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SINCE 1952

SINCE 1952. ALWAYS IN THE FOREFRONT IN EXTRUSION SYSTEM . Aluminium Middle East 2013 Innovation Podium. HIGH RELIABILITY AND EFFICIENCY ALUMINIUM EXTRUSION PLANTS Author : Giulia Bertoli – Sales Manager OMAV S.p.A. Italy . OMAV - 2013. Facility 20.000 sqm

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SINCE 1952

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  1. SINCE 1952 ALWAYS IN THE FOREFRONT IN EXTRUSION SYSTEM

  2. Aluminium Middle East 2013 InnovationPodium HIGH RELIABILITY AND EFFICIENCY ALUMINIUM EXTRUSION PLANTS Author : Giulia Bertoli – Sales Manager OMAV S.p.A. Italy

  3. OMAV - 2013 • Facility 20.000 sqm • Employees 180 people • Turnover 2011 45 mln euro • Products press feedingline • handlingsystems • agingoven • diecleaningequipments • aluminiumfoudries • heat treatment furnaces

  4. OMAV - 2013

  5. THE GROUP

  6. QUALITY ASSURANCE PRE-ASSEMBLY AS A QUALITY TEST

  7. THE ELECTRICAL & SOFTWARE DEPARTMENT Thissectionofour company isdedicatedto planning and designing the electrical project, prepareand complete all the wiring on boardof the machines. Wemakesafety and reliabilityour prime objectives and use the latesttechnologytoensurethatourmachinesmeetallelectricalsafetystandards and customer’s requirements.

  8. OMAV hasfocused on the standardizationof middle sizeextrusionlinesforlogsofdiameters 7” (177,8 mm) – 8” (203,4 mm) – 9” (228,6 mm) in ordertobe more competitive and tobeabletoreach a 99% AVAILABILITY for the press feedingline and 99% for the handling system line. EAP - EQUIPMENT AVAILABILIY PERCENTAGE (Availabletime – Downtimetime) x 100% Availabletime HIGH AVAILABILITY AND HIGH EFFICIENCY EXTRUSION LINE

  9. PROFILE STACKER AGING OVEN COLD SAW LOG STORAGE TABLE LOG FURNACE 7” EXTRUSION LINE – STD CONCEPT HOT LOG SHEAR HAND OFF PULLER WITH SAW ON BOARD STRETCHER TAILSTOCK STRETCHER HEADSTOCK LOG PUSHER AIR COOLING SYSTEM

  10. SECTION OF THE PLANT 7” EXTRUSION PLANT – STD CONCEPT

  11. 7” EXTRUSION LINE – MAIN DATA

  12. LOG FURNACE • LOG FURNACE PRODUCTIVITY • 2450 kg/h 35 b/h • ENERGY CONSUMPTION from180 kcal/kg to 220 kcal/kg ± 10%for 2450 kg/h at 400°C

  13. REDUCTION OF HEAT DISPERSION • New concept of door for the log entry and exit • Thermocouplegate LOG FURNACE

  14. BETTER MAINTENANCE • Movableexternalprotection • Thermocouple on the top of the furnace • Increasingofrollersmean-lifeof 30% thankstobetteralloy and new design. LOG FURNACE

  15. HIGH INSULATION • First layerfacedto the burnersmade in refractory concrete • Secondlayermadewithinsulating material in ceramicfiber LOG FURNACE • BIGGER HEAT EXCHANGERtoreach 300° C air temperature. • CONTINUOUS REGULATION of the COMBUSTION RATIO in functionof the temperature of the combustion air.

  16. MAIN FEATURES • Horizontalshearing. • Movableknivesto facilitate the introductionof the log into the shear body reducing the log deformation (8%) and toavoidblisters on the profiles. • Optimizationof the cyclethrough a software thatallowstouse the pre-cutbilletswithoutchanging the tools. • Reductionof the shearingtimethanksto the system of auto -measurementof the log. Shearingcycleof 40 sec. • Special cycle for hard alloy and pre cut billets. HOT LOG SHEAR

  17. MAIN FEATURES • OMAV hasengineered and built hot log saws up to 14”. • In case of hard alloys the cutting temperature is more than 500°C. • A doubleblade system in case oflogswithdiameter more than 335 mm to reduce the chips. • Controlledlubrication system withnebulized spray directly on the bladeteeth. • Controlof the cuttingspeed. • No needofcooling the blade. • Aspiration system tosuck the smokes due tobladelubrication. HOT LOG SAW

  18. OMAV engineers and buildsdifferentcoolingsystemsaccordingto the customers’ requirements. OMAV offersdifferentsolutionsforthesetypesofcoolingsystems: • Intensive air cooling • Water spray and water wave • Water wave, water spray and air in the samequench COOLING SYSTEMS - GENERAL

  19. 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

  20. Thisconfigurationgives the maximumflexibility on the coolingregulationof the tunnel, allowingtoadjustanydeformationsof the profiles due to the asymmetricshape. All the valves, ON/OFF and the proportionalones, are controlledby the PLC, itispossibletochoose a coolingconfiguration, accordingto the profileshape, to put in the PLC memory and torecall the wanted configuration in case ofusingthe samedie. COOLING SYSTEMS

  21. 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. DOUBLE PULLER • 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

  22. 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

  23. DOUBLE PULLER INSTALLED POWER

  24. The movementisprovidedbypoweredwheels. • Jawwithfingersfor a bettergrippingof the profile and equippedwith a common holetolocktogetherallfingers in case ofsolid bar. • Stretching drive throughhydrauliccylinder. • Positioningof the tailstockbyanabsolute encoder or laser photocell. • The positioningof the tailstockislockedby a properanchoring pin. • The scraps are 500 mm long each part (headstock and tailstock) butit can changeaccordingtodifferenttypesofprofiles. STRETCHER

  25. QUALITY • Cutting surfaces completely smooth • High cutting precision • Optimization of the cycle with a scrap handling • RELIABILITY • 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 blade • EFFICIENCY • High performance system for chips evacuation, that are sucked from three points, upper lower and lateral position. • 95 % chips aspiration • Cuttingcycleof 30 sec COLD SAW

  26. OMAV SAW GAUGE TABLE - LATERAL • Lateralmoveablegaugetravels on lateralguides. • Movementthrough AC motor and frequencyconverter • actingthrough a piniongear and rackmounted on the frame. • Lockingbrakeactuatedby air-oil pressure booster, clamps the gauge stop firmly in position.

  27. 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 withoutspacers • 35 sec withspacersdistribution system • HIGH AVAILABILITY

  28. OMAV is alwaysfocusing on the satisfactionofhiscustomers and wantstobeeven more closetothem. • Forthisreasonwebelievethatisstrategictohave a wellorganizedaftersales office. Wehave a unit in OMAV withdedicated people whofollow up the customersfrom the starting project up to the aftersales. Thenwehaveestablishedtwootherunits: • OMAV FOSHAN forourChinesecustomers • OMAV NORTH AMERICA for the American market, withdedicated people on the service and aftersales. • Webelievethat the resultsthatwehavealreadyreachedwillbe a beginningforevenbetterlong-termresultswith the mainobjectivestosatisfyourcustomers. OMAV’s CHALLENGE FOR THE FUTURE

  29. THANK YOU FOR YOUR ATTENTION We are availableforanyquestions or anyadditional information

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