ALWAYS IN THE FOREFRONT IN EXTRUSION SYSTEM

SINCE 1952

Aluminium Middle East 2013 Innovation Podium

HIGH RELIABILITY AND EFFICIENCY ALUMINIUM EXTRUSION PLANTS

Author : Giulia Bertoli – Sales Manager OMAV S.p.A.

Italy

•Facility 20.000 sqm

•Employees 180 people

•Turnover 2011 45 mln euro

•Products press feeding line handling systems aging oven die cleaning equipments aluminium foudries heat treatment furnaces

OMAV - 2013

OMAV - 2013

THE GROUP

PRE-ASSEMBLY AS A QUALITY TEST

QUALITY ASSURANCE

THE ELECTRICAL & SOFTWAREDEPARTMENT

This section of our company is dedicated to planning and designing the electrical project, prepare and complete all the wiring on board of the machines.We make safety and reliability our prime objectives and use the latest technology to ensure that our machines meet all electrical safety standards and customer’s requirements.

OMAV has focused on the standardization of middle size extrusion lines for logs of diameters 7” (177,8 mm) – 8” (203,4 mm) – 9” (228,6 mm) in order to be more competitive and to be able to reach a 99% AVAILABILITY for the press feeding line and 99% for the handling system line.

EAP - EQUIPMENT AVAILABILIY PERCENTAGE

(Available time – Downtime time) x 100% Available time

HIGH AVAILABILITY AND HIGH EFFICIENCY EXTRUSION LINE

7” EXTRUSION LINE – STD CONCEPT

LOG STORAGE TABLE

LOG PUSHER

LOG FURNACE

HOT LOG SHEAR

AIR COOLING SYSTEM

HAND OFF PULLERWITH SAW ON BOARDSTRETCHER HEADSTOCKSTRETCHER TAILSTOCK

PROFILE STACKER

COLD SAW

AGING OVEN

SECTION OF THE PLANT

7” EXTRUSION PLANT – STD CONCEPT

MAIN TECHNICAL FEATURES

PRODUCTIVITY OF THE LINE 1.000 kg/h

LOG DIAMETER 7”

LOG FURNACE PRODUCTION 2.450 kg/h – 36 b/h

LOG FURNACE LENGTH 12,3 m

HOT LOG SHEAR 80 Ton

MAX PROFILE WEIGHT 8 kg/m

PROFILE DIMENSION height = 150 mm; width = 350 mm

QUENCH UNIT 6 m with air cooling6 m water spray cooling - 120m3/h water consumption

LATERAL DOUBLE PULLER WITH SAW ON BOARD

20 kg - 100 kg pulling force

STRETCHER FINGERS TYPE 50 Mton

FINAL CUT SAW 7.500 mm

7” EXTRUSION LINE – MAIN DATA

LOG FURNACE

LOG FURNACE PRODUCTIVITY

2450 kg/h 35 b/h

ENERGY CONSUMPTION from 180 kcal/kg to 220 kcal/kg ± 10% for 2450 kg/h at 400°C

REDUCTION OF HEAT DISPERSION• New concept of door for the log entry and exit• Thermocouple gate

LOG FURNACE

BETTER MAINTENANCE• Movable external protection• Thermocouple on the top of the furnace• Increasing of rollers mean-life of 30% thanks to better alloy and new design.

LOG FURNACE

LOG FURNACE

HIGH INSULATION• First layer faced to the burners made in

refractory concrete• Second layer made with insulating material

in ceramic fiber

BIGGER HEAT EXCHANGER to reach 300° C air temperature.

CONTINUOUS REGULATION of the COMBUSTION RATIO in function of the temperature of the combustion air.

HOT LOG SHEAR

MAIN FEATURES Horizontal shearing.

Movable knives to facilitate the introduction of the log into the shear body reducing the log deformation (8%) and to avoid blisters on the profiles.

Optimization of the cycle through a software that allows to use the pre-cut billets without changing the tools.

Reduction of the shearing time thanks to the system of auto -measurement of the log. Shearing cycle of 40 sec.

Special cycle for hard alloy and pre cut billets.

HOT LOG SAW

MAIN FEATURES

OMAV has engineered and built hot log saws up to 14”.In case of hard alloys the cutting temperature is more than 500°C.A double blade system in case of logs with diameter more than 335 mm to reduce the chips.Controlled lubrication system with nebulized spray directly on the blade teeth.Control of the cutting speed.No need of cooling the blade.Aspiration system to suck the smokes due to blade lubrication.

OMAV engineers and builds different cooling systems according to the customers’ requirements. OMAV offers different solutions for these types of cooling systems:

• Intensive air cooling• Water spray and water wave • Water wave, water spray and air in the same quench

COOLING SYSTEMS - GENERAL

AIR COOLING The cooling occurs from the top through air channel with suitable slot nozzles near the profiles and from the bottom with air channel. The hood is fed by a fan dedicated controlled by frequency converter and butterfly valve.

AIR COOLING FOR LIGHT PROFILES

This configuration gives the maximum flexibility on the cooling regulation of the tunnel, allowing to adjust any deformations of the profiles due to the asymmetric shape. All the valves, ON/OFF and the proportional ones, are controlled by the PLC, it is possible to choose a cooling configuration, according to the profile shape, to put in the PLC memory and to recall the wanted configuration in case of using the same die.

COOLING SYSTEMS

OMAV has engineered and built pullers up to 4000 kg (8800 lbs) pulling force.

In 2002 OMAV introduced a revolutionary puller system with a rack and pinion drive system.

•The drive motor is installed directly on board on the puller carriage. • The movement occurs thorough a rack and pinion system (helical-toothed). • Power supply by contact rails or power track

DOUBLE PULLER

Key Advantages• Smooth and precise movement of the puller carriage with no surface damage to the profiles (vibrations, die marks). • Significantly lower power requirement for the drive motor due to elimination of power transmission elements (chains, cables)

DOUBLE PULLER

DOUBLE PULLER INSTALLED POWER

MAIN DATA OMAV PULLER

TRADITIONAL PULLER WITH

TRANSMISSION BY CHAIN

OMAV’s PULLER WITH TRANSMISSION BY RACK-PINION AND MOTOR ON BOARD

Pulling force 200 kg 200 kg

Max Extrusion speed 80 m/min 80 m/min

Max Return speed 200 m/min 200 m/min

INSTALLED POWER 27 KW 11 KW

STRETCHER

• The movement is provided by powered wheels.• Jaw with fingers for a better gripping of the profile and equipped with a

common hole to lock together all fingers in case of solid bar. • Stretching drive through hydraulic cylinder.• Positioning of the tailstock by an absolute encoder or laser photocell.• The positioning of the tailstock is locked by a proper anchoring pin.• The scraps are 500 mm long each part (headstock and tailstock) but it can

change according to different types of profiles.

COLD SAW

QUALITY •Cutting surfaces completely smooth•High cutting precision •Optimization of the cycle with a scrap handlingRELIABILITY•Hard sharps according to the type of alloy•Increase of number of cuts per blade•Reduction of the noise during the cutting phase thanks to silencer bladeEFFICIENCY•High performance system for chips evacuation, that are sucked from three points, upper lower and lateral position.•95 % chips aspiration•Cutting cycle of 30 sec

OMAV SAW GAUGE TABLE - LATERAL

Lateral moveable gauge travels on lateral guides.

Movement through AC motor and frequency converter acting through a pinion gear and rack mounted on the frame.

Locking brake actuated by air-oil pressure booster, clamps the gauge stop firmly in position.

OMAV AUTOMATIC PROFILE STACKER

TYPE: Overhead stacker with 3-axis, with brushless motors and semi-automatic feeding system of spacers.

SPACER DISTRIBUTOR: This is a semi-automatic station for spacer feeding. The spacers must be placed manually by the operator inside of a collection box under which are installed the pickup devices. Automatically then the spacers are picked up and sent to feeding position under the stacker.

MAIN FEATURES•HIGH STACKING PRECISION•HIGH QUALITY PRODUCT KEPT THROUGH ALL THE CYCLE •HIGH CYCLE TIME –

30 sec without spacers 35 sec with spacers distribution system

•HIGH AVAILABILITY

OMAV is always focusing on the satisfaction of his customers and wants to be even more close to them. For this reason we believe that is strategic to have a well organized after sales office. We have a unit in OMAV with dedicated people who follow up the customers from the starting project up to the after sales. Then we have established two other units:

• OMAV FOSHAN for our Chinese customers

• OMAV NORTH AMERICA for the American market, with dedicated people on the service and after sales.

We believe that the results that we have already reached will be a beginning for even better long-term results with the main objectives to satisfy our customers.

OMAV’s CHALLENGE FOR THE FUTURE

THANK YOU FOR YOUR ATTENTION

We are available for any questions or any additional information