Common problems encountered in the operation of double-wall corrugated pipe production lines

Production line of double wall corrugated pipes is a very essential one to produce the pipes used for sewage, drainage, as well as cable casing. Though it's machines are constructed for the sake of continuous and stable production operation, there are still quite many problems occurring every day during the pipe making process. These problems could be the issues to slow down the production rate, to make the corrugated pipe extrusion line of low quality, or even to halt the line operation. In some factories, tiny faults such as fluctuating temperature or improper material feeding could develop into massive problem of production. Knowledge of these issues is helpful for the operators to be responsive promptly and to continue the line operation with less pause.

Safety relationship between machine and personnel operation

Machine safety and person operation in the double wall corrugated pipe producing line cannot be a side matter. On the spot of production sites, most accidents arise not from failure of machines but from small negligence in daily production operation. For instance, an operator putting his hand into the calibration tank without the production line stops or adjusting the extruder before the machine stops completely would cause fatal injuries within seconds.The relationship between machine and operator should rely on control, not imagination. Each moving part, heating element and pulling section, have their potential dangers. Therefore, all safety covers, Emergency Stop buttons, Warning lights must always work properly and not be put aside to save time.In some of the factories, issues occurred when the new operators were not fully trained. They can't get the sense of how fast the forming unit pulled the corrugated pipe production line and how hot the extrusion unit is. One case they have often encountered is an operator removing pipe obstruction by hand when the screw cools down and results in burn and entanglement.Good habits are so simple to follow. Lock out all electricity supply before cleaning the machine, wear gloves and fireproof equipment when you are working in a hot area and follow the machine stop procedures. The machine can not feel when you are under risk, it only knows to run fast or to continue.

The production line should be regularly maintained.

Regular maintenance has become one of the most critical aspects of stable operation for a double-wall corrugated pipe production line. In many plants people will only consider there is an issue when something breaks down, however in practice almost every malfunction begins as a minor issue and progressively worsens. A loose connection of heater, a worn-out sealing ring, or a clogged vacuum port, while it might not immediately bring the machine to a halt, might contribute to changes in pipe shape, wall thickness or surface quality over time.Let's consider the forming section. If the molds are not cleaned on a regular basis, residue of plastic can accumulate and the pipe might start sticking to the molds and being ejected with scratches on the surface. Machine operators might even attempt to "fix" this by varying the pressure and speed of the forming line, but the root cause of the problem might simply be dirty molds, and cleaning of the molds at scheduled stops might save hours of downtime later.The vacuum and cooling system can be considered another important part to keep a watchful eye on. If there are dirt or scale residues in the cooling water tank, this might affect the efficiency of the cooling process and lead to deformities in the corrugated pipe extruder , especially if pipes of larger sizes are being produced. Some plant workers have reported seeing pipes appearing oval-shaped instead of circular, and after an inspection, they realize the problem might be due to poor water flow resulting from clogged filters.Electrical components require regular checks as well. Aging sensors or loose connections of electrical parts could potentially lead to instability of temperature control. With unstable temperatures, layers might not bond properly and the finished pipe might be weak. A simple check of terminals and the responsiveness of the sensors can prevent this problem.The routine maintenance work should not be viewed as a one-time big repair event. Regular checks on a daily basis, such as ensuring proper lubrication, checking oil levels, listening for any unusual sounds, and observing temperature readings, all play a significant role in overall smooth operation of a production line, with unexpected downtimes being minimized.

Common problems during equipment operation

A double wall corrugated pipe producing line in the everyday operation may often exhibit problems without the machines necessarily looking wrong. Most problems begin as small faults and then cause the finished product to become bad if it is noticed too late.One frequently observed problem is the pipe wall thickness fluctuation. The workers will usually see the wall become thinner or irregular on one side or the other. Usually this is a symptom of erratic raw material supply, or an erratic extrusion screw speed. This could be brought about on the factory floor by an irregular rate of material supply from the feed hopper as the contents diminish. Often the simple solution is just keeping a constant supply and making sure that the screw speed and feed mechanism are operating correctly.Another frequently observed problem is the forming quality of the pipe. The pipe can come through appearing rough in texture, with incomplete corrugation or even some deformation of the walls. This is generally due to worn dies, or dirty forming blocks. The solution of simply cranking up the pressure or heat makes it worse, whereas cleaning the die and also making sure that the vacuum on the forming block is adequate usually solves the problem.Fluctuating temperature of the extruder itself can cause the same effects. Lack of consistent temperature in the heating zones does not allow the melted plastic to be uniformly extruded. When the pipes are being joined, there is usually a weakness in the bonding between the internal and outer wall. This will become apparent when a cracked pipe is observed some time after the tube has been cooled down, but it had been identified in one factory that it was due to an erroneous reading being taken from the temperature sensor.Problems with the cooling system are another issue. Weak or uneven flow of cooling water will tend to make the pipe bend, and this will also tend to prevent the pipe maintaining a truly circular shape. Sometimes the reason for this problem is due to a blockage in the filter or a dirty water tank. Often the problem is soled with a simple clean and checking the water pump is operating properly.Strange noises and machine vibration should also never be disregarded. These could well indicate a loose screw, worn bearings, or an alignment problem. Quite often the operator gets so accustomed to the noise that they ignore it, but these are often the precursors to catastrophic failures of other components of the machine.Most of these problems can be mitigated by regular observation and simple routine checks before they become real breakages of a complex and important production tool.