Rubber Kneader Machine

Rubber kneader machine is mainly used for plasticizing and mixing of natural rubber and other high polymer elastomers in the rubber industry. The purpose of plasticizing and mixing is to improve the molding function or change the intrinsic properties of the material. Plasticizing is the process of transforming elastic raw rubber into a plastic state. Mixing is divided into master batch mixing and final batch mixing. The master batch is made by putting the plasticized sheet film into the mixing chamber, and then adding carbon black, compounding agent, oil, etc. for mixing in the mixing chamber, so that the material can achieve the required dispersibility, distribution and viscosity. The final batch mixing is to add sulfur into the rubber after mixing to make it evenly distributed in the rubber.

1. Preparations before the dry test

1) The dry test can only be carried out after the foundation is completely dry.

2) Check whether there are foreign materials in various parts of the machine, and whether the connecting parts and fasteners are loose.

3) Check whether the lubricating pipelines and hydraulic pipelines are connected correctly, whether all lubricating and hydraulic oils are suitable, whether the oil level is correct, and whether the lubrication of the lubricating parts is in place.

4) A separate inspection test is required for the auxiliary equipment of the internal mixer before no-load running to verify whether its performance meets the specified requirements.

5) Check whether the cooperation between the electrical equipment and the hydraulic system and air control system is correct.

6) Before connecting the coupling, first run the main motor for 20 minutes. After there is no abnormality, install the coupling and install the protective cover.

7) At the high-speed shaft end of the main reducer or at the coupling, manually turn the transmission system to make the rotor rotate for two weeks, and confirm that there is no abnormality.

2. No-load test run

1) First start each lubricating oil pump and hydraulic station to check whether the oil supply of each part is normal. After the oil pump and hydraulic station work normally for 15 minutes, start the main motor, and check whether the rotating direction of rotor is correct from the water outlet of the mixing chamber. Unload test in user’s plant for more than 12 hours.

2) Turn on the cooling water system and check if there is leakage.

3) In the manual and automatic operation state, the pressing ram, feeding door and discharging door should be opened many times, and the actions should be flexible and reliable.

4) Check the following items during the dry test.

a. The lubrication points of the transmission gear and bearing of the reducer should be fully lubricated, and each sealing part should be well sealed.

b. There shall be no large vibration and periodic noise during operation.

c. During no-load running, the main motor is single-speed, and its power consumption should be less than 15% of the rated power.

d. There should be no sudden rise in the bearing temperature of each part, and the temperature rise of the rotor bearing and the reducer bearing should not exceed 20℃.

e. There shall be no leakage in hydraulic, cooling (heating), air and lubrication piping systems.

3. Load test run

1) After the no-load test run is qualified, the load test run can be carried out. During the load trial operation, each equipment needs to be operated continuously under a continuous load of no less than 20 batches.

2) During the load test run, the rotation speed should be carried out from low speed to high speed respectively, and the soft material should be tested first and then the hard material.

3) During the load trial operation, the amount of compound added gradually increases from 50% and 75% of the working volume to the full load.

4) The machine should have an interlocking device to start the main motor following the lubricating oil pump start. At the same time, the machine should run for 10-15 minutes before loading trial operation.

5) After the last batch of rubber mixing is completed, the machine should be no-load running for 15~20min and then shut down. During no-load running, the section seal lubrication system continues to inject oil into the sealing surface to clean and lubricate the sealing surface.

6) The following items should be checked during load test.

a. Whether the basic technical parameters meet the specified requirements of the machine.

b. The temperature rises of the rotor bearing should not exceed 40℃. The temperature rises of the reducer bearing should not exceed 40℃. The maximum temperature of rotor and reducer bearing is not more than 80℃. The oil temperature in the hydraulic system oil tank is not more than 60℃.

c. The maximum temperature of the fixed ring of the rotor section sealing device is not more than 85℃.

d. The compound discharging temperature (actual measurement) and the sensor display (thermocouple) temperature value should be consistent, and the difference is 3-5℃, or the difference is a constant value.

e. There is no leakage of compound or powder at the sealing part of the rotor section, and the mixture of compound, oil and powder is allowed to leak out.

f. The discharge door should be well sealed without leakage.

g. Electric, hydraulic and other control systems should be flexible, safe and reliable.

h. The temperature control effect of the temperature control system can meet the requirements of the rubber mixing process, and the discharge temperature should be within the allowable range of the process conditions.

After the internal mixer is confirmed to have no abnormality after the load test, it can be handed over for production.

1. Operation and precautions

1) After stopping production of the machine for a long time, the first start should be carried out according to the requirements of the above-mentioned no-load test and load test.

2) Daily start

a. Start the water inlet and drain valves of the cooling system such as the main engine, reducer and main motor.

b. Start the equipment according to the instructions of the electrical control system.

c. During operation, pay attention to check the oil volume of the lubricating oil tank, the oil level of the reducer and the oil tank of the hydraulic station, and ensure that the lubrication of the lubrication point and the hydraulic operation are normal.

d. Pay attention to the operation of the machine, whether the work is normal, whether there is abnormal sound, and whether the connecting fasteners are loose.

3) Precautions for daily operation

a. Stop the machine according to the requirements of mixing the last batch of material while load running. After the main motor stops, turn off the lubricating motor and hydraulic motor, cut off the power supply, and then turn off the air source and cooling water source.

b. In the first week of production, the fastening bolts of each part of the mixer should be tightened at any time, and then check and fasten the bolts one time in a month.

c. When the pressing ram of the machine is in the upper position, the discharge door is in the closed position and the rotor is rotating, the feeding door can be opened to feed compound into the mixing chamber.

d. When the internal mixer stops for some reason during the mixing process, after the fault is eliminated, the main motor can be started only after the compound in the mixing chamber is discharged.

e. The feeding amount of the mixing chamber shall not exceed the design capacity, the current of full-load operation generally does not exceed the rated current, the instantaneous overload current is generally 1.2~1.5 times of the rated current, and the overload time is not more than 10s.

4) Maintenance work after completing the production

a. After the production is over, the mixer can be stopped after 15~20min of no-load running. During no-load running, it is still necessary to lubricate the rotor face seal with oil.

b. When the machine is stopped, the discharge door is in the open position, open the feeding door and insert the safety pin, and lift the ram to the upper position and insert the ram safety pin. Operate the machine in reverse procedure when starting up.

c. Remove the adhering material on feeding door, ram and discharging door, clear the work site, and remove the oil, powder mixture of the rotor end face sealing device.

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