Expanded Applications of New Type Rollers at Aluminum Profile Extrusion Outlets

Abstract: This paper mainly discusses the novel application of "new PBO high-temperature roller" at the "outlet" position in the aluminum profile extrusion process, replacing the traditional graphite method, and provides multiple product options such as "fixed" and "adjustable" types, thereby optimizing the production process, improving the yield, and continuing to develop and innovate based on practical work.

Keywords: Expanding applications , broad applicability, improving quality, continuous optimization

1. Introduction

As we all know , "quality is the lifeblood of an enterprise," and only with top-notch quality can one secure a broad market. Therefore, how to improve product quality is an eternal topic for every company . In the aluminum processing industry, preventing material defects due to improper operation or use after materials enter the production line is crucial. Utilizing new technology materials and fully applying new technologies to production is a good breakthrough in this critical task .

2. Preliminary Application of the New Type of Roller

After nearly two years of vigorous promotion, our newly developed "Jiawang PBO High Temperature Roller" has been put into use on the extrusion production line equipment of many large aluminum profile manufacturers, with remarkable results.

This is a composite roller designed for industrial environmental protection, and it has obtained a national patent. Currently, it is mainly used in the transmission area of ​​extrusion equipment for support and rolling conveying. Its advantages are prominent:

2.1 The honeycomb structure helps dissipate heat, giving the metal frame of the roller superior heat resistance, with a maximum temperature resistance of up to 600℃;

2.2 It adopts a layered structure, with tight adhesion between layers, making it less prone to loosening; it has a rubber layer, is integrally molded, has good elasticity, plays a buffering role, reduces the damage rate, and further improves its wear resistance;

2.3. It is water-resistant, oil-resistant, corrosion-resistant, scratch-resistant, and cost-effective.

2.4 The length can be customized according to the customer's cooling bed dimensions, making it highly adaptable and widely applicable;

2.5 The metal skeleton, rubber layer, and felt layer are multiple layers that make it less prone to damage. Furthermore, the felt layer can be replaced if it is damaged, effectively reducing production costs.

2.6. It has a longer service life than traditional methods, eliminating the need for frequent replacements that waste time, manpower, and resources;

2.7 During the production and transportation process, it can effectively avoid scratches and improve the yield rate; it can adapt to various water-cooled and air-cooled cooling beds, ensuring the quality of aluminum materials.

3. Expanded Applications of New Type of Rollers

Given the advantages of the new roller in the conveying area, and in order to further expand its application, especially in the extrusion exit area, the R&D team collected a lot of data in the early stages. For example, they compared the performance of PBO high-temperature rollers with graphite plates and high-temperature felt gaskets. A brief list is shown in the table below:

After understanding the performance advantages of their own materials, they have more confidence in expanding their applications.

In traditional production, graphite blocks are often used to support the discharge port, which has the disadvantages of being easily scratched and having graphite powder easily sticking to the surface of the metal profile. Ordinary single-layer high-temperature rollers, due to their relatively soft materials , have support problems, and the friction between the metal profile and the felt roller surface can easily cause carbonization and caking, resulting in high production costs for overall replacement. In contrast, the Jiawang PBO high-temperature roller is made of high-quality materials and rigorous processes. Its special honeycomb structure metal frame and other composite layers work closely together, achieving a completely new upgrade in performance, greatly increasing the roller's strength, wear resistance, and heat insulation effect.

Furthermore, considering the actual production situation and the fact that many of our current partners, including several well-known aluminum companies, use "one-outlet-multiple-die" dies in their extrusion presses, the conventional discharge port support is insufficient to meet their needs. To solve this problem, our R&D team had a brilliant idea: a grid-like material distribution support. With this good idea in mind, the focus shifted to the specific work of R&D and manufacturing. Through continuous analysis and effort, this new roller development project finally yielded results, producing the "King Clamp PBO Discharge Port Roller," available in both "fixed" and "adjustable" types, which effectively meet the needs of our customers.

In addition to inheriting the advantages of the original new rollers, such discharge rollers are "temperature resistant, wear resistant, and long service life", they also have more advantages: First, the structure is simple and easy to understand, and easy to use; second, they are highly adjustable and can adapt well to various discharge needs; they have a more obvious advantage in protecting the profiles of multi-hole die extrusion presses, effectively improving the yield; they are easy to maintain, recyclable, and environmentally friendly, etc.

This product has already been launched by several companies and has become increasingly mature in production practice. It is our company's recent "star product" and we believe it will soon gain more attention and recognition from customers.

4. Future Prospects for New Type of Roller

Throughout the product expansion process, what impressed me most was the radiating effect of new products and technologies. As a fixture sector within the aluminum processing industry, although it represents only a small part overall, by observing more closely and learning more new things, we can utilize new technologies and products to advance the entire industry, and then extend this small progress to other areas. This gradual accumulation of progress will eventually lead to a significant leap forward. Take the new roller as an example; it has already achieved certain results in transmission and discharge. Looking to the future, I believe that this excellent technology, materials, and service will continue to expand into other application areas. Of course, this requires gradual exploration to find its new shining points.

5. Conclusion

In this era of innovation, where a hundred boats race against the current, only those that paddle hardest will succeed. Let us join hands, muster our energy, forge ahead, and live up to this wonderful era, making the most of our lives. Only by closely integrating our lofty goals with a realistic foundation, a scientific attitude, and a spirit of hard work can we move forward in this turbulent current and continue our journey!

Author: Gao Maojun

(Guangdong Clamp King Technology Co., LTD Sihui Yanchuang Electric Appliance Co., Ltd.)