An extrusion control system for wire and cable applications enables precise adjustment of grams/meter yield, improves product integrity and reduces operating costs, announced Maguire Europe. A subsidiary of Maguire Products Inc., a global supplier of plastics processing auxiliary equipment headquartered in Aston, PA, Maguire Europe will showcase the system at the Wire 2020 trade show in Düsseldorf, Germany, later this year.
The Maguire + Syncro extrusion control system can be deployed in extrusion or co-extrusion operations and in new or retrofit installations. Using data from a digital post-extrusion encoder and tachometer, the system adjusts extruder screw RPM and capstan speed to ensure tight coating tolerances and end-product consistency. In co-extrusion, ratio control provides accurate dimensions for multiple sheathing layers or identifying stripes.
|The schematic shows control components for a wire and cable extrusion line courtesy Maguire Products Inc.|
The Maguire + Syncro system comprises three basic components:
- The Maguire WXB Weigh Extrusion Blender, which incorporates a gain-in-weight (GIW) weigh bin and loss-in-weight (LIW) mix chamber;
- the Maguire 4088 controller, which controls the loading, blending and metering of raw materials to the extrusion process; and
- the Syncro controller, which uses consumption data from the 4088 controller and downstream encoders to adjust line speed and haul-off.
Modes of extrusion control available with the Maguire + Syncro system include grams per meter (or ounces per foot) of extruded product and kilograms (or pounds) per hour.
“Given the high speeds in wire and cable extrusion, any coating errors can quickly escalate into severe rejection rates, extensive downtime and costly waste of polymer compound and conductor or optical fiber,” said Paul Edmondson, Managing Director of Maguire Europe. “The Maguire + Syncro extrusion control system enables the manufacturer to maximize throughput while maintaining tight tolerances, drawing on Maguire’s expertise in control of material handling with Syncro’s expertise in controlling extrusion lines.”
|The design of the Maguire + Syncro system draws on Maguire’s expertise in control of material handling with Syncro’s expertise in controlling extrusion lines. Image courtesy Maguire Products Inc.|
The Maguire + Syncro system is the product of a partnership between Maguire and Italy-based Syncro srl that began in 2016 when Maguire took an investment position with Syncro, which specializes in controls for all types of extrusion processes. The Syncro components in the extrusion control system for wire and cable include a master PLC touchscreen controller, digital encoder and tachometer, and a co-extrusion interface—one per layer—that provides polymer consumption data from each additional extruder via the Maguire WXB blender.
Because color is a key factor in wire and cable for branding and coding, Maguire also supplies the MGF gravimetric feeder, which precisely measures the amount of additive that is fed directly into the extruder throat. “Over-coloring to compensate for possible inaccuracies in color addition is a problem because it wastes a costly additive and can compromise electrical and mechanical performance,” said Edmondson. “The MGF feeder prevents this by automatically recalibrating its dosage rate and holding the let-down ratio to within +/- 0.2%.”