Sensing & control of ConformTM extrusion gap between wheel and tooling plates

The results of an investigation into the automation of the Conform ^TM extrusion process using mechatronic solutions are presented. Conform extrusion is a very versatile manufacturing process, enabling the production of a wide variety of high quality products in continuous lengths. During the extrusion, it is very important to maintain an appropriate gap between the wheel and tooling, in order to achieve product quality. An active gap sensing and control system for improving the Conform extrusion product quality is presented. The gap is measured using an air gauge system and controlled using a hydraulic actuation system. A feedback controller is employed to attain the required gap, specified by the user. Alternative gap sensing and measurement technologies have also been investigated. In particular, research results on an ultrasonic-based gap measurement technique are presented