Double station flat vulcanizing mold press for the production of
rubber seals and other rubber products
machine construction:
The double-station flat plate vulcanizer is a kind of equipment
specially used for vulcanizing rubber products. Its manufacturing
principle includes many aspects, from mechanical structure to the
design and implementation of control system. The following is the
manufacturing principle of the double-station flat plate
vulcanizer:
Manufacturing principle
1. Mechanical structure
1.1 Frame and platform
Frame: welded or cast with high-strength steel, providing stable support
and able to withstand high pressure and high temperature.
Working platform: two independent flat workbenches for placing molds and performing
vulcanization operations. Each workbench is equipped with a heating
and cooling system.
1.2 Hydraulic system
Hydraulic cylinder: used to provide the pressure required for vulcanization, and the
pressure is transmitted through the
hydraulic pump and hydraulic cylinder.
Hydraulic pump: provides the power required by the hydraulic system to ensure
that the hydraulic cylinder can work stably.
Control valve: adjusts the flow and pressure of the hydraulic oil to achieve
precise control of the vulcanization pressure.
2. Heating and cooling system
2.1 Heating system
Heating plate: an electric heating element embedded in the working platform that
can evenly heat the mold. Common heating methods include electric
heating and steam heating.
Temperature sensor: monitors the temperature of the heating plate in real time and
feeds back to the control system to adjust the heating power to
ensure temperature stability.
2.2 Cooling system
Cooling pipe: The cooling pipe embedded in the working platform cools down the
vulcanized rubber products through cooling water or coolant.
Cooling control: adjust the flow of coolant through the control valve to achieve
precise temperature control.
3. Control system
3.1 PLC controller
Programmable logic controller (PLC): realizes the control of the entire vulcanization process,
including the setting and monitoring of parameters such as
temperature, pressure and time.
Human-machine interface (HMI): provides an intuitive operation interface for operators to set
parameters and monitor the operating status of the equipment.
3.2 Sensor and feedback system
Pressure sensor: monitors the pressure of the hydraulic system and feeds back to
the PLC for adjustment.
Temperature sensor: monitors the temperature of the heating plate and cooling system
to ensure the accuracy of temperature control.
Time controller: set the vulcanization time according to the vulcanization process
requirements and accurately control each vulcanization cycle.
4. Safety system
4.1 Safety protection device
Emergency stop button: In an emergency, the operator can press the emergency stop button
to stop the machine immediately.
Overload protection: Prevent the equipment from running under overload conditions,
protect the safety of the equipment and operators.
Safety door and guardrail: Prevent operators from entering dangerous areas by mistake, and
ensure personal safety.
4.2 Safety standards
International safety standards: During the design and manufacturing of the equipment, relevant
international safety standards are followed to ensure the safety
and reliability of the equipment during use.
Summary
The manufacturing principle of the double-station flat plate
vulcanizer combines mechanical engineering, hydraulic technology,
heating and cooling control, and automatic control technology.
Through precise mechanical design and advanced control systems, an
efficient and precise vulcanization process is achieved, while
ensuring the safety of operation and the durability of the
equipment. The comprehensive application of these principles and
technologies has made the double-station flat plate vulcanizer
widely used in the production of rubber products.
Product parameter:
Type | XLP500×500×2 | XLP600×600×2/4 | XLP700×700×2 | XLP750×850×2/4 | XLP900×900×2Q |
Total pressure (MN) | 0.63 | 1.00 | 1.20 | 1.60 | 2.00 |
Plate distance(mm) | 125 | 125 | 125 | 200 | 300 |
Working layer number | 2 | 2-4 | 2 | 2-4 | 2 |
Unit area pressure of hot plate(Mpa) | 2.52 | 2.77 | 2.45 | 2.51 | 2.47 |
Plunger stroke(mm) | 250 | 250/400 | 250 | 400 | 400 |
Heating mode | electricity/steam | electricity/steam | steam | electricity/steam | steam |
Main motor power (KW) | 2.2 | 2.2 | 2.2 | 3 | 5.5 |
Overall dimension (L×W×H) (mm) | 1750×600×1540 | 1880×720×1680 | 2000×850×1750 | 2250×1200×2200 | 1400×900×2400 |
Frame form | Post | Post | Post | Frame | Frame |
Product advantage:
The double-station flat vulcanizer produced by Qingdao Beishun is a
kind of equipment used for vulcanizing rubber products. It has two
worktables and can perform two vulcanization operations at the same
time. The following are some of the main advantages of the
double-station flat vulcanizer:
Advantages
1. High production efficiency
Dual-station design: Two worktables can perform vulcanization operations at the same
time, which greatly improves production efficiency and reduces
waiting time.
Continuous production: After the vulcanization of one station is completed, the other
station can start vulcanization immediately, realizing continuous
production and further increasing output.
2. Precise control
Independent control system: Each station is equipped with an independent temperature,
pressure and time control system, which can be accurately adjusted
according to the requirements of different products to ensure the
quality of vulcanization.
Multi-point temperature control: Multi-point temperature monitoring and control to ensure
temperature uniformity during vulcanization and improve product
consistency.
3. Flexible operation
Multiple modes: Different working modes can be selected according to production
needs, such as single-station independent work or double-station
simultaneous work, which can flexibly adapt to different production
requirements.
Simple operation: Equipped with a user-friendly operation interface, the operation
is simple and intuitive, reducing the difficulty of operation and
training time.
4. Space saving
Compact design: The dual-station design realizes two vulcanization stations on
the same equipment, saving space in the production workshop and
suitable for production environments with limited space.
Integrated structure: The overall design of the equipment is compact, which reduces the
equipment footprint and is convenient for installation and
movement.
5. High reliability
High-quality materials: The key components are made of
high-strength steel and wear-resistant materials to ensure
long-term stable operation of the equipment under high temperature
and high pressure environments.
Sturdy structure: The equipment has a sturdy structure, strong
impact resistance, long service life and low maintenance cost.
6. High safety
Safety protection device: Equipped with multiple safety protection devices, such as overload
protection, emergency stop button, etc., to ensure the safety of
operators.
Compliance with safety standards: The design and manufacturing comply with international safety
standards to ensure the safety and reliability of equipment
operation.
7. Versatility
Wide range of application: Suitable for vulcanization processing of various rubber products,
such as tires, seals, shock pads, etc.
Quick mold change: Modular design facilitates rapid mold replacement, reduces
downtime and improves production efficiency.
8. Energy saving and environmental protection
Energy-saving design: adopt energy-saving heating system to reduce energy consumption
and production costs.
Environmentally friendly materials: use environmentally friendly materials and processes to reduce
exhaust gas and wastewater emissions, and be environmentally
friendly.
The double-station flat vulcanizer has important application value
in the production of rubber products through its advantages of high
production efficiency, precise control, flexible operation, space
saving, high reliability, high safety, versatility and energy
saving and environmental protection. It can significantly improve
production efficiency and product quality, while reducing
production costs and maintenance costs. It is an ideal equipment in
the production of modern rubber products.
Here is a comprehensive FAQ for a Double Station Flat Vulcanizing
Machine:
FAQ: Double Station Flat Vulcanizing Machine
1. What is a Double Station Flat Vulcanizing Machine?
A Double Station Flat Vulcanizing Machine is a specialized piece of
equipment used for vulcanizing rubber products. It features two
independent workstations, allowing simultaneous vulcanization
processes to increase production efficiency.
2. What are the main applications of a Double Station Flat
Vulcanizing Machine?
This machine is widely used in the manufacturing of various rubber
products, such as:
- Tires
- Seals and gaskets
- Shock absorbers
- Conveyor belts
- Engineering rubber components
3. How does a Double Station Flat Vulcanizing Machine work?
The machine operates by heating and applying pressure to rubber
molds placed on two separate workstations. Each station has its own
heating and pressure system, allowing for independent control of
temperature, pressure, and vulcanization time to meet specific
production requirements.
4. What are the advantages of using a Double Station Flat
Vulcanizing Machine?
- High Production Efficiency: Two workstations allow simultaneous vulcanization operations,
significantly increasing throughput.
- Precise Control: Independent temperature, pressure, and time controls ensure
high-quality vulcanization.
- Operational Flexibility: The machine can be used in single or dual station modes, adapting
to varying production needs.
- Space-saving Design: The compact design saves valuable floor space in production
facilities.
5. How do I choose the right Double Station Flat Vulcanizing
Machine?
Consider the following factors:
- Product Specifications: Ensure the machine can handle the size and weight of your rubber
products.
- Production Capacity: Choose a machine that matches your production volume
requirements.
- Technical Parameters: Check the temperature range, pressure capacity, and cycle time.
- After-sales Support: Select a supplier that offers reliable after-sales service and
support.
6. How should I maintain and care for my Double Station Flat
Vulcanizing Machine?
- Regular Inspections: Conduct routine checks on the hydraulic, heating, and control
systems.
- Lubrication: Regularly lubricate mechanical parts to reduce wear and tear.
- Cleaning: Keep the machine clean to prevent dust and debris from affecting
performance.
- Calibration: Periodically calibrate the control systems to ensure accurate
temperature and pressure settings.
7. What are common issues with Double Station Flat Vulcanizing
Machines and how can they be resolved?
- Uneven Heating: Check the heating elements and clean any debris that might be
causing uneven heating.
- Insufficient Pressure: Inspect for hydraulic leaks and ensure the hydraulic pump is
functioning correctly.
- Control System Failures: Verify the PLC or control unit is operational; reprogram or
replace if necessary.
8. How can I improve the production efficiency of my Double Station
Flat Vulcanizing Machine?
- Optimize Process Parameters: Adjust temperature, pressure, and time settings according to the
specific requirements of different rubber products.
- Regular Maintenance: Keep the machine in good working condition to minimize downtime.
- Operator Training: Ensure operators are well-trained to handle the machine correctly
and troubleshoot issues promptly.
9. What safety measures are included in Double Station Flat
Vulcanizing Machines?
- Emergency Stop Button: Allows operators to immediately halt the machine in case of an
emergency.
- Overload Protection: Prevents the machine from operating under overload conditions,
protecting both the equipment and operators.
- Safety Guards and Barriers: Prevent unauthorized access to hazardous areas, ensuring operator
safety.
10. What should I do if my Double Station Flat Vulcanizing Machine
requires repairs?
- Contact the Supplier: Reach out to the supplier or manufacturer for technical support
and service.
- Use Genuine Parts: Ensure that any replacement parts are genuine and compatible with
your machine.
- Professional Repairs: Have repairs done by qualified technicians to avoid further
damage or safety issues.
Conclusion
A Double Station Flat Vulcanizing Machine is an essential tool in
the rubber manufacturing industry, offering high efficiency,
precise control, and operational flexibility. Understanding its
operation, maintenance, and troubleshooting can help maximize
productivity and ensure safe, reliable performance.
