HC2200 Extruder

The extruder base consists of fabricated and precision machined steel structures with mountings for the machine head, main drive, cartridge change table and supporting systems.

The machine head frame consists of a bolted and dowelled substantial steel structure secured to the base assembly.  The head is through-bored to accept the main shaft assembly.  This critical component has been extensively stress tested using industry leading FEA to ensure maximum longevity and trouble-free service.

The extrusion wheel is supported by a flange on either side and held in place by the front and rear bearing hubs. These components are clamped together by means of a large central tie-bolt screwed into the front bearing hub and pre-stressed by a hydraulically loaded nut. This feature gives essential compressive support to the extrusion wheel together with providing a means for dismantling of the main shaft assembly for rapid extrusion wheel replacement. Drive to the extrusion wheel is transmitted through the rear hub and flange using a combination of friction and dowels.

The main shaft bearings are high capacity spherical roller bearings mounted on the front and rear bearing hubs. The bearings and shaft assembly are mounted directly into the main head side plates and retained with sealed housings. The bearings are supplied with continuously filtered and temperature controlled lubrication oil.

The Main Drive consists of a variable speed DC electric motor coupled to a multi-stage bevel-helical reduction gearbox with a right-angle output shaft. This configuration results in the motor and gearbox being parallel to the extrusion line, thus saving space. Input and output shaft connections to the main drive gearbox are by grease-filled double engagement gear couplings.

The central cartridge assembly contains the groove sealing segments and the extrusion die. It consists of a faceted steel block with cut-outs to suit the various die combination pieces. The cartridge, with its tooling in place can be quickly removed from the machine for die maintenance.

The cartridge holder assembly & shear provides support for the cartridge and contains temperature control systems to improved process consistency whilst managing the excess heat generated by the process. A hydraulically controlled shear blade cuts the extruded product once the production run has been completed.

The cartridge within its holder is clamped from behind, below and above. The clamping pressures are dynamically adjusted to precisely balance the opposing process forces and keep the cartridge in the optimum working position. The upper and lower clamps are integrated into the head-frame and the rear clamp is held in position by two hydraulically actuated latch pins. In order to change the cartridge the latch pins are retracted and the rear clamp and cartridge holder are driven back. The cartridge may then be pulled out of the holder and onto an adjacent table ready for maintenance or exchange.

The hydraulic system consists of two hydraulic power packs. One provides medium and high pressure supply to the precision critical components while the other one supplies low and medium pressure to the rest of the extruder for general operation.

The feedstock is guided under a hydraulically adjustable, compacting roller which compresses the rod into the wheel groove. The compressed rod is then carried round by the wheel to the extrusion zone. The coining wheel is carried in substantial roller bearings, mounted in a hydraulically adjustable frame, enabling the penetration of the wheel in the groove to be adjusted. The hydraulic power is provided by connecting to the machine hydraulic system. The compacting wheel of the coining roll assembly is a separate piece which can be replaced in the event of damage, wear, or change of groove size.

The Wheel Scraper and Inlet Rod Shear are situated on the inlet side of the wheel. The scraper removes any leakage material from the wheel in order to keep it clean and to avoid the build-up of material on the outside of the cartridge. A shear is provided to cut the feedstock and stop the process to enable die or coil changes.

A cooling water system is provided to cool the main shaft hubs, cartridge holder and coining roll shaft . Additional supply and drain points are provided for standard accessories. The cooling water is recirculated via a pump and water-to-water heat exchanger.

In addition, a gas tube and cooling trough are situated directly after the extruder to provide immediate cooling and conditioning of the product. The temperature controlled and filtered water is held in a reservoir and uses adjustable flood and spray nozzles to supply directly to the product. This is followed by an air drying unit.

Our range of coilers and take up units are used to wind extruded products onto drums. For single product take up, the TU26 Traversing Take Up Unit is an ideal solution, with the unit traversing to allow neat layers of wound product.

The frame allows for varying drum sizes and the drive is carefully controlled to ensure coil quality is maintained.

Holton Crest has designed and manufactured an automatic changeover twin coiler that is designed to continuously wind wire produced on a Holton Crest machine into open coils without any interruption in production speed.

The unit consists of two horizontally mounted expanding mandrels. When the required coil size has been wound, the wire is sheared from that coil and automatically hooked onto the other mandrel to start producing the next coil.

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Holton Crest machines can accept a wide range of different feedstocks, from cast bar to rod and granular particle feed. We provide a range of different payoff methods to ensure a smooth, fast payoff whilst supporting your individual requirements, including:

Rotary Payoff - Includes a payoff turntable for accommodating continuously cast copper or aluminium rod feedstock.

Automatic Vertical Payoff - Allows for single or dual input configurations, with twin coils being automatically unwound vertically and straightened before entering the extruder, enabling precise control over feedstock preparation.

Particle Feed - Includes a particle hopper mounted on top of the extruder to allow for continuous feed of granular feedstock and controlled production.

Product cooling is a key part of the continuous rotary extrusion process, minimising oxidisation and ensuring the high quality of the extruded product. The Holton Crest cooling unit consists of a free standing tank and cooling trough.