Optimized dimensional change by modular design
• Future oriented control systems
• High product quality proven and documented by state of the
art measuring equipment

R.Mickley 42 November 2005

 Aluminium composite pipe extrusion

Competence in Aluminium Composite Pipe Extrusion

R.Mickley 43 November 2005