Archives: Produkte

Produkte listing

Taper Quench

PRODUCT:
Taper Quench

The extrutec taper quench will give sophisticated extrusion plants two key benefits.  Using a billet with a temperature taper will allow for an isothermal extrusion process.  At the same time, creating the temperature taper by quenching the billet, creates a unique microstructure.

extrutec Taper Quench

Special Features:
  • the billet to be tapered is heated to the required temperature by the gas- /induction furnace
  • an integrated temperature measuring device measures the actual billet temperature
  • the quench consists of a stainless-steel housing with 5 quench zones
  • each zone consists of 3 ring-segments, equipped with nozzles providing a full cone spray pattern
  • each zone is supplied with water via an individual proportional valve and is equipped with a flow meter and temperature probe
  • a fan feeds the water vapor to a condenser and the Condensate is fed back into the tank
  • once the desired temperature gradient is achieved, the billet is transferred to the press
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EHKO (Patented Inline-Version)

PRODUKT:
Electrically Heated High Convection Oven (EHKO)

In response to the changing market situation due to energy shortages and the need to substitute fossil energies, extrutec has developed a high convection furnace equipped with electric resistance heating elements. The idea of operating the oven exclusively with electricity opens up the possibility of completely avoiding CO2 emissions, provided that the oven is operated with “Green” electricity.

For heating of aluminum logs (Patented Inline-Version)

High convection means heat transfer by means of heated air, which is directed at very high speed through specially designed slot nozzles onto the aluminum logs to be heated. Resistance-heated heating registers in conjunction with powerful and frequency-controlled hot gas circulation fans serve as the heat source here. In order to react quickly to changing production requirements and to ensure a precise and reproducible temperature taper, extrutec recommends adding an induction furnace module downstream of the high convection furnace in a patented "inline design" or as a "stand-alone variant". This combines the advantages of a high convection oven, which has a significantly higher thermal efficiency than a gas-fired oven (87 percent compared to a gas-fired furnace) with a powerful multi-zone induction oven module.

This induction furnace module is responsible for final and precise temperature control, and when the EHKO and inline induction furnace are installed together, an overall efficiency of 82 percent is achieved. Furthermore, with this concept, the output can be perfectly adjusted to the required throughput without reducing the efficiency. Another positive side effect is the space-saving installation and the considerable reduction of the investment compared to a classic induction furnace in "stand-alone variant" (In-line arrangement of both heaters, no lateral manipulator required). With this heating variant the log is also transported by means of the proven driven roller system (Maintenance-free), which allows the oven to be emptied quickly and easily to the rear or to the front if required.The EHKO concept is also highly eligible for funding with various government funding programs.

Technical highlights of this heating concept:

  • Particularly uniform and gentle heating process thanks to high air speeds (use of hot-gas high-convection fans)
  • Proven transport system with driven, maintenance-free and non-wearing rollers
  • The possibility of zone synchronization capability for homogeneous power distribution
  • Very accurate power control with real temperature measurement (With pneumatical operated measuring needles) avoiding dead zones, which occur for example in magnetic induction furnaces
  • The heater chamber are prepared for easy inspection of the furnace interior by means of inspection probes
  • Combination with hot water operated log preheating possible (extrutec worldwide patented ESU concept). => Thus a world-wide unmatched low energy consumption (< 100kWh/tAl) is reached
  • Easy and maintenance-friendly change of the heating registers by means of a changing device
  • Integrated control cabinet platform with access and integrated cable routing => reduced installation costs due to maximum optimized cable length
  • Optimized TMV cycles to avoid entry of cold external air into the heating chamber
Label PFT

Integrated Power Focus TechnologyTM for peak load reduction (25%) and energy/gradient control. This extrutec technology reduces the peak load from the EHKO as well as from the induction module.

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Profile Cooling

PRODUCT:
Profile Cooling

„Worlds most advanced profile cooling“

We are well familiar with material strength, ductility, and dimensional stability. Our sophisticated profile cooling systems provide the right answers.

Profile Cooling

Special features:
  • In parallel to the profile course, water quench nozzle holders arranged on all sides and swivelled by motor
  • Multi-zone division with proportional pressure control
  • Optional visualisation of the profile geometry (real data)
  • Use of “inoculated” air with high impact velocity

Constant material optimisation of profiles leads to ever higher demands on plant technology, in particular concerning the flexibility of cooling. This is a challenge that we rise to every day.

NEW TECHNOLOGY:
Alpha Flex Technology

The Alpha Flex Technology is a technical extension of the existing profile cooling system from extrutec. In the future, the axially rotatable nozzle will consist of a two-chamber AL extruded profile.

In the large chamber 1, solid jet nozzles are still used, with which a very high α-value of at least 7,000 W/m2K is achieved for the most intensive water cooling (typical nozzle size V=6/l/min at 7 bar).

Label AFT

 

In the future, extrutec will close the previously very large "α-gap" between air and water cooling with soft cooling using the patented Alpha Flex Technology with α-values of 500 W/m2K to 1,000 W/m2K (typical nozzle size V=1.3/l/min at 7 bar). Here, water nozzles with very low flow rates are used in the small chamber of the double profile to produce a fine spray cone. These are brought into position by simply rotating the 2-chamber profile axially by 180°, and can of course also be swiveled (+/- 20°) to adapt to asymmetrical profile geometries. Depending on the application, the cooling intensity of Alpha Flex Technology can be adjusted to values less than 500 W/m2K or greater than 1,000 W/m2K by selecting a different nozzle size.

The following heat transfer coefficients are achieved for the individual variants:

  • Water quench (full jet nozzles) α at least 7,000 W/m2K (39,750 BTU/h ft2 F)
  • Soft cooling water mist Alpha Flex Technology (new patent) α 300 W/m2K to 1,500 W/m2K (1,700 and 8,500 BTU/h ft2 F), depending on nozzle size
  • Intensive air cooling (at vair = 50 m/s) α up to 200 W/m2K (1,140 BTU/h ft2 F)
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Die Heaters

PRODUCT:
Die Heaters

Simple chest heaters and fully automatic overhead heaters are equally part of our product range. The latter are provided with nitrogen atmosphere on request. We are the only manufacturer to supply heaters with gas-tight inner housings.

Die Heaters

Special features:
  • Heaters with gas-tight inner housings are more expensive in production, but significantly reduce nitrogen consumption
  • All extrutec die heaters work by way of convection, i.e. by means of air circulation
  • This heating principle is more expensive to purchase, but ensures very even and gentle heating, which is a great advantage in particular for sensitive dies
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Ageing Ovens

PRODUCT:
Ageing Ovens

Different oven concepts are used depending on the space required and transport logistics. In addition to simple floor-mounted ovens with longitudinal transport by roller conveyors, overhead ovens loaded either by way of scissor lifts or vertically suspended hydraulic cylinders are also used. Third version available are ageing ovens with side- opening doors served by an automatic shuttle. These systems are characterized by a particularly low overall height and are thus also well suited for retrofitting in older buildings. Regardless of the transport concept, extrutec heaters are cross-ventilated by default. These ovens operate on the principle of double air flow. This means that the two rows of baskets placed next to each other are each flown through separately. In addition to the ageing ovens, our portfolio also offers annealing ovens.

extrutec Ageing Oven System in  floor mounted configuration with laterally opening heater doors and shuttle system

Characteristics and functional description:

The batches to be aged are removed from the storage and are assembled manually by means of a building crane (alternatively fully automatically via a higher-level control system and automatic crane) on so-called storage benches. From there on they are then picked up by a floor-guided shuttle system and transported in front of the selected ageing oven. The shuttle positions itself in front of the selected storage station and is firmly locked there. The assembled stacks of baskets (2x4 baskets are to be aimed for) are then picked up and positioned on the shuttle carriage by means of an electro-hydraulic driven lifting device that is integrated in the shuttle. The shuttle then travels with the batch parallel to the ageing oven system until it is positioned in front of the selected aging oven. From there, the basket stacks are loaded into the respective oven chamber and the ageing cycle starts after the shuttle is out of the door range and the oven door is closed The shuttle then continues to the next selected target position. After completion of the ageing cycle, unloading takes place in reverse order. The batches are again picked up fully automatically and temporarily stored on another free storage bench for cooling and ongoing transport.

 

extrutec Ageing Oven System in  overhead configuration with hydraulically operated scissors lifting table

Characteristics and functional description:

The batches to be aged are removed from the storage and are assembled manually by means of a building crane (alternatively fully automatically via a higher-level control system and automatic crane) on so-called storage benches. From there on they are then picked up by a floor-guided shuttle system and transported in front of the selected ageing oven. One individual hydraulic scissors lifting table with fix mounted oven door on top is installed under each ageing oven chamber. Die vorbereiteten, auszulagernden Chargen werden dann (Mittels einer elektromotorisch verfahrbaren und hydraulisch Heb-/ und senkbaren Hubeinrichtung, welche in das Shuttle integriert ist) auf den abgesenkten Scherenhubtisch mit Ofenboden platziert. The prepared batches to be aged are then placed on the lowered scissors lift table by means of an electro-hydraulic lifting and transport device that is integrated in the shuttle. After the loading process is completed, the oven doors are closing automatically and the selected heat-treatment program is started. After completion of the ageing cycle, unloading takes place in reverse order. The batches are again picked up fully automatically and temporarily stored on another free storage bench for cooling.

 

extrutec Ageing Oven System in  floor mounted configuration with basket conveying systems and shuttle system

Characteristics and functional description:

The batches to be aged are removed from the storage and are assembled by the operating personnel directly on the roller tables in front of the furnace system by means of an overhead crane. The ageing process can then be started manually and runs according to a predefined routine. The assembled batches then move in automatic mode by means of floor conveyor technology (chain or roller design) into the preheated furnace chamber and the heat treatment process starts after closing the furnace door. After completion of the ageing process, the batches are moved out in reverse order onto the floor conveyors behind the ageing oven system.

 

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Log Preheating (ESU)

PRODUCT:
Log Preheating

We have been committed to a resource-preserving approach to fossil fuels, and therefore to the continuous effort to lower CO2 emissions as far as possible, from the very beginning. This guiding principle constantly drives us to develop new ideas and solutions. The most recent development is the Eco Shower Unit (ESU), for which a patent is pending.

Log Preheating

Special features:
  • The Eco Shower Unit (ESU) uses the residual heat from the gas heater exhaust to heat up water to 90 °C (195 °F)  in an air-water heat exchanger
  • In a unit upstream of the gas heater, the aluminium billets are preheated to temperatures of up to 90 °C (195 °F) by laminar wetting of the entire surface with hot water
  • The log preheating length is typically three times the log length
  • A high-pressure log cleaning system can be integrated as an option
  • Energy savings of approx. 15 – 17% are achieved, depending on the temperature profile

In addition, we have fundamentally redesigned the heat exchanger (previously a purchased part) and now manufacture it ourselves. The efficiency of the system was further significantly increased by the in-house development of the heat exchanger.

This is another innovation for the benefit of our customers and the protection of our environment.

Winner of the Metef Innovation Award 2022

During Metef 2022 in Bologna, extrutec's Eco Shower Unit (ESU) was awarded the Metef Innovation Award in the Technology and Processes category. The Innovation Award recognizes companies that have developed outstandingly innovative new technologies. The jury's particular focus was on the topic of sustainability and energy saving.

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Hybrid Systems

PRODUCT:
Hybrid Systems

The process-related requirements to temperature control when heating metals for forming processes have increased steadily in the last few years. An ever-increasing range of input materials and batch sizes ultimately leads to a need for considerably greater flexibility in heating concepts. The combination of gas and induction-heated heater systems performs this task with great efficiency.

Inline Oven (worldwide patented)

extrutec has marketed the Inline furnace (In-line furnace), patented around the world, for many years. It combines a gas and induction heater arranged in line with each other. This combination has various advantages as compared to stand-alone solutions.

Special features:
  • Significantly higher efficiency due to omission of the field extender
  • Lower space requirement due to installation of the gas and induction modules in series instead of side by side as in the classic arrangement
  • Significantly better efficiency due to the elimination of the field extender of the inuction oven (induction billet heater)
  • Additional savings due to the elimination of one coilsegment and the associated reduced converter and recooling power as well as the elimination of an additional loading unit for the induction furnaceGeringer Platzbedarf

Gas Oven with Standalone Indoction Heater

Special features:
  • Entirely self-sufficient heater concepts
  • Redundancy
  • Rapid alloy changes
  • Heating of special alloys exclusively in the induction heater
  • Reliable process control in required metallurgical processes, e.g. when the heating temperature is very close to the liquidus point

Both concepts have features that have been essential in the purchasing decisions of many of our premium customers in the last few years. Cost-effective basic heating with of gas and subsequent application of a precise taper or exact temperature adjustment by induction is the best heating concept currently available for most applications. These properties in the heating concept are particularly important in areas such as automotive engineering, where demands on the end product are high. This hybrid heating concept is established as the technological standard in the aluminium industry.

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Log Cleaning Systems

PRODUCT:
Log Cleaning Systems

extrutec high-pressure cleaning systems effectively clean the billets/logs of any kind of contamination with hot water and a pressure of 210 bar (3000 psi). This is an advantage that is clearly evident in the service lives of extrusion dies and the profile-surface quality.

Log Cleaning Systems

Special features:

High-pressure cleaning does not change the cast rough surface, in contrast to cleaning with brushes. This significantly increases gas heater efficiency. The high-pressure cleaning system is equipped with an automatic filter integrated into the closed water circuit by default.

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Material Handling Systems

PRODUCT:
Material Handling System

extrutec material handling systems are characterised by high reliability, ease of maintenance, and long service lives.

Overhead Manipulator

Special features:

The extrutec overhead manipulator stands out with its sophisticated design. Precise linear guides in either movement direction, frequency-controlled drives, and a pneumatic self-locking clamp are some of its special features.

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Hot and Cold Sawing

PRODUCT:
Hot and Cold Sawing

extrutec hot or cold log saws are a top product from extrutec with many unique selling points.

Hot and Cold Sawing

Special features:

extrutec saws are equipped with the world’s thinnest saw blades. This advantage is reflected in 5-digit savings on scrap every year. Since they have no hydraulic system, extrutec saws are extremely easy to service. In combination with the in-line heater, the rejector is equipped with an integrated log core temperature measurement. In addition, the aluminium column remains clamped by the ejector mechanism throughout transport. This causes the column to “float” through the induction heater, which has a very positive effect on maintenance.

In addition to hot and cold saws, hot shears continue to be part of the extrutec product portfolio.

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