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Automatic Butyl Extruder
About Automatic Butyl Extruder
The Automatic Butyl Extruder is an advanced machine designed for the precise application of butyl sealant in the production of insulating glass units (IGUs). This equipment is essential in the manufacturing process of double or triple-glazed windows, where a durable, airtight, and moisture-resistant seal is critical. The extruder automates the application of butyl, ensuring consistent, high-quality results with minimal human intervention.
By employing modern control systems, the automatic butyl extruder ensures precise dispensing, reduces waste, and significantly enhances production efficiency. It is a key component in the glass fabrication industry, contributing to both the reliability and longevity of the final product, whether for residential, commercial, or industrial applications. Designed for high-speed and high-precision tasks, this machine is capable of working with various glass sizes and thicknesses, offering flexibility for different production requirements.
Key advantages of the automatic butyl extruder include automation of the sealing process, improved sealant application consistency, reduced labor costs, and greater overall efficiency in large-scale production lines. With its user-friendly interface, minimal maintenance needs, and compatibility with various butyl formulations, this machine is an ideal choice for manufacturers looking to improve production quality and streamline their insulating glass production process.
You will find detailed information on the key parameters and performance metrics of the Automatic Butyl Extruder, including its sealant application capacity, power requirements, production speed, and adjustable settings. These specifications will help you understand the machine’s capabilities and ensure it aligns with your production needs, providing valuable insights for optimizing efficiency and integration into your existing production line.
| Model | Power Supply | Total Power | Working Air Pressure | Max. Glass Size( mm) | Min. Glass Size (mm) | Coating Speed | Overall Dimension (mm) | Weight (kgs) |
|---|---|---|---|---|---|---|---|---|
| JYT-2025 | 380V/50Hz | 11.0kW | 0.6-0.8MPa | 2,000 x 2,500 | 190 x 450 | 5-40m/min | 8,600 x 1,500 x 3,200 | 2,500 |
| JYT-2030 | 380V/50Hz | 12.0kW | 0.6-0.8MPa | 2,000 x 3,000 | 190 x 450 | 5-40m/min | 10,000 x 1,500 x 3,200 | 3,000 |
| JYT-2535 | 380V/50Hz | 13.0kW | 0.6-0.8MPa | 2,500 x 3,500 | 190 x 450 | 5-40m/min | 11,100 x 1,500 x 3,600 | 3,500 |
- What Are the Key Features?
Precise Sealant Application
High-Speed Operation
Adjustable Bead Thickness and Width
Servo Motor Control for Precision
Minimal Sealant Waste
User-Friendly Interface
Durable and Long-Lasting Components
Automatic Cleaning System
Flexible Sealant Compatibility
- 11 Core Components of Automatic Butyl Extruder
Servo Motor System
Extrusion Head
Sealant Delivery System
Control Panel
Precision Positioning Mechanism
Sealant Heating and Cooling System
Material Feed System
Safety System
Cleaning and Maintenance System
Servo Control System
Power Supply and Electrical Components
Do You Provide Customizations & Options?
| Customization Option | Description | Benefits |
|---|---|---|
| Extrusion Head Customization | - Single or dual extrusion heads. - Adjustable bead size for different glass specifications. - Quick-change extrusion heads. | - Increased flexibility for different glass sizes. - Faster production with dual heads. - Reduced downtime with quick-change features. |
| Sealant Compatibility | - Compatibility with various types of butyl sealants. - Heating and cooling systems to adjust viscosity. - Multiple sealant storage tanks. | - Ability to use different sealants for specific applications. - Easy switching between sealants. - No cross-contamination. |
| Control System Customization | - Touchscreen interface with multiple language options. - Programmable settings for multiple glass types. | - Greater ease of operation. - User-friendly interface. - Improved efficiency with automatic switching between settings. |
| Automatic Cleaning System | - Automated cleaning cycles. - Self-cleaning nozzles and automatic flushing system. | - Reduced maintenance time. - No manual cleaning required. - Higher production uptime. |
| Servo Motor Speed & Pressure Adjustments | - Variable speeds and adjustable extrusion pressure. | - Customizable extrusion for different glass types. - Improved control over production. |
| Sealing Thickness Control | - Variable bead thickness settings. - Automatic thickness monitoring and adjustment. | - Precise control of bead thickness. - Consistent seal quality. |
| Dual Pump System for Multiple Sealant Types | - Two independent pumps for different sealants (e.g., butyl, polyurethane). - Quick sealant switching. | - Flexibility to use different sealants. - Minimizes downtime and sealant wastage. |
| Glass Handling and Positioning Mechanism | - Adjustable support rails for various glass sizes. - Customizable positioning for complex glass shapes. | - Can handle a wide variety of glass sizes and shapes. - Enhanced accuracy for complex applications. |
| Safety and Compliance Features | - Additional emergency stop buttons. - Regional safety compliance (e.g., CE, UL). - Noise reduction features. | - Improved safety for operators. - Meets global safety standards. - Reduced operational noise. |
| Energy Efficiency Options | - Energy-saving modes. - High-efficiency motors. | - Lower energy consumption. - Reduced operational costs. |
Download Our Comprehensive User Manual Today!
To ensure you’re maximizing the performance and efficiency of your Automatic Butyl Extruder, our User Manual is your essential guide. It provides all the details you need, from initial setup to daily maintenance, allowing you to operate your machine confidently and with ease.
By downloading the user manual, you'll gain:
- Step-by-step instructions for installation and setup.
- Detailed maintenance and troubleshooting tips to keep your machine running smoothly.
- Clear operational guidelines for achieving optimal results in your production process.
- Expert recommendations to help you optimize efficiency and reduce downtime.
Maintenance Tips for the Automatic Butyl Extruder
Proper maintenance is crucial for ensuring the longevity, efficiency, and performance of the Automatic Butyl Extruder. Below are essential maintenance tips to ensure your equipment continues to operate at optimal levels and reduces the likelihood of costly breakdowns.
| Maintenance Activity | Description | Frequency | Benefits |
|---|---|---|---|
| 1. Regular Cleaning of Nozzles and Extrusion Head | - Clean the extrusion head and nozzles after each production run to prevent sealant buildup. - Use appropriate cleaning solvents for different sealant types. | After each production run | - Prevents clogs and inconsistent sealant application. - Ensures smooth extrusion and precise sealant placement. |
| 2. Sealant Storage Tank Maintenance | - Regularly check and clean the sealant storage tanks to avoid contamination between different types of sealants. - Monitor sealant viscosity and replace when necessary. | Every 2-3 weeks | - Prevents cross-contamination of sealants. - Improves production quality by using pure, uncontaminated sealant. |
| 3. Servo Motor and Drive System Check | - Inspect the servo motor for any signs of wear, overheating, or irregular sounds. - Lubricate motor components and check connections. | Every 6 months | - Ensures the servo motor operates smoothly. - Prolongs the life of motor and drive components. |
| 4. Inspection of Pressure and Speed Controls | - Check and calibrate the pressure and speed control systems to ensure the correct extrusion settings are maintained. | Quarterly | - Helps maintain consistent extrusion quality. - Prevents under-extrusion or over-extrusion of sealant. |
| 5. Checking and Replacing Filters | - Inspect and replace filters in the pump and sealant lines. - Regularly clean the filters to ensure proper sealant flow. | Every 3-6 months | - Ensures consistent flow of sealant. - Prevents clogging and interruptions in the sealing process. |
| 6. Sealing Head and Bead Thickness Calibration | - Regularly calibrate the sealing head to maintain precise bead thickness. - Ensure nozzles are aligned properly to maintain uniform bead consistency. | Monthly | - Ensures precise control of bead thickness. - Helps maintain high-quality seals and improves product consistency. |
| 7. Electrical System and Wiring Inspection | - Inspect all electrical connections and wiring for damage or wear. - Check the control panel for any error signals or malfunctions. | Quarterly | - Prevents electrical failures. - Ensures all electrical systems are functioning properly, avoiding operational disruptions. |
| 8. Regular Inspection of Safety Features | - Test all safety features, including emergency stop buttons, safety guards, and sensors. - Ensure all systems are functioning to prevent accidents. | Monthly | - Ensures compliance with safety standards. - Protects operators and minimizes risk of injury. |
| 9. Coolant and Temperature System Checks | - Inspect the cooling system to ensure that the extrusion system maintains optimal temperature. - Check for coolant leaks or blockages. | Every 6 months | - Prevents overheating and damage to the extrusion system. - Ensures consistent performance under all conditions. |
| 10. Routine Software Updates | - Ensure the control system is updated with the latest software to enhance functionality and address any known issues. | Annually | - Keeps the system running smoothly. - Enhances functionality and introduces new features to improve performance. |
What is Your Production Time?
At Jingyou Glass, we prioritize efficiency and timely delivery while ensuring the highest standards of quality in our manufacturing processes.
| Stage | Timeline | Description |
|---|---|---|
| Order Confirmation & Initial Review | Day 1-2 | Upon receiving your order, we confirm the specifications and review your custom requirements. |
| Production Planning & Resource Allocation | Day 3-5 | Our team prepares the production plan and allocates necessary resources (materials, components, etc.). |
| Component Procurement & Pre-Assembly | Day 6-10 | We source and procure any additional components and begin pre-assembling machine parts. |
| Assembly & Testing | Day 11-18 | Full assembly of the machine begins. All components are carefully assembled and thoroughly tested to ensure top performance. |
| Quality Control & Final Inspection | Day 19-22 | After assembly, a comprehensive quality control process ensures every machine meets our stringent standards. |
| Packaging Preparation | Day 23-25 | Machines are carefully packed with protective materials to ensure safe transportation. |
| Shipping Documentation & Final Approval | Day 26-28 | We prepare all shipping documents and obtain final customer approval for shipping. |
| Shipping & Delivery | Day 29-30 | The machine is shipped to the destination port, ready for delivery. Delivery time depends on the destination. |
Will Production Be Affected by Peak Seasons or Holidays?
| Holiday | Holiday Duration | Dates | Potential Production Impact |
|---|---|---|---|
| New Year's Day | 1-3 days | January 1st | Minimal impact, quick production recovery |
| Chinese New Year | Typically 1.5 months | January/February - Lunar calendar, normal recovery by March | Most significant impact, factories usually shut down for about 1.5 months, full recovery by March |
| Qingming Festival | 3 days | April 4th/5th | Short impact, quick recovery after holiday |
| Labor Day | 3 days | May 1st-3rd | Short delay if high order volume, 3-day break |
| Dragon Boat Festival | 3 days | June - Lunar calendar | Short impact, minimal delay expected |
| Mid-Autumn Festival | 3 days | September/October - Lunar calendar | Minimal impact, short disruption |
| National Day | 7 days | October 1st-7th | Moderate impact, 1 week delay possible |
What Are the Payment Terms and Conditions?
Deposit and Balance Payments
- Upon signing the contract, customers are required to pay a 30% deposit of the total purchase price. This deposit is necessary to initiate the order and begin the production or customization of the machinery.
- The remaining 70% balance is due before shipment of the equipment. This ensures that the majority of the payment is secured prior to the dispatch of the fully assembled production line.
Telegraphic Transfer (TT)
- We accept payments via Telegraphic Transfer (TT), a reliable and commonly used method for international transactions.
- This method allows for quick and secure transfer of funds directly between banks, ensuring both parties have documented proof of transaction, which is essential for international trade and financial security.
Common Troubleshooting Issues
| Issue | Cause | Solution |
|---|---|---|
| Sealant Clogging or Inconsistent Extrusion | Accumulation of hardened sealant, improper mixing, or contamination in sealant material. | - Clean extrusion nozzle regularly to remove hardened sealant. - Ensure proper mixing of sealant. - Perform cleaning cycles to prevent clogging. |
| Uneven Sealant Application | Incorrect pressure settings, nozzle blockage, or misalignment of extrusion head. | - Adjust pressure settings based on glass type. - Clean nozzle and check for obstructions. - Align extrusion head correctly. |
| Sealant Leakage Around the Nozzle | Worn-out nozzle seals, excessive pressure, or incorrect sealant viscosity. | - Check and replace worn nozzle seals. - Lower extrusion pressure if too high. - Ensure sealant is within recommended viscosity range. |
| Inconsistent Sealant Thickness | Incorrect machine calibration, uneven glass positioning, or faulty servo motor controls. | - Recalibrate machine for sealant thickness. - Ensure glass alignment on conveyor system. - Inspect and maintain servo motors. |
| Machine Not Starting or Power Failure | Electrical connection issues, blown fuses, or control panel errors. | - Check power supply and connections. - Inspect and replace blown fuses. - Reset control panel and troubleshoot error codes. |
| Excessive Vibration or Noise During Operation | Loose components, misaligned parts, or wear in servo motor or gearbox. | - Tighten any loose screws or parts. - Check alignment of mechanical components and adjust. - Inspect servo motor and gearbox for damage and replace if needed. |
| Inaccurate Sealant Positioning on Glass Edges | Misalignment of robot's sealing arm, incorrect calibration of position sensors, or servo motor issues. | - Recalibrate sealing arm and position sensors. - Align robotic arms correctly. - Inspect and ensure servo motors are functioning properly. |
| Sealant Quality Issues (e.g., Surface Irregularities, Bubbles) | Improper sealant temperature, incorrect mixing ratios, or low-quality sealant material. | - Monitor and adjust sealant temperature. - Ensure correct mixing ratios. - Use high-quality, fresh sealant. |
| Servo Motor Failure or Malfunction | Overheating, electrical issues, or mechanical blockages. | - Ensure motors are not overheating. - Check for damaged wiring. - Inspect and clear mechanical blockages. |
| Frequent Sealant Supply Interruptions | Air pockets, low-pressure supply, or air leaks in the system. | - Bleed the system to remove air pockets. - Check and stabilize sealant supply pressure. - Seal any air leaks in the system. |
| Poor Adhesion of Sealant to Glass | Contaminants on the glass surface or incorrect sealant formulation. | - Thoroughly clean glass before sealing. - Ensure correct sealant type and formulation. |
| Error Codes or Malfunctions in the Control System | Software bugs, incorrect settings, or communication failure between components. | - Refer to the error code guide for troubleshooting. - Reset control system and adjust settings. - Check component communication and wiring. |
| Insufficient Heating of the Sealant | Faulty heating system, incorrect temperature settings, or inadequate sealant flow. | - Inspect heating system for malfunction. - Adjust temperature settings for proper sealant heating. - Ensure even sealant flow. |
| Slow Response Time or Delay in Sealant Application | Malfunctioning sensors, insufficient pressure, or servo motor lag. | - Recalibrate sensors for responsiveness. - Adjust pressure settings. - Inspect servo motors for lag and repair if necessary. |
| Overheating of the Extruder | Extended operating time, insufficient ventilation, or mechanical strain. | - Allow machine to cool during extended use. - Ensure adequate ventilation. - Inspect for mechanical strain and replace damaged parts. |
FAQs
The Automatic Butyl Extruder is primarily designed to handle butyl rubber sealants for insulating glass production. It can also be used with certain other sealants that have similar viscosities and curing characteristics, such as silicone sealants and polyurethane. However, it is important to confirm with the manufacturer whether a specific type of sealant is compatible based on the extruder’s configuration.
The typical production capacity of the Automatic Butyl Extruder depends on the extrusion speed, glass size, and application requirements. Generally, it can produce up to 400-600 meters of extruded sealant per hour. For high-volume production environments, the machine can operate continuously for extended periods, maximizing output while maintaining consistency and quality.
The maximum extrusion speed of the Automatic Butyl Extruder typically reaches up to 12 meters per minute. This speed can vary depending on factors such as the sealant viscosity, glass size, and thickness. It’s essential to optimize the machine’s settings to achieve the best results for your specific production requirements.
The Automatic Butyl Extruder is designed to handle a wide range of glass sizes, from small insulating units to large commercial glass. The minimum glass size it can handle is 300 mm x 300 mm, while the maximum size can go up to 3000 mm x 2500 mm, depending on the configuration of the machine and the extrusion nozzle.
The Automatic Butyl Extruder typically requires a three-phase electrical supply with a voltage range of 380V to 415V and a frequency of 50Hz to 60Hz. The power consumption will depend on the specific model and configuration, but the typical power requirement ranges between 4 kW to 8 kW for optimal performance.
The Automatic Butyl Extruder can handle a maximum sealant pressure of 8-10 bar (116-145 psi). This pressure range ensures that the sealant is extruded smoothly and consistently across the entire glass perimeter. It is adjustable based on the sealant type and desired application quality.
Yes, the Automatic Butyl Extruder is capable of working with different sealant thicknesses. The extrusion head and nozzle sizes can be adjusted to accommodate a range of sealant thicknesses, from 1.5 mm to 4 mm typically. This flexibility allows the extruder to handle various sealing requirements depending on the type of insulating glass being produced.
The energy consumption of the Automatic Butyl Extruder will depend on several factors, such as the speed of operation, type of sealant, and the overall workload. On average, the extruder consumes approximately 4 kW to 8 kW of electrical power during continuous operation. The energy efficiency can be optimized by adjusting machine settings to suit production requirements, which can help minimize operational costs.
The space required for installing the Automatic Butyl Extruder depends on the model and configuration, as well as any auxiliary equipment. Generally, you should allocate at least 3 meters (length), 2 meters (width), and 2.5 meters (height) of floor space for the machine. It is also important to ensure there is enough clearance around the machine for maintenance access and optimal airflow.
No, specialized tools are generally not required for installing the Automatic Butyl Extruder. However, basic tools such as wrenches, screwdrivers, and pliers may be needed for assembly and securing connections. For electrical installation, a licensed electrician should handle wiring and power connections. Installation tools are typically simple and standard for industrial equipment setups.
Installation of the Automatic Butyl Extruder typically takes 1 to 2 days for a basic setup. This time frame includes positioning the machine, making power and sealant system connections, and performing initial system tests. If more complex integration with existing lines is required, installation may take a bit longer. The installation process is straightforward and usually completed within the specified timeframe.
Yes, the Automatic Butyl Extruder comes with a detailed installation manual and video guides to assist you through the setup process. These resources cover everything from positioning and wiring to configuring settings for the optimal extrusion process. If you need any additional support, our technical team can provide further assistance.
The Automatic Butyl Extruder is designed for ease of operation. It features a user-friendly control panel that allows operators to quickly adjust settings such as extrusion speed, pressure, and temperature. The machine has been optimized for both novices and experienced operators, with clear instructions on the display and intuitive buttons for controlling key parameters. Regular training and familiarity with the user manual will ensure smooth operation.
Yes, the Automatic Butyl Extruder allows you to control both the extrusion speed and sealant pressure. The extrusion speed can be adjusted based on the production requirements and the type of sealant used. Similarly, the pressure can be fine-tuned to ensure the correct amount of sealant is applied without over or under extrusion. These adjustable parameters help optimize sealant application, improving the quality and consistency of the finished product.
Yes, regular calibration of the Automatic Butyl Extruder is recommended to ensure consistent performance and precise sealant application. Calibration should be done at least once every 6 months or whenever there is a noticeable drop in sealant quality or performance. The calibration process ensures that the extrusion speed, pressure, and other settings are aligned with the machine’s optimal operating conditions.
Yes, the Automatic Butyl Extruder can handle different types of glass, including low-e (low emissivity) glass, tinted glass, and coated glass. The extruder is designed to work with various glass types that require butyl sealant, as long as the glass dimensions fall within the machine’s capabilities. It is important to ensure that the settings (speed, pressure) are adjusted based on the glass type to ensure optimal sealant application.
The Automatic Butyl Extruder should be cleaned regularly to maintain optimal performance. For general operation, it is recommended to clean the machine at least once every week or after every production run, especially if you are switching between different sealants. If the extruder operates continuously, cleaning may need to be done more frequently, depending on usage. Regular cleaning ensures that the nozzle, extrusion head, and internal components are free from accumulated residue or sealant build-up, preventing clogging and ensuring smooth operation.
The nozzle and extrusion head are critical components of the Automatic Butyl Extruder and must be maintained properly to ensure precise sealant application. To maintain these parts:
- Regularly inspect the nozzle for any build-up of sealant or clogging.
- Clean the nozzle after each production run to remove any residual sealant, preventing blockages.
- Check the extrusion head for wear—if you notice uneven extrusion or reduced flow, it may be time to clean or replace the head.
- Use non-abrasive cleaning tools and solvents recommended by the manufacturer to avoid damaging the nozzle or extrusion head.
If the nozzle or extrusion head shows signs of significant wear (e.g., cracks, dents, or inability to extrude properly), it should be replaced immediately to maintain optimal performance.
Replacing worn-out parts on the Automatic Butyl Extruder can be done easily by following these steps:
- Turn off the machine and disconnect the power supply.
- Loosen any fasteners or clamps that hold the worn-out part (e.g., nozzle or seal) in place.
- Carefully remove the worn-out part and dispose of it according to the manufacturer’s guidelines.
- Install the new part, ensuring it is properly aligned and secured in place.
- Tighten the fasteners and check that the new part is correctly positioned and functioning.
- Run a test extrusion to ensure proper function and verify that the new part is operating as expected.
We recommend keeping spare parts on hand, such as nozzles, seals, and other consumables, to minimize downtime.
The Automatic Butyl Extruder is designed to require minimal lubrication. However, some mechanical components (such as the drive motor, gears, or moving parts) may require regular lubrication to prevent friction and ensure smooth operation. It is recommended to:
- Lubricate moving parts according to the manufacturer’s guidelines, typically every 3 to 6 months depending on usage.
- Use the specified type of oil or lubricant for the machine’s components. Consult the maintenance manual for the correct type and quantity.
- Always check for signs of wear or squeaking sounds, which may indicate the need for additional lubrication.
Be sure to regularly check lubrication levels and avoid over-lubricating, which can attract dust or debris and cause performance issues.
