Description:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(Section 10 and Rule 13)

1. TITLE OF THE INVENTION:
AIRFLOW CONTROL SYSTEM FOR AN EXTRUDER

2. APPLICANT:
Meril Life Sciences Pvt. Ltd., an Indian company of the address Survey No. 135/139 Bilakhia House, Muktanand Marg, Chala, Vapi-Gujarat 396191, India.

The following specification particularly describes the invention and the manner in which it is to be performed:

 
FIELD OF INVENTION
[001] The present invention relates to the field of extruders. More specifically, the present invention pertains to an airflow control system for an extruder.
BACKGROUND OF INVENTION
[002] Extrusion is a widely employed manufacturing process within the plastics and polymer industries, wherein raw materials such as plastic pellets, powders, or granules are melted and continuously conveyed through a heated extruder barrel using a rotating screw. The molten material is subsequently forced through a specially designed die to form continuous products, including but not limited to tubes, pipes, films, sheets, profiles, or cables.
[003] In the tube extrusion process, an airflow is introduced into the hollow section of the extruded tube. This airflow serves a critical function: the airflow prevents the soft tube walls from collapsing before solidification, and helps to maintain a stable and consistent internal diameter (ID). Furthermore, the internal air pressure can be adjusted to fine-tune the internal diameter of the extruded tube.
[004] Despite the critical role of airflow in tube manufacturing, conventional extruders typically manage internal airflow manually or through rudimentary mechanical methods. This lack of precise control often leads to suboptimal results. Excessive airflow pressure can cause the molten tube to deform or rupture, while insufficient pressure may result in the collapse of the tube wall or failure to achieve the desired internal diameter.
[005] Thus, there arises a need for an airflow control system for an extruder line that overcomes the problems associated with conventional extruders.
SUMMARY OF INVENTION
[006] The present invention relates to a system for controlling airflow in an extruder. The system includes a regulator configured to regulate supply of airflow to a die head of the extruder, an inspection unit configured to measure one or more attributes of an extruded tube and a control unit coupled to the inspection unit and the regulator. The control unit includes a memory configured to store one or more predefined attributes. The control unit is configured to determine a deviation between the measured attributes received from the inspection unit and the corresponding predefined attributes fetched from the memory. The control unit compares the determined attribute with an allowable tolerance range. The control unit is configured to direct the regulator to adjust the airflow based aforesaid comparison.
[007] The foregoing features and other features as well as the advantages of the invention will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures.
BRIEF DESCRIPTION OF DRAWINGS
[008] The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the apportioned drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale.
[009] Fig. 1 depicts a schematic view of an airflow control system 300 in an extrusion line 100, in accordance with an embodiment of the present disclosure.
[0010] Fig. 2 depicts a cross-sectional view of a die head 112 of an extruder 110, in accordance with an embodiment of the present disclosure.
[0011] Fig. 3 depicts a cross-sectional view of the die head 112 with a regulator 304 in accordance with an embodiment of the present disclosure.
[0012] Fig. 4 depicts a flowchart of a method 400 for controlling the airflow in the die head 112 of the extruder 110, in accordance with an embodiment of the present disclosure.
DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0013] Prior to describing the invention in detail, definitions of certain words or phrases used throughout this patent document will be defined: the terms "include" and "comprise", as well as derivatives thereof, mean inclusion without limitation; the term "or" is inclusive, meaning and/or; the phrases "coupled with" and "associated therewith", as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have a property of, or the like; Definitions of certain words and phrases are provided throughout this patent document, and those of ordinary skill in the art will understand that such definitions apply in many, if not most, instances to prior as well as future uses of such defined words and phrases.
[0014] Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment, but mean “one or more but not all embodiments” unless expressly specified otherwise. The terms “including,” “comprising,” “having,” and variations thereof mean “including but not limited to” unless expressly specified otherwise. An enumerated listing of items does not imply that any or all of the items are mutually exclusive and/or mutually inclusive, unless expressly specified otherwise. The terms “a,” “an,” and “the” also refer to “one or more” unless expressly specified otherwise.
[0015] Although the operations of exemplary embodiments of the disclosed method may be described in a particular, sequential order for convenient presentation, it should be understood that the disclosed embodiments can encompass an order of operations other than the particular, sequential order disclosed. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Further, descriptions and disclosures provided in association with one particular embodiment are not limited to that embodiment, and may be applied to any embodiment disclosed herein. Moreover, for the sake of simplicity, the attached figures may not show the various ways in which the disclosed system, method, and apparatus can be used in combination with other systems, methods, and apparatuses.
[0016] Furthermore, the described features, advantages, and characteristics of the embodiments may be combined in any suitable manner. One skilled in the relevant art will recognize that the embodiments may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments. These features and advantages of the embodiments will become more fully apparent from the following description and apportioned claims, or may be learned by the practice of embodiments as set forth hereinafter.
[0017] The present disclosure relates to an airflow control system (or system) integrated on an extrusion line. The system is configured to regulate the airflow supply to the extrusion die head during the manufacturing of tubes, pipes, or similar hollow profiles through an extrusion process. The system ensures that a controlled and consistent airflow is maintained within the extruded tube as the semi-solid tube exits the extrusion die head, thereby preventing the collapse of the tube walls. The extruded tube is subjected to a cooling process to be solidified. Upon solidification, the attributes such as, internal diameter, external diameter, and, wall thickness, etc. of the extruded tube are measured. If any of these attributes deviate from a predefined tolerance range, the system dynamically adjusts the airflow supplied to the extrusion die head. This real-time adjustment modifies the airflow within the subsequently extruded tube, enabling slight adjustments in the attributes. As a result, the system ensures that the dimensions of subsequent tubes produced after the adjustment consistently fall within the specified tolerance limits.
[0018] The extrusion die head includes one or more inlets to allow compressed air to be supplied within the extrusion die head and subsequently, into the extruded tube to maintain the internal cavity of the tube during the extrusion process. The controlled airflow ensures that the walls of the extruded tube do not collapse or deform due to external forces or gravitational sagging. Further, the controlled application of air pressure enables fine adjustment of the tube’s attributes by carefully modulating the airflow. The airflow exerts an outward force against the inner surface of the extruded tube while the material remains in a pliable, formable state, and minor corrections to the attributes can be achieved.
[0019] Now referring to figures. Fig. 1 depicts a schematic view of an airflow control system 300 for controlling airflow in an extruder 110 of an extrusion line 100. The extrusion line 100 includes the extruder 110, a cooling unit 120, a puller unit 130, and a conveyor unit 140 arranged sequentially along a production line. The extruder 110 is configured to melt a raw polymer material and shape it into a tubular profile. The extruder 110 includes a die head 112 for extruding a tube; the molted raw polymeric material is continuously pushed through the die head 112, referred to as an extruded tube. As the extruded tube exits the die head 112, the extruded tube is directed into the cooling unit 120, where rapid cooling induces crystallization and stabilizes the extruded tube's shape and dimensions. The solidified extruded tube is then pulled by the puller unit 130 from the cooling unit 120. The puller unit 130 maintains tension and regulates the extrusion speed of the extruder 110. Finally, the extruded tube is delivered onto the conveyor unit 140, which transports the extruded tube at a consistent, controlled rate, ensuring production uniformity and minimizing the risk of stretching or deformation.
[0020] The airflow control system 300 (interchangeably referred to as a system 300 hereafter) is integrated into the extrusion line 100. The system 300 is configured to control the airflow of the die head 112. The system 300 includes, without limitation, an inspection unit 302, a regulator 304, and a control unit 308. The inspection unit 302 is positioned along the production line. In an embodiment, the inspection unit 302 is provided on the puller unit 130. The inspection unit 302 is configured to measure one or more attributes of the extruded tube in real time, such as without limitation, an inner diameter, an outer diameter, a wall thickness, an ovality or roundness of the extruded tube, or a surface quality or smoothness of the extruded tube or puncture.
[0021] In an embodiment, the inspection unit 302 includes a support frame mounted along a central axis of the extrusion line 100. The support frame includes an annular ring, which encircles the extruded tube path, and a mounting base structurally coupled to the annular ring to provide stability and support. In an embodiment, the inspection unit 302 includes one or more sensors arranged around the periphery of the annular ring to perform non-contact measurement and detection of the extruded tube. The one or more sensors are configured to measure one or more attributes of the extruded tube in real time. The one or more sensors may include a laser gauge, an ultrasonic gauge, an optical sensor, or any combination thereof. In an embodiment, the one or more sensors include at least one laser gauge and at least one optical sensor. The laser gauge is configured to measure one or more attributes. The one or more attributes include without limitation, an inner diameter, an outer diameter, a wall thickness, and an ovality or roundness of the extruded tube, or a surface quality or smoothness of the extruded tube or puncture, etc. The optical sensor is configured to detect scratches, bubbles, burn mark, contamination or discoloration, burrs, rough edges, hole, and perforation, etc. The sensor is configured to transmit the measured attributes to the control unit 308.
[0022] The regulator 304 is provided on and is fluidically coupled to the extruder 110 using a hose 305 (shown in Fig. 1). As used herein and throughout the description, the term fluidically coupling refers to a connection interface between the regulator 304 and the extruder 110 that enables the flow of a fluid, such as air, gas, or liquid, from the regulator 304 to the extruder 110. The regulator 304 is configured to regulate supply of airflow to the die head 112 of the extruder 110. The regulator 304 is configured to regulate the airflow parameters, such as flow rate and pressure, within the die head 112 of the extruder 110. The regulator 304 may include a mass flow controller, servo-controlled pneumatic regulators, or electropneumatic valves, which maintain a constant mass flow rate regardless of changes in upstream or downstream pressure and enable rapid response to fluctuations in process parameters, thereby improving process stability. The type and specification of the regulator 304 may vary based on the application requirements, such as the type of polymer material being extruded, the target tube geometry, and the throughput rate.
[0023] In an embodiment, the system 300 includes a display unit 135 coupled to the control unit 308 and positioned at a desired position to ensure easy accessibility and visibility for an operator. The display unit 135 is includes a user interface that enables the operator to input or modify the predefined data of the extruded tube, such as dimensional, quality threshold, or sorting criteria. The display unit 135 is configured to display real-time and historical data related to the extruded tube, including, but not limited to, measurements, inspection outcomes, and processing status. The display unit 135 may include, without limitation, a human-machine interface (HMI), a touchscreen panel, a programmable logic controller (PLC)-based graphical interface, a graphical LCD or LED panel, or an integrated control panel featuring either physical buttons or a touchscreen interface. In an embodiment, the display unit 135 is a human-machine interface (HMI) providing both representation and editing capabilities. The HMI enables the operator to configure and manage system parameters intuitively. The predefined data displayed are user-configurable through the display unit’s interface, facilitating operational flexibility and customization based on specific extrusion requirements.
[0024] The control unit 308 is operatively coupled to the inspection unit 302 and the regulator 304. As used herein and throughout the description, the term operative coupling refers to a connection between two or more components such as they functionally cooperate, such as the coupling of the control unit 308 with the inspection unit 302 and the regulator 304, enabling them to interact, communicate, or control one another either directly or indirectly. Such coupling may be established through physical connections such as electrical wiring, wireless communication interface, software-based interactions, or any combination thereof.
[0025] The control unit 308 is configured to receive real-time measured attribute data from the inspection unit 302. Further, the control unit 308 is configured to compare the received attribute data with a one or more predefined attribute data stored in the control unit 308. The one or more predefined attribute data may include, but are not limited to, physical and dimension values, allowable deviation range, and historical dimension range data, etc. Based on the comparison, the control unit 308 generates and transmits one or more control signals to the regulator 304 to correct the respective attributes of subsequent tubes to be extruded. The control unit 308 orchestrates and synchronizes the overall operation of the system 300, including initiating inspection, controlling the pulling speed, executing precise cutting, and directing the sorting of the extruded tube.
[0026] The control unit 308 includes a processor (not shown) and memory (not shown) coupled to the processor. The memory may include various types of storage, such as read-only memory (ROM), random-access memory (RAM), flash memory, or hard disk drives. In an embodiment, the memory is configured to store one or more predefined attributes of the extruded tube, including measured attributes of the extruded tube and allowable deviation range, analysis algorithms, and historical data for trend analysis and predictive maintenance, and previously measured attributes of the extruded tube over a period of time, etc. In an embodiment, the processor may be a microcontroller, microprocessor, application-specific integrated circuit (ASIC), or any other suitable computing device. The processor is configured to execute the instructions associated with various functions of the control unit 308.
[0027] The control unit 308 continuously compares real-time measured attributes of extruded tube received from the inspection unit 302 with the corresponding predefined data stored in the memory. Based on the comparison, the control unit 308 is configured to determine a deviation between the measured attributes and corresponding predefined attributes of the extruded tube stored within the control unit 308. The control unit 308 is configured to determine the deviation between the measured attributes and the predefined attributes by comparing the measured attributes against the predefined attributes. When the deviation is determined, the control unit 308 further evaluates whether the deviation exceeds a predefined allowable tolerance range or not. If the measured attributes are within this tolerance range, the control unit 308 is not required to make any adjustments to extrusion process. However, if any of the measured attributes deviate from the allowable tolerance range, the control unit 308 is configured to direct the regulator 304 to adjust the airflow supplied to the extrusion die head based on the comparison of the determined deviation and the allowable tolerance range. That is, when the deviation surpasses or falls below the predefined allowable tolerance range, the control unit 308 generates and transmits a corrective signal to the regulator 304. This control signal includes instructions to either increase or decrease the airflow to correct respective attributes of the tube to be extruded, depending on the nature and direction of the deviation (explained below). Upon receiving the corrective signal, the regulator 304 accordingly increases or decreases the airflow within the die head 112 to ensure that attributes of subsequent tubes to be extruded fall within the acceptable range.
[0028] The variations in airflow directly influence the one or more attributes of the subsequent tubes to be extruded due to internal pressure created within a lumen of the tube. This internal pressure affects the dimensions of the subsequent tubes to be extruded. For example, an increase in airflow raises internal pressure, leading to an expansion of the inner diameter of the subsequent tubes to be extruded while a decrease in airflow reduces internal pressure, resulting in contraction of the internal diameter of the subsequent tubes to be extruded. For instance, when the measured inner diameter of the extruded tube is smaller than the predefined inner diameter, the control unit 308 instructs the regulator 304 to increasing the airflow within the die head 112. This increase in air flow elevates internal pressure, causing the inner diameter of the subsequent tubes to be extruded to increase.
[0029] Conversely, for instance, when the measured inner diameter is greater than the allowable tolerance range, the control unit 308 instructs the regulator 304 to decrease the airflow within the die head 112, thereby reducing the internal pressure causing the inner diameter of the tubes extruded post aforesaid adjustments.
[0030] It is to be noted that while the control unit 308 determines adjustments to airflow for subsequent tube extrusion cycles basis the current tube extrusion cycle, the inspection unit 302 continues to measure the internal diameter to verify whether the internal diameter of the extruded tube at a given point in time, is within the allowable tolerance range or not. If the measured internal diameter is outside the allowable tolerance range after the adjustment, the control unit 308 continues to adjust the airflow through the regulator 304 until the measured internal diameter is within the predefined allowable tolerance range.
[0031] In an exemplary extrusion process, a predefined internal diameter of the extruded tube is set to be 5.00mm. The inspection unit 302 detects a real-time internal diameter of 4.85mm. Upon comparison, the control unit 308 determines a deviation of negative 0.15 mm. An allowable tolerance range for the internal diameter is set to be ±0.10 mm. The control unit 308 compares the determined deviation with allowable tolerance range. Since the deviation falls below the allowable tolerance range, the control unit 308 generates a control signal instructing the regulator 304 to increase the air flow into the die head 112. This increases the magnitude of the pressure exerted by the air on an internal surface of the subsequent tubes to be extruded, causing a slight outward expansion of the subsequent tubes to be extruded. As a result, the internal diameter of the subsequent tubes to be extruded, increases. Subsequently, the inspection unit 302 again measures the internal diameter of the extruded tube to verify whether it falls within the acceptable tolerance range. If the internal diameter remains outside the allowable tolerance range after the aforementioned adjustments, the control unit 308 continues to adjust the airflow through the regulator 304 until the measured internal diameter is restored within the predefined allowable tolerance range.,
[0032] In another exemplary extrusion process, a predefined internal diameter of the extruded tube is set to be 5.00 mm. The inspection unit 302 detects a real-time internal diameter of 5.20 mm. Upon comparison, the control unit 308 detects a deviation of positive 0.20 mm. An allowable tolerance range for the internal diameter is set to be ±0.10 mm. The control unit 308 compares the detected deviation with allowable tolerance range. Since the deviation exceeds the allowable upper limit, the control unit 308 generates a control signal instructing the regulator 304 to decrease the airflow into the die head 112. This reduces the magnitude of the internal pressure exerted on an internal surface of the subsequent tubes to be extruded, resulting in a slight inward contraction of the tube walls. Consequently, the internal diameter of the subsequent tubes to be extruded decreases, thereby restoring the internal diameter of the subsequent tubes to be extruded within the acceptable tolerance range.
[0033] The predefined allowable tolerance range may be determined based on factors such as product specifications, process capability indices, material behavior under pressure, and end-use requirements. The system 300 ensures stability by avoiding frequent or unnecessary adjustments, maintaining consistent airflow conditions, and minimizing the risk of overcorrection during continuous extrusion operations.
[0034] Additionally, the control unit 308 is configured to continuously monitor the rate of change of the measured attributes over time. A sudden or unexpected fluctuation in attributes of the extruded tube, such as a sharp drop in wall thickness or an abrupt change in roundness, triggers the control unit 308 to flag an operational anomaly. In such cases, the control unit 308 transmits a control signal to the regulator 304 and/or triggers an alert to notify the operator via the display unit 135 or sound generation. The control signals generated by the control unit 308 are configured to instruct the regulator 304 to increase or decrease the airflow supplied to the die head 112 based on the nature and direction of the detected deviation.
[0035] The control unit 308 is further configured to analyze trends by comparing current real-time measured data with historical data stored in memory, enabling the detection of potential process drift or gradual equipment degradation. The historical data may include records of previously measured attributes of extruded tubes, corresponding airflow rates, deviation values, adjustment commands issued, the frequency of such adjustments and so forth. To support this predictive analysis, the control unit 308 comprises an integrated machine learning module that leverages historical extrusion data and operational parameters for intelligent, adaptive control. The integration of a machine learning module optimizes control parameters and airflow settings based on both historical and real-time extrusion data. The machine learning module continuously learns from past deviations and corresponding corrective actions, enhancing the system's 300 ability to anticipate issues before defects occur. This proactive, data-driven approach enables more precise and timely airflow adjustments, leading to improved extrusion quality, increased process efficiency, and enhanced responsiveness of the system 300 over extended production cycles.
[0036] Fig. 2 depicts a cross-sectional view of the die head 112. The extrusion die head 112 includes a die 203 and a tip 205 arranged concentrically, defining an annular extrusion passage 209 between an inner surface of the die 203 and an outer surface of the tip 205. The molten material is forced through this annular passage, forming a continuous tubular structure as the molten material exits the extruded die head, thereby creating the extruded tube.
[0037] The die head 112 includes at least one or more inlet port 201 configured to receive air (compressed air). The inlet ports 201 are disposed at a predefined location of the die head 112. In an embodiment, the inlet ports 201 are positioned diametrically opposite to each other, extending towards an internal cavity 210 of the tip 205 of the die head 112. In an embodiment, each inlet port 201 extends towards the internal cavity 210 of the die head 112 from an outer surface of the die head 112, effectively forming a passage from the outer surface to the internal cavity 210 of the extrusion die head. The inlet port 201 allows compressed air to be introduced into the internal cavity 210 of the tip 205. As a result, the compressed air flows into the hollow interior of the extruded tube immediately upon its formation at the annular extrusion passage 209, helping to maintain the tube's shape and prevent wall collapse during the critical cooling stage.
[0038] The inlet port 201 and the regulator 304 are fluidically coupled via a connector 207 the connector 207 is coupled to the hose 305 of the regulator 304. As depicted in Fig. 3, an inlet port 201 is fluidically coupled to the regulator 304 via the connector 207. The other inlet port 201 is coupled to one or more sensors, such as a pressure sensor or a temperature sensor. The sensors are configured to measure the internal air pressure and/or temperature within the extrusion die head during operation. Alternatively, both the inlet ports 201 may be coupled to the regulator 304 through respective connectors 207.
[0039] Fig. 4 illustrates a flowchart of a method 400 for controlling airflow in the die head 112 of the extruder 110, according to an embodiment of the present disclosure. The method 400 ensures real-time control of the airflow supplied to the die head 112 of the extruder 110. The air flow control is based on continuous monitoring and evaluation of the extruded tube's attributes. The precise control of the airflow in the die head 112 maintains consistent product quality and dimensions. The method 400 is executed by a control unit 308, a regulator 304, and an inspection unit 302.
[0040] At step 402, the inspection unit 302 measures one or more attributes of the extruded tube using one or more sensors, such as, without limitation, inner diameter, outer diameter, wall thickness, ovality, surface smoothness, or puncture presence. These attributes are captured in real time as the extruded tube exits the die head 112 of the extruder 110.
[0041] At step 404, the control unit 308 continuously receives the measured attribute data from the inspection unit 302 in real time. This data may be analog or digital signals converted into processable values.
[0042] At step 406, the control unit 308 compares the received measured real-time attribute with a corresponding predefined attribute. The control unit 308 retrieves the predefined attribute values stored in the memory, representing the desired specification range for each measured attribute. The processing unit compares the received data with the predefined values to assess conformity.
[0043] At step 408, the control unit 308 determines whether a deviation outside the allowable tolerance limit is present between the measured attributes and the predefined attributes.
[0044] At step 410, in response to when the deviation exceeds or subseeds the predefined allowable tolerance range, the control unit 308 generates a corrective signal including instructions to either increase or decrease the airflow, depending on the nature and direction of the deviation.
[0045] At step 412, the control unit 308 transmits the corrective signal to the regulator 304 to adjust the airflow within the die head 112 to restore the attributes of the subsequent tubes to be extruded within the acceptable range as explained above.
[0046] The present disclosure offers several significant advantages over conventional airflow control systems used in extruders. The present system provides a closed-loop, real-time control mechanism for regulating airflow within the extruder, thereby ensuring improved dimensional accuracy and enhanced quality of the extruded tube. The system effectively minimizes product non-conformities and material wastage by continuously evaluating one or more attributes of the extruded tube and dynamically adjusting the airflow supplied to the extrusion die head based on detected deviations. The system enables immediate corrective action via real-time comparison of tube attributes against threshold values, to adjust the attributes of the subsequent tubes to be extruded to significantly reduce material wastage, running downtime and enhances process stability.
[0047] Operational efficiency of the system is further improved by the integration of a machine learning module that optimizes control parameters and airflow settings based on both historical and real-time extrusion data. The system also allows flexible operation through a user-friendly interface for modifying attribute thresholds and supports process traceability and continuous improvement with its historical data storage capabilities. Its compatibility with a variety of sensor types, including laser micrometers, ultrasonic gauges, and optical sensors, enables versatile deployment across diverse extrusion applications, ensuring reliable performance and high product consistency.
[0048] The scope of the invention is only limited by the appended patent claims. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings of the present invention is/are used. , C , Claims:WE CLAIM
1. A system (300) for controlling airflow in an extruder 110, the system 300 comprising:
a. a die head (112) for extruding a tube;
b. a regulator (304) configured to regulate supply of airflow to the die head (112) of the extruder 110;
c. an inspection unit (302) configured to measure one or more attributes of the extruded tube; and
d. a control unit (308) coupled to the inspection unit (302) and the regulator (304);
e. wherein the control unit (308) is configured to determine a deviation between the measured one or more attributes received from the inspection unit (302) and corresponding predefined attributes stored within the control unit (308);
f. wherein the control unit (308) is configured to compare the determined deviation with an allowable tolerance range; and
g. wherein the control unit (308) is configured to direct the regulator (304) to adjust the airflow based aforesaid comparison.
2. The system (300) as claimed in claim 1, wherein one or more attributes comprise an inner diameter, an outer diameter, a wall thickness, and an ovality or roundness of the extruded tube, or a surface quality or smoothness of the extruded tube or puncture.
3. The system (300) as claimed in claim 1, wherein the system (300) comprises a display unit (135) coupled to the control unit (308), the display unit (135) configured to display real-time and historical data related to the extruded tube.
4. The system (300) as claimed in claim 3, wherein the display unit (135) comprises a user interface configured to enable an operator to input or modify the predefined attributes stored in the memory.
5. The system (300) as claimed in claim 1, wherein the control unit (308) comprises a memory configured to store data including predefined data, historical data, and previously measured attributes of the extruded tube over a period of time.
6. The system (300) as claimed in claim 1, wherein the control unit (308) is configured to determine the deviation between the measured attributes and the predefined attributes by comparing the measured attributes against the predefined attributes.
7. The system (300) as claimed in claim 1, wherein the inspection unit (302) comprises one or more sensors configured to measure one or more attributes of the extruded tube.
8. The system (300) as claimed in claim 6, wherein the one or more sensors include a laser gauge, an ultrasonic gauge, an optical sensor, or any combination thereof.
9. The system (300) as claimed in claim 1, wherein the control unit (308) comprises a machine learning module trained to optimize the airflow settings based on historical and real-time extrusion data.
10. The system (300) as claimed in claim 1, wherein the regulator (304) in response to receiving a corrective signal from the control unit (308) to increases or decreases the airflow supplied into the die head 112.
11. A method (400) for controlling airflow of an extruder (110), the method (400) comprising:
a. measuring, by an inspection unit (302), one or more attributes of an extruded tube in real time;
b. receiving, by a control unit (308), one or more attributes measured by the inspection unit (302);
c. comparing, by the control unit (308), the measured one or more attributes against a predefined attributes stored in a memory;
d. determining, by the control unit (308), whether a deviation exists between the measured attributes and the predefined attributes of the extruded tube or not;
e. generating, when the deviation exceeds or subseeds the allowable tolerance range, a corrective signal by the control unit (308); and
f. transmitting, by the corrective signal, the control signal to a regulator (304) to adjust the airflow within a die head (112).