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Real-time, predictive-maintenance system for extruders reduces unplanned downtime

DS Activ-Check
DS Activ-Check from Davis-Standard (Pawcatuck, CT) monitors key parameters including extruder reducer, lubrication system, motor characteristics, the drive power unit, and barrel heating and cooling.

Extrusion and converting technology company Davis-Standard LLC (Pawcatuck, CT) has introduced a real-time, predictive-maintenance system that reduces unplanned downtime while collecting valuable data. DS Activ-Check, which was demonstrated at the recent NPE2018, is an available option with Davis-Standard’s Integrator, Epic III and DS-eVue control systems.

Via Activ-Check, users receive notifications of machine-related issues via e-mail or text; continuous monitoring of production machine status is available on smart devices and remote PCs. Key parameters monitored include extruder reducer, lubrication system, motor characteristics, the drive power unit, and barrel heating and cooling. 

Overview screens provide a quick reference of monitor points and trend windows. Vibration sensors on the extruder reducer provide data regarding the condition of the gears, bearings and lubrication system. The extruder motor is equipped with combination temperature sensors and vibration sensors, and the reducer lubrication system, if provided, includes pressure, flow and temperature sensors to monitor system performance. Operators are also able to oversee key health indicator parameters in the drive power unit, providing an early indicator of potential power unit issues. 

“The Activ-Check system provides much-needed data for processors to improve performance, including being able to plan production around scheduled maintenance activities,” said John Clemens, Director of Extrusion Controls at Davis-Standard. “Having the capability to monitor extrusion line variables such as mechanical and electrical system conditions is essential in order to bring products to market faster and minimize unplanned downtime. This technology will also allow customers to address a pending condition that could become a more serious issue in the future. All of this is valuable and much-needed knowledge to strengthen existing extrusion and converting processes,” said Clemens.

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