PVC calendering machine, planetary extruder, internal banbury mixer

Product Overview

Description

PVC Calendering Machine, Planetary Extruder, Banbury or Internal Mixer, Open Mixer, Filtering Machine, Cooling Roller and Auxiliary Machine, Applied for transparent PVC film and other PVC sheet.

 

 

 

 

PVC Calendering Line Equipment List

1.High-speed open mixer of PVC calendering machine

 

1. Main parameter of open mixer:

1-1 Total volume 500×1(L)

1-2 Feeding capacity per turn 100-160kg

1-3 Quantity of agitating vane 2 sets

1-4 Agitating vane rotating speed 0-900rpm

1-5 Heating or cooling mode Self-friction

1-6 Motor power 110KW

1-7 Motor power 110KW

1-8 Discharge hole diameter 250mm

1-9 Bearing of open mixer use tile smelting bearing, electric components adopt joint venture quality products.

1-10 Open mixer main motor's bearing with lubricating mouth

1-13 Open Mixer main motor control adopt French Schneider soft starter.

 

2. Cold blending machine of PVC calendeing machine

 

1-1. Motor of cold blending machine:15KW,AC motor(Automatic control of temperature and time setting);

1-2. Internal barrel is made of SUS304 stainless steel,thickness of 8mm,polishing finished.

1-3. The barrel of cold blending machine has a gas vent

1-4. Cooling water circulation

 

3. Planetary extruder of PVC Calendering Machine

 

1. Main parts of planetary extruder:

1-1. Length of barrel inner gear set is the 1000 mm, there are two stages in planetary screw extrude, one is 1000mm, the other is 500mm. The single main screw with 10 small screws. Locking ring is made of special formula of smelting forging, after heat treatment, with properties of high strength and wear resistance, corrosion resistance.

1-2. Gear box of planetary extruder adopt hard gear, the oil temperature cooling system adopt outer cooling circulation structure, gear box shaft bearing adopt imported famous brand NSK bearing.

1-3. Connection of planetary extruder : oil heating adopting rotary joint, imported seal parts. Main motor shaft and the gearbox high-speed shaft adopt flange type flexible shaft connector. The feed motor shaft and screw adopt the reducer connection.

1-4. Hopper of planetary extruder: hopper is made of stainless steel, equipped with double material level meter.

1-5. Feeding raw material method of planetary extruder is forced feeding type.

1-6. All parts of planetary extruder need to be nitrided finished, adopts gun barrel steel alloy.

2. Heating and cooling section of planetary extruder:

2-1. Barrel temperature is controlled by 2 sections of oil temperature conduction control device, according to the products.

2-2. The main screw temperature is controlled by 1 section of oil conduction temperature control device.

2-3. Cutter(locking ring) and feeding section are equipped cooling structure.

3. Electronic parts of planetary extruder:

3-1. The main motor power: 200 KW AC motor, speed controlled by frequency changer.

3-2. Feeding motor 7.5 KW AC motor, speed controlled by frequency changer.

3-3. Push button operation form, with functions of single control and multi-control.

3-4. An electrical control cabinet of which low voltage apparatus adopt Schneider brand.

4. Output: PVC half hard or soft film extrusion capacity of 1500-1500 kg/h

(slight changes on the basis of different products).

5. 150 metal separator (S+S Germany):optional customized.

 

4. Open Mixer of PVC Film Calendering Machine

 

1. The open mixer main specifications:

1-1. The open mixer main motor: AC 90 KW*6P

1-2. Electronic emergency safety brake

1-3. Lubrication motor of open mixer power: 0.37 KW, with CB-B6 gear pump

1-4. The open mixer roller speed ratio of front and back: 1:1. 22

1-5. Front open mixer roller speed: 21.91 rpm; back open mixer roller speed: 17.92 rpm

1-6. The hard tooth face precision of open mixer's gear box: 6 levels

1-7. Electrical cabinets and operating box of open mixer are separated

2. Body roll wheels of  open mixer 

2-1. Style: hollow roller wheel (Bored Roll) 2 piece

2-2. Material: Alloy Chilled cast iron, surface hardness HS68-72, grinding processing after normalization processing.

2-3. Bearing adopt high temperature resistance, automatic registration of bearing ball 4 piece

2-4. Bearing pedestal adopt cast iron of which after tempering treatment processing, additional lubricating oil hole 4 piece

2-5. Rotary joints and metal hose 2 sets

2-6. The pedestal is welded by structural steel, mechanical processing after the tempering treatment 1 piece

3. Auxiliary and transmission device of  open mixer 

3-1. The drive pedestal welded by structural steel, and integrated processing after tempering treatment 1 piece

3-2. Reduction gear box: double output, sealed lubrication oil bath type 1 set

3-3. The reduction gear and motor adopt flange coupling.

3-4. The reduction gear and roll wheel driven by universal shaft 2 piece

3-5. The gap adjusting range: 0-15 mm 2 units

3-6. Use manually adjust gap, composed of the handwheel guide rod, nut and reduction unit.

3-7. Material blocked by baffle plate (on both sides of the configuration in the roller) 2 units

3-8. The baffle plate adopt cast iron, polished and chrome plating

3-9. Cutters: cutter special steel, cutter holder attached with 3 sets of restructuring 3 sets

3-10. Manually adjust the cutter location

3-11. Tray of material 1 piece

3-12. Brake system: gliding within a quarter circle after braking

4. Lubrication and electrical consol of  open mixer 

4-1. The lubrication system of open mixer : bearing forced lubrication mode 1 set

4-2. Lubrication unit composed of 0.37 KW oil pump, fuel tank, pressure regulating valve, filter oil cooling system etc

4-3. Lube oil pipe in the machine 1 set Part 5.Φ10" filtering machine of PVC Film Calender Line

 

5. Filtering machine of PVC calendering machine

 

1. The filtering machine main specifications:

1-1 Reducer of filtering machine: 315 type hard tooth surface gear box, ratio is 20:1

1-2 Screw of filter machine: 250 diameter, surface roughness Ra0.03, material is 38 38CrMoAl, Nitriding treatment, hollow water cooling, surface hard chromium plating, screw discharging mouth front-end designed of eccentric structure

1-3 Barrel of filter machine: material is gun barrel steel alloy, smooth surface

1-4 Honeycomb plate of filtering machine: stainless steel material, taper hole 10 < 1:10

1-5 Main motor power of filter machine: 90 kw - 4 P/AC

1-6 Electrical control system of filtering machine: 90 KW variable frequency speed governor which can more meet the demand of production process

1-7 Heating mode of filtering machine: high temperature heating oil, 3 section on barrel,1 section on die head.(all independent temperature control) 1-8 Other accessories: hydraulic station 1 unit, electrical control cabinet 1 unit, operating cabinet 1 unit, filter screen 2 sets

1-9 Die head of filtering machine: hydraulic double die head can be used interchangeably, easy to exchange, the die head cavity is finished by hard chrome plating, smooth and non-stick.

 

6. Calendering machine & auxiliaries

 

1. Parameter of Calendering Machine :

1-1. Calendering Machine Roller dimension and quantity:Φ660×2030 mm, 5 piece

1-2. Calendering Machine Roller layout: headstand L

1-3. Calendering Machine production rate:0~60m/min

1-4. Calendering Machine motor power: 1# roller AC90 KW -4P, 2# roller AC110 KW-4P, 3# roller AC110 KW -4P, 4# roller AC110 KW -4P, 5# roller AC90 KW -4P

1-5. Main motor of Calendering Machine adopts Taiwan Datong frequency AC motor, photoelectric encoder feedback.

1-6. Auxiliary transmission motor of Calendering Machine adopt Taiwan Datong frequency conversion motor, photoelectric encoder feedback.

1-7. Speed feedback photoelectric encoder of Calendering Machine adopt Japan Koyo brand.

2. Features of Calendering Machine :

2-1. Calendering Machine Roller adopt chilled alloy cast iron, work surface hardness is HS74±2°. 1#,2#,3#,4#,5# roller are rim drill roller,1#,2#,3# roller surface is finished by cold grinding; 4#,5# roller surface finished by hard chromium plating, grinding after heated to 180 ºC temperature, polishing processing, surface roughness is Ra0.01.

2-2. Calendering Machine Roller heating medium is hot oil, each roller with rotary joints and high-quality metal hose.

2-3. 1#,2#,3# Roller bearings is made by Wafangdian metallurgical bearing group co., LTD, double row taper roller bearings, high precision, high strength, high wear resistance, long service life, resistant to 250 ºC high temperature, bearing body sealing performance is good, ensure no leakage, match with forced lubrication oil pump station. 4 #, 5 # roller bearing adopt U.S. TIMKEN iron bearing.

2-4. 1 #, 2 #, 3 #, 4 #, 5 # roller is driven by five groups of 2.4/1.5 kW double speed motor and gap is adjusted by reducer.

2-5. 4# Roller is installed shaft cross device, structure is electric adjustable pitch,and hydraulic locking system. Maximum cross measure:±25mm (To solve difference of the product thickness)

2-6. Hydraulic station of Calendering Machine adopt Taiwan read brand.

2-7. Once power cut, the roller can be quickly opened by the UPS (uninterruptible power supply) system.

2-8. 5# Calender Machine roller is installed unbending device.

2-9. Using 5 hard tooth surface gear box, driven by 5 cross universal transmission shaft to drive the roller, each roller driven by separate transmission shaft, make each roller speed is adjustable.

2-10. Accumulation material show on the screen display, easy to observe and control calender feeding situation, screen display placed in calender work station.

2-11. Adjusting gap device of Calendering Machine : high and low double section speed control (high precision), low speed:0.72mm/min,high speed: 2.91mm/min.

2-12. Roller gap of Calendering Machine is controlled by Taiwan LVDT measuring instrument.

2-13. The heating medium of Calendering Machine : heat conduction oil.

2-14. Heating raw material device:Frequency conversion control, motor power is 1.5KW, speed is 85m/ min.

3. Calendering auxiliary units:

3-1. Drive off device:

3-1-1. Drive off roll specifications: Φ 195 x 2030 mm / 5 pieces

3-1-2. Drive off roller structure and transmission: Structure: Clipping cavity type heater, surface hard chromium plating, mirror face processing, temperature error is ±1 ºC Transmission: 1 #, 2 # driven by one power, 3 #, 4 #, 5 # driven by one power, 5 of them adopt universal joint transmission Lifting: 1 #, 3 # adopt linear guide, mechanical lifting, 2 # fixed.

3-1-3. With two groups of motor power: AC 4KW-4P Taiwan Datong variable frequency controller, vector control.

3-1-4. The end face attached with 1 1/4 "thread type rotary joints and metal hose.

3-1-5. The roller dynamic and static balance≤0.02kg.

3-1-6. The motor put in the lower part of reducer, in order to lengthen the transmission universal joint, avoid roller run-time speed is not stable.

3-2. Embossing device:

3-2-1. Method: vertical type

3-2-2. Embossing roller adopted mirror roller, surface plating 14 aurora, diameter(Φ240~Φ360)×length 2030mm.

3-2-3. Rubber roller size: Φ320×2030mm(EPDM, Surface including liquid silicone, containing 600 mesh emery)

3-2-4. Embossing roller is controlled by Φ80 oil cylinder

3-2-5. Embossing roller driven by AC7.5 KW Taiwan Datong frequency conversion motor, with vector control.

3-2-6. Attached 1 1/2 " threaded type rotary joints and metal hose.

3-2-7. The roller dynamic and static balance≤0.02kg

3-3. Cooling device:

3-3-1. Cooling roller specification:Φ350×2030mm 21 pieces clipping cavity type,surface finished by hard chromium plating, mirror face processing; roller gap is 10 mm.

3-3-2. Cooling auxiliary power (4 sets) : AC5.5 KW - 4P Taiwan Datong variable frequency motor, vector control, helical gears hardened tooth surface reducer.

3-3-3. Cooling roller linear speed:200M/min

3-3-4. The roller dynamic and static balance≤0.02kg

3-3-5. Attached 1" one-way rotary joints and metal hose.

3-3-6. Adopted hermetic type reducer driving system.

3-3-7. Cooling system gather and distribute water pipe:4 pieces.

3-4. Cold cutting scrap tractor: straight shank type.

3-4-1. Attached scrap edge material traction unit 1 set(AC2.2 KW-4P frequency conversion control, without the encoder feedback)

3-4-2. Configuration of umbrella shape scrap material auxiliary winding roller (chrome plated surface treatment) 3 pieces

3-5. Single wheel surface automatic winder: 200M/min.

3-5-1.Winding roller: Φ450*1,7.5KW,AC Taiwan Datong frequency conversion or Japan Yaskawa frequency conversion control. 3-5-2. Automatic feeding, manual cutting, 3 inflatable shafts.

4. Calentering machine electrical control system

4-1. The whole electrical system is controlled AC system, auxiliary machines frequency inverter adopts Japan Yaskawa with vector feedback.

4-2. Calentering machine electrical control system includes frequency conversion, electric control cabinet and the piano type operating table beside machine.

4-3. The air switch, contactor, button, indicator light adopts Schneider brand, main and auxiliary machines adopt frequency conversion control, frequency converters adopt Japan Yaskawa brand, synchronization accuracy is ±0.5%, other low voltage electrical accessories adopt Schneider products.

4-4. Calendering machine's each unit can run separately, also can run linkage. Work station set up the corresponding high precision digital display which shows on meters (such as main and each auxiliary machines' linear velocity, current, roll gap, roll temperature etc).

4-5. Electrical control system of calendering machine is equipped with protection mechanical interlock control. Only when the lubrication station, preload oil pump, gear pump, cooling motor are in normal condition, calender machine frequency conversion motor start, and while the calenter machine main frequency conversion motor start, lubrication station, preload oil pump, gear pump, cooling motor cannot be closed.

4-6. Calendering machine each operating post has stop device to protect the safety of the machine and personal.

 

7. Internal mixer or banbury mixer of PVC Calendering Machine   

 

1.Internal mixer or banbury mixer features

1.1.The banbury mixer or internal mixer of the plastics and rubber industries is the internal mixer, in which heat and pressure are applied simultaneously.

1.2.The Banbury mixer resembles a robust dough mixer in that two interrupted spiral rotors move in opposite directions at 30 to 40 rotations per minute.

1.3.The shearing action is intense, and the power input can be as high as 1,200 kilowatts for a 250kg (550-pound)

 

2.Internal mixer or banbury mixer priciple

2.1The banbury mixer is a type of industrial machine that’s able to force the cohesion of heavy rubbers and plastics, things that wouldn’t normally blend together without a lot of pressure and energy.

2.2 Its operation is pretty straightforward.

2.3 The internal mixer has a roughly cylindrical shape with a large hopper into which all the ingredients and additives are poured or placed; then, a series of rams and rotators compress the materials while pressure builds and the hopper begins to spin.

2.4 In most cases heat is also an important element, both through natural friction and external supply.

 

8.Conveyer belt of PVC Calendering Machine

 

Quantity:3 set

1.PE250 planetary extruder→SK660X2500

The open mixer mills: 1 set

The width B = 200 conveyer belt

The motor without feedback, reducer with AC1.5 KW variable frequency controller.

Main components put in the planetary extruder in mechanical and electrical control cabinet, operated in operating station of planetary extruder.

2.SK660X2500

The open mixer mills→Φ250 filtering machine 1 set

The width B = 200 conveyer belt

The motor without feedback, reducer with AC1.5 KW variable frequency controller.

Electrical control put in mixing mills' electric control cabinet, the main components put in mechanical and electrical control cabinet of mixing mills.

3.Φ250 filtering machine→LD-5ΓΦ660×2030 calenter machines 1 set

The width B = 200 conveyer belt The motor without feedback, reducer with AC1.5 KW variable frequency controller.

Swing supporting reducer mechanical motor: 0.75kW

Electrical control put in filtering machine's electric control cabinet, the main components put in mechanical and electrical control cabinet of filtering machine.

 

9. Temperature control device of PVC Calendering Machine

 

Quantity: 12 sets

1. Main parameters: 1)Control valve adopt the A&D tee electric proportional valve, electric actuator adopt Baelz of Germany. Temperature control meter adopt Germany baelz6490B-y thermometer.

2..Circulating pump adopts heat conduction oil pump of Wujin NO.1 pump factory, high efficiency and low noise.

3.Circulating pump motor adopts Siemens brand.

4.Cooling device adopt air cooling device with conduction oil radiator.

5.Manual valve adopts high-quality corrugated pipe stop valve.

6.Circulation pump oil outlet installed 1.6 Mpa pressure gauge.

7.Check valve adopts lift check valves of Gemany standard.

8.Electric valve adopts the DN25 / PN16.

 

10.PVC calender line end products sample