Rubber Belt Production Line
A. Hydraylic Vulcanizing Press XLB900X5000X2-1350ton
Date: March 7, 2015
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Description
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Hydraulic Vulcanizing Press XLB900x5000x2-1350ton
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Remark
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Quantity of heating plates
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3
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Floor
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2
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The sizes of plates, mm
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900mm x 5000mm x 80mm
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Heating method of heating plate
/ heating power
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Electricity heating
72kw / pc x 3pcs = 216kw
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The max T. °C.
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250°C
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Moving speed of heating plate
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12mm/S
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Clamping time
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50”
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Parallelism and planeness
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≤0.06 mm
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Roughness of a working surface of plates
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Ra≤1.6a (2.5 μm)
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Regulation of temperature with accuracy
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±5°C
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The maximal effort of compression of plates, tn.
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1350ton
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Max. Pressure of plate per square centimeter
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30kg/cm2
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The effort press should be adjustable
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From 10 ton-1350 ton
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Course/Diameter/Number of plunger
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300mm /φ450mm / 5pcs
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Gleam between plates, mm.
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600mm
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Structure
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Frame structure
Carbon steel Q235A，thickness 40mm
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PCL automatic control
(OMRON PLC)
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Automatical clamping, opening and stop, automatic pressure and temperature control, exhaust, vulcanizing timing etc. In English.
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Weight, kg
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59.00 tons
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Dimension（mm）
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L1600x W5000x H2900mm
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B. Calender XY3F-360x1120 and auxiliary equipment
ⅠTechnical parameter
1. Calender XY3F-360x1120
The calender XY3F-360x1120 is used for calendaring rubber sheet, frictioning on fabric, rubberizing, rubber and fabric (rubber and rubber) duplicating.
1.1 main parameter
(1) diametr of roll……………………………φ360mm
(2) width of roll…………………………… 1120mm
(3) lind speed of roll ……………………0～30m/min
(4) roll gap regulation range…………………0～30mm
(5) width of product ………………………… ≤850mm
(6) thickness of product…………………… 0.3～4.0mm
(7) power of main motor……………………18.5KW / 22KW
rotating speed…………………………… 1000rpm
(8) power of roll gap regulation motor……………………1.5KW
rotating speed………………………………………………1440rpm
1.2 structure
It has base, machine frame, rolls, motors, reduers, roll gap regulation device, axis crossing device, baffle regulation device, dry lubrication device, hydraulic system, temperature control system and main parts. The rolls are arranged with type “Γ”, see general assembly drawing.
(1)The roll is hollow roll, the heating medium or cooling medium can be passed through for heating or cooling. The material of roll is chilled alloy iron cast, fine polishing process (RA0.8), surface is smooth and has the high hardness（HS68-72）and great wear resistance.
(2)The driving system: the motor drive the reducer, three output shaft of reducer drive rolls to rotate oppositely through the crossed universal coupling. The speed ratio between rolls can be customized according to the requirement of user.
(3)The temperature control device: there is the bidirectional inlet and return rotary joint is assembled on the end of roll. The hot and cold medium enters into the surrounding holes of roll for itinerant work through the rotary joint. The actual temperature is controlled through controlling external temperature, medium, flow. The user can order the extra cold and hot source and temperature controller and flow controller by themselves or from the manufacturer of calender together.
(4)Roll gap regulation device: there is a set of electric roll gap regulation device on tow sides of 1# roll and 3# roll separately. The roll can be regulated independently or at the same time inside guide rail of machine frame.
(5)Axis crossing regulatory device: there a set of axis crossing regulation device on 1# roll and make 1# roll can cross deflect move relatively 2# roll within the plane of 60 degrees with the horizontal through the axis crossing regulation device. In this way, it can reasonably compensate different deflections which maybe generate during roll calender to produce different rubber sheet. The main structure consist of the mechanical drive, hydraulic cylinder opposite balance lock and self aligning device. The mechanical drive consist of AC speed regulating motor AC380V、0.75KW（5—50HZ）+ cycloidal pin gear worm speed reducer + alloy screw + helical pair + spherical filler block; the opposite lock hydraulic cylinder isφ90/d45, the hydraulic thrusting and mechanical drive part lead the balance force and achieve the performance of axis cross regulation together.
(6)lubrication system
a. Bearing of roll lubrication: grease lubrication. Full the grease into every bearing when install the machine, and the independent grease pump station supply the bearing lubrication, the grease can be increased regular for ensuring the better bearing lubrication.
Gap regulation device lubrication: full grease between gap regulation nut and screw pair, between the head of gap regulation screw and gap regulation worm gear pair; cycloid pin wheel reducer is oil immersed lubricating.
Lubrication form
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Lubrication
position
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Lubrication oil
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oiling
cycle
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Changing cycle
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Model
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Name
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kinematic viscosity
40℃
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Main reducer
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N220
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middle-load industrial gear oil
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198～242mm2/s
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Keep quantitative
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A year
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Gap regulation reducer
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120#
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industrial gear oil
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90~120 mm2/s
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Keep quantitative
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A year
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Gap regulation
worm gear pair
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ZN-2
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sodium base grease
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penetration degree
25°C 265~269
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Keep quantitative
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A year
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Gap regulation
screw
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ZN-2
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sodium base grease
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penetration degree
25°C 265~269
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A week
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A year
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Axis cross
worm gear pair
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ZN-2
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sodium base grease
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penetration degree
25°C 265~269
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Keep quantitative
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A year
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Axis cross screw
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ZN-2
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sodium base grease
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penetration degree
25°C 265~269
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A week
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A year
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Roll bearing
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ZN-2
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sodium base grease
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penetration degree
25°C 265~269
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Keep quantitative
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A year
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Hydraulic station
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N46
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middle-load industrial gear oil
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68mm2/s
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Keep quantitative
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A year
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After the machines is used first 300-600h, release the hydraulic oil inside the hydraulic station and reducer, clean it by kerosene, then inject the new lubrication oil.
(7)The machine frame is welding structure though tempering treatment, keep the structure stable. CNC machining center process and assure the precise with the size. The base is welding structure and tempering treatment.
2. Auxiliary equipment
The auxiliary equipment for calender XY3F-360x1120 is used for rubber product calender, sheet and duplicate.
2.1 constitute
The front part: 4pcs four units rubber unwinding device, cloth coiling device, belt 1, belt 2, duplicating device, cooling device;
The behind the part: 2pcs two units unwinding device and rubber coiling device.
2.2main parameter
(1)rubber unwinding device
rubber unwinding dimension：Φ650×1450mm
rubber sheet and belt pressure：1500kg
course angle：30°
rotating air cylinder：MBC125，行程course 260mm
compressed air：7kg.cm
regulation range：650～1000mm
(2) cloth coiling device
cloth coiling motor：YLJ112M-10-6，10.N.m，900r/min
reducer：TKY-67-10.74-B3-B
cloth coiling dimension：Φ100×1000mm
coiling line speed：30m/min
air compressing through shaft type clutch model：NKC
regulation gas cylinder：MBF100，行程400mm
compressed air：7kg.cm
regulation range：650～1000mm
(3) belt 1
belt motor：YVP132M-4P，7.5KW，1440rpm
reducer：TK87-25-B3-A
line speed：30m/min
size：Length 9800mm，Width 1000mm，Thickness 5mm
(4) duplicating device
duplicating roll motor：YVP112M-4，4KW，1440r/min
reducer：TK77-35.58-B3-A
duplicating roll line speed：30m/min
duplicating pressure：3500kg
air cylinder：CSIC200，行程100
compressed air：7kg.cm
(5) belt 2
belt motor：YVP112M-4，4KW，1440r/min
reducer：TK67-24.26-B3-B
line speed：29.4m/min
size：length 3800mm、4800mm，width 1000mm，thickness 5mm
(6) cooling device
cooling roll size：Φ560×1000mm，4支
cooling roll transmission motor：YVP112M-4，4KW，1440r/min
reducer：TK67-31.73-W
cooling water temperature：18～30℃
cooling water pressure：3kg/cm2
(7) cloth unwinding device
cloth unwinding size：Φ400×1000mm
cloth unwinding damper（Chip: friction plate）
unwinding shaft size：Φ72×1000mm
regulation air cylinder：MBF100，行程400mm
compressed air：7kg.cm
regulation range：650～1000mm
(8)rubber coiling device
rubber coiling size：Φ650×1000mm
pressure of rubber sheet and belt：1500kg
rotating angle：30°
rotation air cylinder：MBC125，行程course 260mm
compressed air：7kg.cm
regulation range：650～1000mm
3. lubrication form
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Lubrication position
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lubrication oil
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Oiling cycle
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换油周期
Changing
cycle
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model
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name
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kinematic viscosity
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reducer
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N220
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Middle-load industrial gear oil
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198～242mm2//s，25℃，265～269
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Keep quantitative
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一年
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bearing
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ZN-2
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grease
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Keep quantitative
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一年
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Gear and chain wheel
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ZN-2
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grease
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Keep quantitative
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一年
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4. model of bearing
4.1rubber sheet unwinding device and coiling device
(1) GB/T276-1994 bearing 60208（40×80×18） 1pc/pc
(2) GB/T297-1994 bearing 33009（45×75×24） 4pcs/pc
(3) GB/T301-1995 bearing 51308（40×78×26） 2pcs/pc
(4) LB80 Linear ball bearing（80×120×165） 2pcs/pc
(5) LB60 Linear ball bearing（60×90×125） 2pcs/pc
4.2 cloth unwinding device and coiling device
(1) GTB50-2/2×760P rolling linear guide 4pcs/pc
(2)GB/T297-1994 bearing 30310（50×110×29.25） 4pcs/pc
(3)GB/T276-1995 bearing 6208（40×80×18） 4pcs/pc
4.3 cooling device
(1) GB288-87 bearing 53520（100×180×46） 8pcs/pc
(2)GB276-89 bearing 210（50×90×20） 2pcs/pc
(3)Z90511 vertical seat bearing 2pcs/pc
(4)TY90511 convex platform round seat bearing 4pcs/pc
(5)323DQW SR-11/2” rotating joint 2pcs/pc
4.4 duplicating device
(1) GB/T288-1994 bearing 22312/w33（60×130×46） 8pcs/pc
5. electric control cabinet
The frequency conversion control is applied for whole production line, inverter is Japan Yaskawa reversible closed loop; PLC programming, low-voltage apparatus is China Zheng tai; touch screen.