Two rotors continuous mixing granulator unit...Brief Introduction The Institute of rubber and...
Transcript of Two rotors continuous mixing granulator unit...Brief Introduction The Institute of rubber and...
Two rotors continuous mixing granulator unit
Rubber and plastic mechanical engineering research center of East China University of Science and Technology Shanghai Nanan Machinery Manufacturing Co., Ltd.
第 1 页 共 21 页 No.130, Meilong Road, Shanghai
TEL:(021)64252363
Email:[email protected]
І. Brief Introduction
The Institute of rubber and plastic engineering research of East China University of Science and
Technology is a research center with high reputation at home and abroad specializing in the molding
processing and equipment of polymer materials. It is composed of many famous doctoral tutors,
professors, doctorate and Masters from home and abroad, and has achieved a number of research
results with international advanced level. Under the support of the National Natural Science Foundation,
the 863 plan and the major special project of Shanghai, the center has developed the Two rotors
continuous mixing granulator equipment in the last 10 years. This equipment could provide strong
filling, dispersion and mixing ability, combining the characteristics of the excellent mixing of the mixer
and the continuous work of the twin screw extruder. Moreover, it has reached the international advanced
level, and passed the technology identification of the China Petrochemical Corp, Jiangsu provincial
science and Technology Department, the State Ministry of education and other organizations,
respectively. The continuous mixing granulation sets has been popular due to its excellent, stable mixing
performance, low energy consumption ratio, high cost performance and good pre and after sales service.
It owes 6 national invention patents and has been evaluated as the national key high-tech new product in
2002 and the second prize for science and technology progress in Shanghai in 2012, and listed in the
national “first (set) extension and application catalogue of major technical equipment”, “development
plan of light industry (2016 - 2020)”, the national development and Reform Commission “high efficiency
and energy saving technical recommendation catalogue”.
This equipment has been purchased for research and production of rubber and plastic blends,
halogen free flame retardant cable materials, high concentration color master-batch, new micro/nano
new materials by many enterprises, research institutes and universities including Beijing University of
Chemical Technology, Xi'an Jiao Tong University, DuPont (China) R & D center, Guangdong Shantou
Rainbow plastic fiber salad factory, Shanghai Wan Yi polymer material Co., Ltd., Suzhou Guo Jia
Polymer Technology Co., Ltd., Zhejiang Ma macromolecule material limited company, golden hair
Technology Co., Ltd., ShunDe yong and so on.
Rubber and plastic mechanical engineering research center of East China University of Science and Technology Shanghai Nanan Machinery Manufacturing Co., Ltd.
第 2 页 共 21 页 No.130, Meilong Road, Shanghai
TEL:(021)64252363
Email:[email protected]
ІІ. Size and Technical index
1—motor(mixer) 2—motor(extruder) 3—gear box 4—gear box(extruder)
5—mixer 6—extruder(heat feed)
Model ECM1000S
mixer
Rotor nominal diameter
(mm)
130
Rotor maximum speed(rpm) 500
Main motor powe(kw) 200
extruder
Screw diameter(mm) 180
Screw length diameter ratio 12
Screw maximum speed(rpm) 88
Motor power(kw) 90
Motor speed regulation AC
Nominal total power(kw) 420
Shape size (length*width*height)(mm) 6600×2000×2800
weight(ton) 15
Rubber and plastic mechanical engineering research center of East China University of Science and Technology Shanghai Nanan Machinery Manufacturing Co., Ltd.
第 3 页 共 21 页 No.130, Meilong Road, Shanghai
TEL:(021)64252363
Email:[email protected]
ІІІ. Configuration and Indicators
1. continuous mixing extrusion system
1.1 continuous mixer
1.1.1 The distribution gear box adopts the high-precision hardened gear, the maximum working speed is
500 rpm;
1.1.2 The rotor nominal diameter is 130mm, uses segmented double mixing section structure, high tensile
chaotic M2 rotor, when replacing the rotor doesn’t need to remove bearings; The rotor material is made
of high quality alloy steel, and the surface is welded with cemented carbide and nitriding;
1.1.3 The barrel adopts split structure, which is convenient and thorough. The cylinder material is made
of high alloy steel, the inner liner is made of imported carbide steel S600, and the surface hardness is
HRC62 with excellent wear resistance;
1.1.4 The exhaust port adopts the original air pressure automatic cleaning valve to solve the blockage
problem of the exhaust port;
1.1.5 The motor adopts SIEMENES variable frequency motor, 110kW power and ABB ACS550-01-
363a-4(200KW-380V) governor;
1.1.6 Using surface sprayed special coating on the discharge door contact with the material;
1.1.7 The barrel is divided into two sections to control the temperature. The imported high efficiency
electric heater is used for heating and water cooling.The core of the core is cooled by water;
1.1.8 The SKF brand products are used for all bearings and sealing elements;
1.2 The melt extruder
1.2.1 The single screw reduction gear box adopts high precision hardened gear box produced by Jiangyin
gear box factor;
1.2.2 The motor adopts SIEMENES variable frequency motor, power 90kw and ABB ACS550-01-180a-
4(90kw-380v) governor;
1.2.3 The screw diameter is 180mm, length to diameter ratio is 1:12, manufactured by 38CrMoAlA
material, nitriding, and hard chromium plating on the outside;
1.2.4 The temperature of cylinder is sectionally controlled, each section is heated by cast aluminum
heater. Using the wind for cooling. And the single screw core is cooled by water;
1.2.5 The auxiliary forced feeding device has the function of limiting and adjusting setting to solve the
Rubber and plastic mechanical engineering research center of East China University of Science and Technology Shanghai Nanan Machinery Manufacturing Co., Ltd.
第 4 页 共 21 页 No.130, Meilong Road, Shanghai
TEL:(021)64252363
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feeding problem of the low thaw material, and ensures the stability and continuity of the single screw
feed.
1.3 Centralized water cooling system
1.3.1 The combined stainless steel cooling water tank has the function of filtering and separating rust
and sundries;
1.3.2 The famous high pressure water pump;
1.3.3 Using high efficiency fin tube heat exchanger to cooling;
1.3.4 The high efficiency cold water machine, model QLB-60S.
1.4 hydraulic network system
1.4.1 The hydraulic station is made in China.
1.4.2 The plate changer is made of nitriding steel and processed by high precision grinder without leakage.
1.4.3 The exchanger is heated by imported high efficiency electric heater.
1.5 Control System
1.5.1 Intelligent Control System
The SIEMENES 6ES7 PLC controller centralized control and data acquisition;
SIEMENS touch-screen display, adjustment, humanized design of human-machine interface,
human-machine interaction and convenient interaction;
The data transmission system is based on Inter realizes real-time query of remote real-time process
parameters and reverse query of previous process parameters.
1.5.2 Control Cabinet
The control cabinet and operating panel adopt dust-proof sealing structure, which has a certain dust-
proof effect.
The main power switch is a domestic CHINT brand.
The temperature control is controlled by the imported PLC temperature control module.
Circuit breakers and contactors are all SIEMENES/ABB products.
Pressure sensor is the famous brand product of Shanghai Zhaohui, 30MPa;
The current voltmeter is from China.
The button is a ABB product.
The solenoid valves are imported CEMC products.
IV. Configuration and Price
Rubber and plastic mechanical engineering research center of East China University of Science and Technology Shanghai Nanan Machinery Manufacturing Co., Ltd.
第 5 页 共 21 页 No.130, Meilong Road, Shanghai
TEL:(021)64252363
Email:[email protected]
1. Scope of Supply
Num. Name Model Quantity Remarks
1 Two rotor continuous
mixer ECM1000S 1 √
2 Electrical instrument
control system 1 √
3 Random data 1 √
4 Random spare parts 1 √
2. Technical Parameters
Num. Functional
Module Project Characteristics Index
1 Overall
Unit
Function 600-1200kg/h
Installation
conditons
Work
environment - 5℃ ~ 40 ℃
Installation
height <=2000m
Humidity
range 10% ~ 70%
Space
Weight 15000kg
Matching
demand
Power Triphase-five-wires 0.4kV
max:420kw
Cooling water Pressure 2MPa Temperature20-
30℃ PH :7
Compressed air 0.3—0.5 MPa
Main
Parameters
Two rotors continuous
mixer
Rotor model M2 rotor
Rotor
nomial
diameter
130mm
Maximum
speed 500r.p.m
Motor
power 200kw
Single screw extruder Screw
diameter 180mm
Rubber and plastic mechanical engineering research center of East China University of Science and Technology Shanghai Nanan Machinery Manufacturing Co., Ltd.
第 6 页 共 21 页 No.130, Meilong Road, Shanghai
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Long to
diameter
ratio
1:12
Maximum
speed 88r.p.m
Motor
power 90kw
Coupling Home-made
Appearance
Main equipment
sandblasting derusting Sa2 grade,
degreasing, iron red epoxy
antirust primer, acrylic
polyurethane finish.
Touch screen electric
box / cabinet a color board
2 Engine base
Bed base
Structure Weldment
Material
Process
Q235 cold-formed rectangular
steel tube and steel plate
Manual arc welding and argon
protection
Rack
Structure Welding parts and cold bending
parts
Material
Process
Q235 cold-formed rectangular
steel tube and steel plate
Manual arc welding and argon
protection
3 Drive
system
Mixer gear
box
transmission ratio 2.9
Bearing brand SKF
Transmission structure 2 stage transmission
Cabinet material HT250
Maximum output speed 500 rpm
Cooling system
The gear box oil line compulsory
lubrication system is equipped
with oil temperature display
instrument.
Single screw
gear box
Gear box model ZLYJ250-16/ Jiangyin gear box
manufacturing Co., Ltd.
Transmission ratio 16.47
Transmission Two stage transmission
Rubber and plastic mechanical engineering research center of East China University of Science and Technology Shanghai Nanan Machinery Manufacturing Co., Ltd.
第 7 页 共 21 页 No.130, Meilong Road, Shanghai
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structure
Cabinet material HT250
Motor(mixer
)
Model
SIEMENS 1LE0001 high
efficiency AC asynchronous
motor
Motor model High efficiency low voltage AC
asynchronous motor
Protection level IP55
Cooling model
Coaxial fan, between motor and
gearbox with baffle isolation
motor air supply.
Tem. Testing protection Protection of KTY84-30 winding
Rated power 200kw
Rated rotation 1283.6N.m
Rated speed 1488r.p.m
Energy rating label LEVEL 3
Rateed pressure 380V + -
Single screw
extruder
motor
Model
SIEMENS 1LE0001 high
efficiency AC asynchronous
motor
Motor model High efficiency low voltage AC
asynchronous motor
Protection level IP55
Cooling model
Coaxial fan, between motor and
gearbox with baffle isolation
motor air supply.
Tem. Testing protection Protection of KT84-30 winding
Rated power 90kw
Rated rotation 578.8N.m
Rated speed 1485r.p.m
Energy rating label Level 3
Rateed pressure 380V + -
Two rotors
continuous
mixer
inverter
Model ABB ACS550-01-363A-4
(200KW-380V);
Cooling model Wind cooling
Maximum adaptable
motor power 200kw
Rubber and plastic mechanical engineering research center of East China University of Science and Technology Shanghai Nanan Machinery Manufacturing Co., Ltd.
第 8 页 共 21 页 No.130, Meilong Road, Shanghai
TEL:(021)64252363
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Rated output index
Rated power200kW, rated input
and output voltage 380V, rated
output current 363A, rated output
frequency 50HZ and short time
overload capacity
Control characteristics Control mode: vector control
AC input reactor Configure AC input reactor
Installation specification
conformance
Conform to EMC standard, heat
dissipation installation standard
(frequency converter manual
specification)
Power requirements
Allowable voltage unbalance
AC380-480V, allowing
frequency fluctuation range to +
5%.
Single screw
extruder
inverter
Model ABB ACS550-01-180A-
4(90KW-380V);
Cooling model Wind cooling
Maximum adaptable
motor power 90kw
Rated output index
Rated power90kW, rated input
and output voltage 380V, rated
output current 180A, rated output
frequency 50HZ and short time
overload capacity
Control characteristics Control mode: vector control
AC input reactor Configure AC input reactor
Installation specification
conformance
Conform to EMC standard, heat
dissipation installation standard
(frequency converter manual
specification)
Power requirements
Allowable voltage unbalance
AC380-480V, allowing
frequency fluctuation range to +
5%.
coupling Model Home-made
Rubber and plastic mechanical engineering research center of East China University of Science and Technology Shanghai Nanan Machinery Manufacturing Co., Ltd.
第 9 页 共 21 页 No.130, Meilong Road, Shanghai
TEL:(021)64252363
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Installation accuracy
Coaxial 0.1mm, face
parallelism 0.1mm, on the
instrument testing.
Two rotors
continuous
mixer
connector
Shield S304
Connection structure Involute spline connection with
thread locking at both ends
Material Science Alloy steel, adjustment treatment
4
Mixing
extrusion
system
Two rotors
continuous
mixer
Mixing cylinder
Form and
structure Inlaid structure
Material
brand
45 (cylinder) B
HLER S600
(sleeve)
Inner hole
precision 6 level tolerance
Heat
treatment
process and
inner surface
hardness
Quenching +
annealing,
HRC=58~62
Corrosion
resistance of
materials
commonly
Wear
resistance of
materials
excellent
Temperature
control
mode
Three stages of
independent
temperature
control; electric
heating and water
cooling
Mixing rotor
Form and
structure
Split structure,
M2 type chaotic
rotor
Material
brand
Double alloy,
38CrMoAlA+W
C
Rubber and plastic mechanical engineering research center of East China University of Science and Technology Shanghai Nanan Machinery Manufacturing Co., Ltd.
第 10 页 共 21 页 No.130, Meilong Road, Shanghai
TEL:(021)64252363
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Inner hole
precision
6 tolerance of
outer diameter
and other 7 level
tolerances
Heat
treatment
process and
inner surface
hardness
Nitriding +
surface plating
hard chromium,
HRC=60~62
Corrosion
resistance of
materials
commonly
Wear
resistance of
materials
excellent
Seal form
Labyrinth seal
and elastic filler
are used in the
feeding end
Labyrinth seal
and pure carbon
filler are adopted
in the
Temperature
control
Core water
cooling
Discharge door
Atmospheric exhaust
system
Form and
structure
Material
Stainless steel
welded structure,
spray F4 on inner
surface
Regulation
mode
Screw adjustable
belt dial
Heating
mode Electric heating
Atmospheric exhaust
system Material
S304 stainless
steel (exhaust
hood) Q235A
Rubber and plastic mechanical engineering research center of East China University of Science and Technology Shanghai Nanan Machinery Manufacturing Co., Ltd.
第 11 页 共 21 页 No.130, Meilong Road, Shanghai
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type steel
(support)
38CrMoAlA
(exhaust pressure
hammer)
Driving
cylinder
model
10A-5/120×350
Comtrol
mode
Manual
control .
Feed chute
Upper cover
S304 stainless
steel, argon arc
welding, with
exhaust pipe,
observation port,
feed pipe
interface, etc
Upper
slideway
S304 stainless
steel, argon arc
welding
Middle
chute
S304 stainless
steel, argon arc
welding
Glide trough
S304 stainless
steel, argon arc
welding
Flexible
connector Si rubbery
Single screw
extruder Screw
diameter 180mm
Ratio of
length to
diameter
12
Material
brand 38CrMoAlA
Manufacturi
ng precision
6 tolerance of
outer diameter
and other 7 level
tolerances
Rubber and plastic mechanical engineering research center of East China University of Science and Technology Shanghai Nanan Machinery Manufacturing Co., Ltd.
第 12 页 共 21 页 No.130, Meilong Road, Shanghai
TEL:(021)64252363
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Heat
treatment
process and
inner surface
hardness
Nitriding + hard
chromium plating
on the surface,
HRC=60~62,
depth of nitrided
layer 0.5~0.7mm
Corrosion
resistance of
materials
Commomly
Wear
resistance of
materials
Excellent
Temperature
mode
Inner water
cooling
Barrel
Material
brand 38CrMoAlA
Manufacturi
ng precision 6 级
Heat
treatment
process and
inner surface
hardness
Nitriding + hard
chromium plating
on the surface,
HRC=60~62,
depth of nitrided
layer 0.5~0.7mm
Corrosion
resistance of
materials
commonly
Wear
resistance of
materials
excellent
Temperature
mode
The four sections
are independent
temperature
control, the feed
section is water
cooled, and the
remaining three
zones are heated
by cast aluminum
Rubber and plastic mechanical engineering research center of East China University of Science and Technology Shanghai Nanan Machinery Manufacturing Co., Ltd.
第 13 页 共 21 页 No.130, Meilong Road, Shanghai
TEL:(021)64252363
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heating sleeve,
and the wind is
cooled.
sheath
structural
mode Weldment
material S304 stainless
steel
welding
technology Plasma welding
Single screw
auxiliary
feeding
device
slideway
structural
mode
Welding parts +
cold stamping
parts, containing
the bypass
material reprint.
material S304 stainless
steel
welding
technology
Argon arc
welding
Pressure hammer
Material 38CrMoAlA
forgings
Heat
treatment
process
Nitriding +
surface plating
hard chromium
Temperature
control
mode
Internal water
cooling
Barrel
Material S304 stainless
steel
welding
technology
Argon arc
welding
Temperature
control
mode
Internal water
cooling
Heating
system General specification
The head thermocouple is
installed on the head of the
machine. The head heating line
has fixed measures on the head,
all the control lines are fixed and
reliable, the metal hose is
Rubber and plastic mechanical engineering research center of East China University of Science and Technology Shanghai Nanan Machinery Manufacturing Co., Ltd.
第 14 页 共 21 页 No.130, Meilong Road, Shanghai
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installed, the wire grooves are
protected with the centralized
wiring, the head mounting screw
is reliable, the head heating
terminal box has the function of
waterproof and locking, the size
of the square box is 70mm×
70mm×70mm。
control mode Solid state control
Heating cable Cable standard FF46-2
High temperature wire GN series
Solid state relay Brand: Seaman, Beijing
Series: H360Z (DC4~32V)
Thermocouple / thermal
resistance
Series:WRN
heating power Mixer 15kw×2
Extruder 12kw×3
Cooling
system
General requirements
The cooling water intake and
return manifold material S304
seamless stainless steel pipe
manufacturing, each cooling pipe
is equipped with S304 stainless
steel joint.
Cooling mode
Water cooled, inlet control valve
is T handle stainless steel needle
valve.
Solenoid valve Control solenoid valve for Italy
CEMC brand, a total of 2
Cooling water tank Volume: 0.8 M3, stainless steel,
scale separation screen with rust
Fin tube heat exchanger 4 M2
Cooling water pump ISWR40-125(Ⅰ)
Cooling-water machine QLB-60S
control mode Relay control
Net change
system
Net
exchanger
Material 38CrMoAlA
Heat treatment process
Nitriding, surface hardness
HRC60, nitriding depth
0.5~0.7mm
Rubber and plastic mechanical engineering research center of East China University of Science and Technology Shanghai Nanan Machinery Manufacturing Co., Ltd.
第 15 页 共 21 页 No.130, Meilong Road, Shanghai
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Porous plate The diameter is 4mm, and the
thickness is 20mm
heating system Cast aluminum electric heater /
stainless steel heating rod
Hydraulic
station
cylinder diameter 120mm
Oil pump 1.5KW, maximum pressure
16MPa
Accumulator 15 liters of volume
5
Electronic
control
system
(host)
operation
panel
Model SIEMENS touch screen TP1200
Installation structure Up-down rotation translation
control
cabinet
Controller hardware SIEMENS PLC S7
Cabinet requirements
Front double door, rear panel /
left door with internal lock /
installation plate galvanized steel
/ laptop carrier / folder / Lighting
/ fan / threshold switch / base
100mm
Operating temperature
(heat dissipation mode
and capacity)
Fan cooling
Terminal brand
Intermediate relay brand ABB
AC contactor brand ABB
Switch brand series
parameter
ABB Motor protector MS
series Circuit
breaker S200 series for heating
Main circuit breaker A series
400V 50Hz 3P/N/PE
Plastic shell switch for main
switch Use electric
operating mechanism
ABB motor protector MS series
Circuit breaker S200 series for
heating Main
circuit breaker A series
Rubber and plastic mechanical engineering research center of East China University of Science and Technology Shanghai Nanan Machinery Manufacturing Co., Ltd.
第 16 页 共 21 页 No.130, Meilong Road, Shanghai
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Temperature
control
(fuselage)
electric box
configuration ET200SP slave station
Interface communication interface PLC with Profinet network port
line Cable brand model,
terminal
The cable length of the
mainframe to the electric cabinet
is 15 meters in length.
Power line BVR;
Control cable RV;
Shielded cable RVVP;
Terminal: ABB ZK series.
Power
supply in the
cabinet
Model
3 phase busbar + Zero row +
ground row;
Frequency conversion cabinet
and control cabinet are
independent power supply.
Grounding Grounding mode Ground row.
6 Spare parts
list
Sealing
element
two sets of melt end seal
assembly and powder end seal
assembly.
O ring 4pieces
Electrical fuse 1 set
Thermo-
coupling 3sets
Single screw
electric
heating
sleeve
1set
Electric
heating plate
for net
exchanger
2
Mixing
mechanical
and
Each 2
Rubber and plastic mechanical engineering research center of East China University of Science and Technology Shanghai Nanan Machinery Manufacturing Co., Ltd.
第 17 页 共 21 页 No.130, Meilong Road, Shanghai
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electrical
heating pipe
Head electric
heater 1set
7 Document
Mechanical
drawings of
equipment
Equipment profile
Schematic diagram of
equipment structure
Drawings of specific
parts, such as head,
formwork, etc.
Electrical
drawings of
equipment
Schematic diagram
Wiring diagram
Instructions
Operation instructions
for the whole machine
Maintenance manual
Packing list
Quality
assurance
card
The warranty period of
the whole machine and
parts
3.Hardware List of Electrical Control Section (Main Engine)
Num. Name Specifications Application Quantity Unit
1 Power 6EP1333-4BA00 Power 1 block
2 CPU 6ES7 513-1AL00-0AB0 CPU 1 block
3
Storage card
(CPU dedicated)
MMC 4MB Memory card 1 piece
4 Guide 6ES7 590-1AE80-OAAO Module installation 1 block
5 PN slave module 6ES7 155-6AU00-OBNO
Front end
temperature input
(slave station)
auxiliary slave
station
2 block
6 Analog input 6ES7 134-6JF00-OCA1 Temperature input 2 block
7 Analog input 6ES7 531-7QD00-OABO Speed feedback of
main motor 1 block
Rubber and plastic mechanical engineering research center of East China University of Science and Technology Shanghai Nanan Machinery Manufacturing Co., Ltd.
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8 Analog input 6ES7 134-6HB00-ODA1 Melt pressure
feedback 1 block
9 Analog output 6ES7 532-5HD00-OAB0 Speed given 1 block
10 Digital input /
output (16/16 bit) 6ES7 523-1BL00-OAAO control equipment 1 block
11
Digital output
(32 bits)
6ES7 522-1BL10-OAAO
temperature control 1 block
12 Front connector 6ES7592-1AMOO-OXBO Joint 2 block
13 Bus connector
2*RJ45 6ES7 193-6AR00-0AA0 Joint 2 piece
14 Touch screen 6AV2124-0MC01-0AX0 Interface 1 piece
15 CF memory card CF memory card 1 block
16 16 digital input 6ES7131-6BH00-0BA0 Auxiliary slave
station 1 block
17 16 digital output 6ES7132-6BH00-0BA0 Auxiliary slave
station 1 block
18 Connector 6ES7193-6BP00-0DA0 Front connector 6 block
Rubber and plastic mechanical engineering research center of East China University of Science and Technology Shanghai Nanan Machinery Manufacturing Co., Ltd.
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ECM1000S Two Rotors Continuous Mixer
Rubber and plastic mechanical engineering research center of East China University of Science and Technology Shanghai Nanan Machinery Manufacturing Co., Ltd.
第 20 页 共 21 页 No.130, Meilong Road, Shanghai
TEL:(021)64252363
Email:[email protected]