KS10.04 – XK400 RUBBER MIXER INSTRUCTIONS

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KS10.04 – XK400 RUBBER MIXER INSTRUCTIONS

This machine is mainly used for rubber plasticizing, mixing, heat refining and pressing.

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Product overview

Product overview

Technical Specifications

The diameter of the front roller is 400 mm

The working length of the roller is 1000 mm

Roller speed ratio 1:1.27

Line speed of front roller 19 m/min

Maximum roll distance 15 mm

A total feeding amount of 50 kg

Main motorPower 45 KWThe rotation speed is 980 r/minVoltage 380 V

Lubricating mode glycerin

Manual baffle type

Overview of the machine

This machine is a double-roll rubber mixer with new structure. The transmission device is connected by the motor reducer

Apparatus composition

The roller is made of cold-hard alloy cast iron, the working surface hardness is HS68-78, hard and wear-resistant. The roller is a hollow structure, and steam or cooling water can be injected into the inner cavity to adjust the working temperature of the roller.

The roller bearing is mounted on the frame and is a rolling bearing with good wear resistance.

The two sides of the machine are respectively provided with electric adjusting distance devices, according to the requirements of the rubber mixing process to adjust the size of the roller distance. Clockwise rotation, the roller distance decreases, otherwise the roller distance increases.

The rubber plate can be adjusted along the axial direction, in addition to prevent the rubber material from flowing out to both ends, but also can control the width of the pressing.

The heating and cooling device has two spray pipes, which extend into the roller respectively. According to the technological requirements, steam or cooling water can be passed into the inner cavity of the roller, so as to control the working temperature of the roller surface well.

An emergency stop device is arranged on the upper part of the machine. When an accident occurs during operation, the button can be moved and the machine will stop running immediately.

In order to make the roller bearing get good lubrication, glycerin lubrication is used. The reducer and speed ratio gear are lubricated by oil pool.

Pitch control system

The front roller is equipped with a distance adjustment device to adjust the distance between the two rollers, more labor saving.

Installation and test run of the machine

Installation：The correct installation of the machine directly affects the service life of the equipment, so it is necessary to pay attention to the installation quality of the machine.The machine needs to be installed on the cement floor, can also be installed on the floor. Before installation, the installation plane should be levelled first, and then the machine should be levelled. The levelling method refer to the installation levelling datum.When the horizontal error of the machine is too large, the iron sheet can be placed under the base of the machine to make the machine in a horizontal state, the horizontal error is not greater than 0.5/1000 mm.After the installation of the machine, the distance adjustment device is used to make the front roller lightly press the back roller, and make the back roller bearing supporting surface close to the support surface of the frame. The clearance is no more than 0.05mm. The tooth side clearance of the driving gear and the big gear should be uniform and consistent, and there should be no biased bite phenomenon.

Test Run：In order to prevent accidents and ensure the good operation of the machine, test runs are carried out in the following order.Make a comprehensive check on the correctness of the connection of the electrical circuit. The shell of all electrical equipment shall be grounded, and no debris shall be stuck on the outer surface of rollers and gears.Check whether sufficient lubricating oil is added into the reducer and gear housing.Sufficient lubricating oil should be added to the roller bearing.Turn the coupling by hand. Only when there is no abnormal clamping in each part, can the machine be started for test run with electricity.Advanced air load test shall run for no less than 6 hours. During the operation, check the conditions of all parts at any time. The temperature rise of each bearing shall not exceed 20℃, and there shall be no leakage in the seal of each part.Load test can only be carried out after the empty load test condition is good.Load test shall be based on the plasticizing of natural rubber and shall be conducted in three stages.Stage 1 Light load test at 25-50% of rated power for not less than 20 hours. 5.2.7.2 Stage 2 Test at 50-75% of rated power for not less than 20 hours.Stage 3 Test at 100% of rated power for not less than 20 hours.In the process of load test, it is necessary to further check whether the lubrication condition is good, whether the oil circuit is smooth, and whether the bearing is overheated. It can be put into production and use after everything is normal.

Precautions for Operation

The temperature of the roller must be adjusted after the machine is running. Drastic changes in temperature should be prevented to avoid the breakage of the roller. Before heating, the two rollers should be kept at a certain distance so as not to crush the roller surface by thermal expansion.

It is strictly prohibited to put frozen raw glue directly into the roll seam, and the temperature of raw glue is generally controlled at 30-40℃.

In case of emergency during operation, the emergency stop lever should be pulled immediately to stop the machine quickly. In daily use, it can not be compared to a stop switch, so as not to damage the machine.

Keep the two rollers parallel when adjusting the distance to prevent the speed ratio gear from biting off.

After the work is finished, stop the machine operation after the temperature of serving roller drops.

Maintenance and repair

No.	Part of lubrication	Mode of lubrication	Code name	Refueling cycle	note
1	Roller barrel bearing	Lubricating by glycerin	Molybdenum disulfide grease	Multiple or continuous shifts per class	Keep the oil clean
2	Speed reduction machine	Gear gear oil	Advanced extreme pressure industrial gear oil VG320	Change it every six months	Keep the oil clean
3	Speed ratio gear	Machinery oil	VG46 machine oil	Change once a month	Keep the oil clean
4	Pitch adjusting device	Lubricating by glycerin	Molybdenum disulfide grease	Change once a week	Keep the oil clean
Fill lubricating oil in each lubricating part of the machine according to the requirements in the table above.
In order to make the machine work normally and ensure the quality of the rubber mixer, the machine should be made to work in a clean environment and keep the machine itself clean.
The pump station used for thin oil lubrication has oil suction filter and oil return filter, which should be cleaned frequently. When cleaning, unscrew the cap, take out the filter, clean, tighten the cap.
Reduction gear and drive gear and bearing lubrication must be sufficient, the amount of refueling must be above the oil level line of the oil hole.
For the lubrication of speed ratio gear, the oil level should be 20 mm deep into the oil surface of the gear teeth. The lubrication condition can be observed through the sight hole of the speed ratio gear cover to prevent the operation in the case of oil shortage.
The nut and screw of the pitch device are lubricated by filling oil into the capping oil cup, and sufficient lubricating oil should be kept constantly.
During operation, attention should be paid to the cleanliness of the surrounding environment, so as not to bring sundries into the rubber material and damage the machine. If the sundries are mixed with glue, bring it into the machine should immediately pull the emergency stop rod, stop after processing.
After the emergency stop, the glue in the roll seam must be cleared before restarting the machine.
When removing the speed ratio gear, pull out the key first. Do not hit the gear with a hammer.
This specification is a general specification, the specific parameters and configuration shall be carried out according to the contract.