For the extrusion production line of plastics, rubber, and chemical fibers,etc., the extruder act an improtant role, its stable running directly determines the product quality and production safety. One key parameter is the the melt pressure, once it is out of control, it can lead to product size deviation and performance degradation, or even cause major accidents such as equipment overload and melt leakage. At this time, melt pressure sensors, melt pressure transmitters, and extruder melt pressure transducers designed specifically for the scene become "precise measurement and control guards" to ensure the efficient operation of the extruder.
Why can't the extruder be separated from melt pressure monitoring?
When the extruder is working, the material is pushed by the screw rotation, heated and melted to form a high-temperature and high-pressure melt, and finally extruded through the die head. In this process, if the melt pressure is not stable will directly lead to
1-product quality issue: product thickness, bubbles, cracks and other defects
2-Equipment safety issue: Excessive pressure may cause the barrel and die head to burst, resulting in equipment damage and production interruption;
3-Realize Energy efficiency optimization: Real-time pressure data can guide the adjustment of parameters such as screw speed and temperature to reduce energy consumption and raw material waste.
Therefore, equipping the extruder with a professional extrusion melt pressure sensor is a rigid demand for modern production.
Melt pressure transducer and transmitter: measurement and control "golden partner"
The melt pressure transducer is a "sensing terminal" that directly contacts the high-temperature melt. Its core function is to convert the pressure signal of the melt into an electrical signal. Taking the flexible tube high-temperature melt pressure sensor of Shanghai Ziasiot Technology Co., Ltd. (Ziasiot) as an example, it is made of 304 stainless steel (ROHS certified), which can withstand the working environment of up to 300°C in the extruder, accurately capture the pressure changes in the range of 0-40MPa, and the accuracy is 0.5% F.S, laying the foundation for data accuracy.
The melt pressure transmitter is the "signal processing center", which amplifies and converts the weak electrical signal output by the sensor into a standard signal (such as RS485), and transmits it to the PLC or DCS system to realize real-time display and intelligent control of pressure data. For example, Ziasiot's PTES melt pressure transmitter supports 24V DC power supply, working current ≤25mA, and is compatible with the industrial control system of the extruder to ensure stable and reliable data transmission.
Practical application of a melt pressure sensor for an extruder
In the extruder production line, the melt pressure sensor for the extruder is usually installed at the end of the barrel or the inlet of the die head, directly contacting the molten material:
Real-time monitoring: Before the material enters the die head, the sensor captures the pressure change in real time to avoid the sudden pressure rise caused by raw material impurities and abnormal screw speed;
Intelligent feedback: The transmitter synchronizes the data to the control system. When the pressure exceeds the preset range, the system automatically adjusts the screw speed or heating temperature to maintain stable pressure;
Safety protection: For high-pressure scenarios, some sensors have Exibl Mb explosion-proof certification (such as the extended application of Ziasiot mining intrinsic safety related technologies), which can effectively avoid the safety risks caused by melt leakage.
