Improving Reliability and Productivity of an Aluminum Extruder by Implementation of Direct Torque Control Technology

Problem statement: The linear motor drive is widely used in driving an extrusion puller in an aluminum extrusion industry. The main disadvantage of this drive is manual and step-wise torque control. This research was done to replace the linear motor drive by AC drive with direct torque control technology. Approach: Mathematical calculations were carried to select an AC drive which satisfied parameters and values required for production process. Motor rotational speed and torque were calculated from required linear velocity of puller machine and pulling force required for extruded aluminum sections. Results: The suggested AC drive with direct torque control was implemented and installed. It proved higher reliability due to elimination of mechanical problems and wears. Higher productivity was obtained due to flexibility and automation of speed and torque control modes. Conclusion/Recommendations: Implementation of AC drive with direct torque control led to savings in electrical energy consumption, reduction in breakdown and maintenance intervals and improvement of product quality. AC drive with direct torque control was suggested to replace other drive types in all industrial applications were torque and speed modes of control were required.