PLC Controlled Rubber Calendering Machine with 200-500mm Diameter
Rollers
Product Description:
Rubber Calender Introduction
Rubber calender is an essential equipment in rubber and plastic
product processing. It is a heavy-duty and high-precision machine
that plays an important role in the rubber and plastic machinery
industry. Here is a detailed and comprehensive introduction to the
rubber calender.
Structural Composition
The rubber calender is composed of several components:
- Working roller: made of high-quality alloy steel, responsible for
the core component of the calender. The surface is finely processed
and treated to ensure its surface finish and flatness.
- Frame: used to support and fix other components such as rollers,
transmission devices, and so on to ensure the stability of the
calender.
- Machine base: plays the role of carrying the entire calender
equipment and is usually made of cast iron or steel structure.
- Transmission device: responsible for transmitting power to the
roller so that it rotates at the set speed.
- Speed and distance adjustment device: used to adjust the speed of
the roller and the distance between the rollers respectively.
- Roller heating and cooling device: used to ensure the plasticity of
the rubber during the calendering process.
- Lubrication system: used to reduce friction and wear, and extend
the service life of the equipment.
- Emergency stop device: used to prevent accidents when the calender
encounters abnormal conditions during operation.
Working Principle
The heated rubber is processed through the gap between two or more
rollers that rotate relatively and are horizontally set, forming
semi-finished products. This process changes the molecular
structure of the rubber, improves its plasticity, and precisely
controls its dimensions.
Classification Method
The classification of rubber calenders can be based on:
- The number of rollers: two-roll calender, three-roll calender, and
four-roll calender.
- The process use: sheeting calender, rubber rubbing calender,
general calender, profile calender, laminating calender, and steel
wire calender.
Parameter Indicators
The important parameter indicators for rubber calenders include:
- Roller linear speed: a parameter that characterizes the production
capacity of the calender.
- Speed range: the range in which the roller can be infinitely
variable.
- Speed ratio: different process requirements for gluing, rubbing, or
pressing during calendering may have different speed ratio
requirements for the roller.
Operation Points and Maintenance
It is essential to know the operation points and maintenance of the
rubber calender.
- Preparation before starting: check whether all parts of the
equipment are normal.
- Feeding operation: feed the rubber raw materials evenly between the
rollers at a moderate feeding speed.
- Adjustment of the calendering process: adjust the roller speed,
spacing, temperature and other parameters in time according to the
molding of the rubber products.
- Stop operation: stop feeding first, and then stop the equipment
after all the rubber on the roller is discharged.
- Daily maintenance: regularly check the operating conditions of the
equipment.
- Regular maintenance: regularly maintain the equipment in a
comprehensive manner.
- Troubleshooting: stop the equipment in time for inspection and
repair when faults occur.
Features:
The Main Features of Rubber Calenders
The rubber calender is a machine used in the production of rubber
products such as tires, conveyor belts, and rubber sheets. It has
the following primary features:
Working Principle
The rubber calender applies pressure to rubber materials through
the relative rotation of multiple rollers. It stretches and thins
the rubber to achieve uniform thickness control. Different roller
configurations, such as two-roller, three-roller, or four-roller,
are employed to achieve the desired results.
Structural Features
The rollers are a key component of the rubber calender. They are
usually made of high-quality steel with high hardness, strength,
and good thermal conductivity. High surface accuracy ensures that
the quality of the calendered products is high. The machine is also
equipped with a complete transmission system that can accurately
control the roller speed and achieve different calendering speeds
and speed ratios. Moreover, a reliable spacing device can flexibly
adjust the spacing between rollers to adapt to calendering rubber
materials of different thicknesses.
Precision Control
The rubber calender is capable of accurately controlling the
thickness, width, and other dimensional parameters of rubber sheets
or profiles. The thickness tolerance can be controlled within a
small range, such as about ±0.02mm.
Temperature Regulation
Most rubber calenders have roller heating or cooling functions with
a temperature control system that can keep the roller at a suitable
working temperature, usually between 50℃ and 150℃. This capability
is helpful in the plasticization and molding of rubber.
Production Efficiency
The rubber calender has high production efficiency and can operate
continuously. It can quickly and efficiently calender a large
amount of rubber raw materials without sacrificing quality. The
hourly output varies based on the machine model and process, with
small ones producing several tons per hour and large industrial
ones producing tens of tons.
Technical Parameters:
Model
| Item | XY-2I()320 | XY-2I()620 | XY-2I()1120A | XY-2I()1500 | XY-2I()1830 | XY-2I()1730 | XY-2I()2430 |
|---|
| Roll dia | 160 | 250 | 360 | 450 | 550 | 610 | 810 |
| Roll working length | 320 | 620 | 1120 | 1500 | 1830 | 1730 | 2430 |
| Roll ratio | 1:1 | 1:1 | 1:1 | 1:1 | 1:1.08 | 1:1 | 1:1 |
| Roll linear speed (r/min) | 7.79 | 14.8 | 3-20.2 | 2.5-24.8 | 2-18.7 | 4-36 | 2-20 |
| Adjusting nip range | 0-4.5 | 0-5.5 | 0-10 | 0-10 | 0-12 | 0-15 | 0.5-25 |
| Min. calendering product thickness | 0.2 | 0.2 | 0.2 | 0.2 | 0.2 | 0.2 | 0.5 |
| Calendering product width | 250 | 580 | 920 | 1250 | 1600 | 1500 | 2150 |
| Motor power (kW) | 5.5 | 15 | 37 | 45 | 75 | 90 | 160 |
| Overall dimensions (L x W x H) (mm) | 2200 x 530 x 1470 | 3100 x 770 x 1590 | 5400 x 1542 x 1681 | 7113 x 1595 x 2446 | 7420 x 1760 x 2760 | 5987 x 1860 x 2988 | 8690 x 3139 x 4270 |
| About weight (t) | ~1.2 | ~3 | ~14.5 | ~22 | ~24 | ~30 | ~62 |
Model
| Item | XY-3I 630 | XY-3I 1120A | XY-3 1120A | XY-3l1120A | XY-3I 1400 | XY-3I 1200 | XY-3I 1500 | XY-3I 1730 | XY-3I 2130 |
|---|
| Roll diameter (mm) | 230 | 360 | 400 | 450 | 610 | 710 | -- | 610 | 710 |
| Roll working length (mm) | 630 | 1120 | 1120 | 1200(1500) | 1400 | -- | 1500 | 1730 | 2130 |
| Roll speed ratio | 1:1:1 | 1:1.42:1 | 1:1:1 | 0.733:1:1
0.733:1:0.733 | 1:1.383:1.383
1:1.383:1 | 1:1.5:1 | 1:1.4:1 | 1:1.48:1 | 1:1.5:1 |
| Middle-roll linear speed (m/min) | 7.97 | 7.0-21.06 | 8.8-26.39 | 8.36-25.08 | 5.4-54 | 8-50 | 2-20 | 3-30 | 2-20 |
| Adjusting nip range (mm) | 0-7 | 0-10 | 0-10 | 0-6 | 0-20 | 0-20 | 0.5-25 | 0-20 | 0-20 |
| Min. calendering product thickness (mm) | 0.2 | 0.2 | 0.2 | 0.15 | 0.15 | 0.15 | 0.5 | 0.15 | 0.15 |
| Calendering product width (mm) | 100-500 | 500-920 | 1200 | 1100(1400) | 1500 | 1900 | 2150 | 1500 | 1900 |
| Motor power (kW) | 7.5 | 40/13.3 | 55/18.3 | 75/25 | 132 | 185 | 220 | 132 | 220 |
| Overall dimensions (mm) | 2570 x 740 x 1500 | 5550 x 1640 x 2120 | 6500 x 1500 x 2440 | 7120(7420) x 2200 x 2900 | 7010 x 3950 x 3730 | 7650 x 4560 x 4080 | -- | 7010 x 3730 x 5920 | 9300 x 5200 x 3150 |
| About weight (t) | ~2.6 | ~11 | ~22 | ~26 | ~52 | ~67 | -- | ~100 | ~126 |
Model
| Item | XY-4I 630 | XY-4L 630 | XY-4630 | XY-41120A | XY-41400 | XY-41500 | XY-41730 | XY-42130 | XY-42430 |
|---|
| Roller dia (mm) | 230 | 360 | 400 | 450 | 610 | 710 | 810 | 610 | 710 |
| Roller working length (mm) | 630 | 1120 | 1400 | 1500 | 1730 | 2130 | 2430 | -- | -- |
| Roller ratio | 1:1:1:1 | 0.73:1:1:0.73 | 1:1.38:1.38:1 | 1:1.5:1.5:1 | 1:1.4:1.4:1 | 1:1.4:1.4:1.4 | 1:1.5:1.5:1 | 1:1.5:1.5:1 | 1:1.5:1.5:1 |
| Middle-roll linear speed (m/min) | 2.1-21 | 2-20.1 | 3-26.3 | 2.5-25 |
Applications:
The following describes the operation process of a rubber calender:
Preparation before starting
- Equipment inspection:
- Carefully check the various components of the calender, including
rollers, transmission systems, spacing devices, temperature control
systems, etc., to ensure that the components are firmly connected
and there is no looseness or damage.
- Check whether the surface of the roller is clean and smooth. If
there is debris or damage, it needs to be cleaned and repaired in
time.
- Material preparation:
- Prepare the rubber raw materials to be calendered to ensure that
their formula is accurate and the mixing is uniform. Generally, the
rubber should be mixed in advance to give it suitable plasticity
and other properties.
- Prepare auxiliary materials such as additives and fillers that may
be used according to production needs, and ensure that their
quality meets the requirements.
- Parameter setting:
- According to the specifications and process requirements of the
rubber products to be produced, set the roller speed, roller
spacing, working temperature and other parameters in the control
system. For example, when producing rubber sheets, the roller
spacing needs to be set according to the thickness requirements of
the sheet; the appropriate working temperature corresponding to
different types of rubber is also different, and it needs to be
accurately set.
Start-up operation
- Start the transmission system: First turn on the transmission
system of the calender, so that the roller starts to rotate slowly,
and observe whether the roller rotates smoothly and whether there
is any abnormal sound or vibration. If there is any abnormality,
stop the machine immediately to check the cause and troubleshoot.
- Preheat the roller: While the roller is rotating, start the
temperature control system to preheat the roller. According to the
set working temperature, the roller is gradually heated to the
appropriate processing temperature range, generally between 50℃ -
150℃, depending on the type of rubber and process. During the
preheating process, the temperature changes should be continuously
monitored to ensure that the temperature rise is uniform and
stable.
Calendering process operation
- Feeding: When the roller reaches the set temperature and rotates
smoothly, feed the prepared rubber raw materials slowly and evenly
into the feed port between the rollers. The feeding speed should be
moderate to avoid too fast causing rubber to accumulate on the
roller and unable to calender normally, or too slow to affect
production efficiency.
- Calendering adjustment:
- During the calendering process, pay close attention to the molding
of rubber products, such as whether the thickness and width meet
the requirements. If the thickness does not meet the requirements,
the spacing between the rollers can be adjusted in time through the
spacing device; if the width deviates, it may be necessary to check
and adjust the uniformity of feeding and other related factors.
- At the same time, observe the flow of rubber between the rollers to
ensure that it is evenly squeezed and stretched. If local
unevenness is found, the speed ratio of the rollers and other
parameters can be adjusted appropriately to improve it.
- Quality monitoring: Continuously check the quality of the
calendered rubber products, including whether the appearance is
smooth and flat, whether there are bubbles or impurities, and
whether the dimensional accuracy meets the standards. If there are
quality problems, analyze the causes in time and take corresponding
corrective measures, such as adjusting process parameters, cleaning
equipment, etc.
Shutdown operation
- Stop feeding: When the current production task is completed or
production needs to be suspended, first stop feeding the rollers,
and let the remaining rubber between the rollers continue to be
calendered until all the rollers are sent out.
- Cooling roller: Turn off the heating function of the temperature
control system, and turn on the cooling function as needed to allow
the roller to gradually cool down to prevent the roller from being
damaged due to long-term high temperature. It is also convenient
for subsequent equipment maintenance and cleaning.
- Stop the transmission system: After the roller has cooled to a
certain degree and the rubber has been fully delivered, stop the
transmission system of the calender to stop the roller from
rotating.
- Equipment cleaning: After the shutdown, clean the calender
thoroughly, remove the rubber and other debris remaining on the
roller surface, feed port, discharge port and other parts of the
equipment, and prepare for the next start-up.
Customization:
Packing and Shipping:
Product Packaging:
- 1 Rubber Calender Machine
- Instruction Manual
- Tools for Assembly
Shipping:
- Weight: 1500 kg
- Dimensions: 200 x 120 x 180 cm
- Shipping Method: Freight
- Delivery Time: 2-4 weeks
FAQ:
Q1: What is the brand name of this product?
A1: The brand name of this product is Beishun.
Q2: What are the available models for this product?
A2: The available models for this product are 4-roller, 3-roller,
and 4-roller.
Q3: Where is this product manufactured?
A3: This product is manufactured in QINGDAO, CHINA.
Q4: What certifications does this product have?
A4: This product has CE, ISO, and SGS certifications.
Q5: What is the minimum order quantity for this product?
A5: The minimum order quantity for this product is 1 piece.
Q6: What is the price range for this product?
A6: The price range for this product is between 10000usd-150000usd.
Q7: How long is the delivery time for this product?
A7: The delivery time for this product is 45 days.
Q8: What are the payment terms for this product?
A8: The payment terms for this product are L/C and T/T.
Q9: What is the supply ability for this product?
A9: The supply ability for this product is 50 sets per year.
