New energy charging pile low-smoke halogen-free cable material granulation combines the high speed and strong mixing of twin screws with the low speed, low temperature and weak shear characteristics of a single screw to maximize strengths and avoid weaknesses. It has a high degree of process automation, assembly line operation, excellent dispersion effect and high output. , the working condition is clean, and it is a model for efficient compounding and modification of today's heat-sensitive and shear-sensitive materials. The low-smoke halogen-free cable material granulator has a unique counter-blowing die surface cutting head with slide rails. The head part is cooled by water, and the core of the single screw is cooled by water, which effectively prevents the phenomenon of particle sticking during the production process. Yield is significantly improved.
Granulation process editor
Internal mixer automatic elevator push-pull cone twin feeder twin-screw extruder single-screw extruder hydraulic plate automatic screen changer air-cooled die surface hot cutting granulation auxiliary machine 1 First-stage cyclone separator Secondary cyclone separator Air-cooled vibrating screen (.) A set of air-blown silos
Technical configuration editor
During the extrusion process, due to the particularity of low-smoke halogen-free cable materials, The molten material generates a large amount of heat due to friction, which requires the extrusion equipment to have a good cooling device to control the process temperature. This is a problem that cannot be ignored. If the temperature is too high, large pores will appear on the surface of the cable. If the temperature is too low, the overall current of the device will increase, which can easily damage the device. I once saw a Shanghai customer change the air cooling of the extruder cooling system to a water cooling system. After the change, the temperature rise was a bit slow, but the temperature rise was steady, the cooling speed was fast, and the system temperature was stable.
Automatic tipping bucket elevator
, loading motor power
, limit switch upper and lower limits, special optimized arc design of the slideway, smooth and reliable transportation.
The lifting hopper is made of stainless steel, and each pot can carry the amount of material per pot.
, transport the lump material kneaded by the kneader to the cone double feeder.
Cone double feeder
Motor power, speed control system adopts imported INVT variable frequency speed regulator.
, Feeding screw conical twin-screw forced cutting, nitride chromium plating treatment, high surface finish.
The surface of the feeding body is polished, smooth and wear-resistant.
The feeding hopper is sturdy and durable, easy to disassemble and assemble.
The feeder adopts a push-pull type for easy cleaning.
The cones are heated by electric heating.
Twin-screw extruder
, reduction box, high-speed and high-torque gearbox, high-torque domestic brand bearings with brand output speed, built-in dual lubrication system, equipped with a separate oil lubrication cooling system to effectively protect the transmission box.
, main motor
) AC motor
) power
) INVT inverter.
, screw
) Diameter
) Aspect ratio
) The screw has a building block structure
) The material of the mandrel, the threaded element and the mandrel are involute connection strength High, large load-bearing capacity, easy to disassemble and assemble
) Threaded components are made of high-quality high-speed tool steel, high-temperature vacuum quenching heat treatment
) Overall hardness
) The screw head and cap connection are anti-thread connections , make sure the connection is tight.
, barrel
) The material is steel as the base body, and the inner hole is made of high-quality double alloy bushing
)/section, a total of nine sections, the two-section cylinder is the discharge barrel, and the remaining cylinders It is a closed cylinder
) The cylinder is cooled by soft water
) The cylinders are connected with hexagonal high-strength bolts.
The heating section adopts high-quality cast aluminum heater.
, Soft water cooling system
) The soft water pipe is separated from the machine body for easy cleaning and maintenance
) Taiwan Qiangshi automatic water control solenoid valve control
) Cooling water pump power
) Water tanks, water pumps, and water pipes are stainless steel pipes
The low-smoke and halogen-free sheath shrinks more sharply during extrusion, causing the outer layer of the sheath to have cooled and shaped, while the inner cable material is still in a high-temperature, unshaped state, and is buried The hidden danger of stress concentration may even eventually lead to stress cracking of the outer sheath of the cable. In order to reduce stress concentration during the production process, it is recommended to use segmented cooling during the sheath extrusion process. Such as hot water cooling (circulating water) warm water cooling air cooling cold water cooling. During the cable cooling process, special attention should be paid to the fact that the cable entering the water tank after coming out of the die mouth must be completely immersed in the cooling water. Otherwise, in addition to the problem of stress concentration, a series of small dots may appear on the surface of the cable, causing The surface of the outer sheath of the cable has pits and pits, which affects the appearance of the cable.
? Precautions for attachments
Equipment installation
Single-screw extruder
The gear (shaft) of the reduction box is made of high-strength alloy steel and processed by carburizing and quenching and gear grinding. The gear precision High hardness, high load-bearing capacity, smooth transmission, low noise, and high efficiency.
, main motor
) AC motor
) Power
) INVT variable frequency speed regulator.
, screw
) diameter
) aspect ratio
) material is nitrided, nitrided, deep brittleness is not greater than grade, and the surface of the screw is hard chromium plated.
, barrel
) The material is nitrided, nitrided, and the deep brittleness is not greater than grade
) The screw barrel is water-cooled
) The barrel is equipped with a protective cover
) The core of the screw is passed through water
, and the heating section adopts high-quality cast aluminum heater.
, Hydraulic plate type automatic screen changing double station contains two porous plates and one hydraulic station.
, a set of cutting machine head, die, heater, etc.
Interlocking control system
The host temperature control system adopts Omron intelligent instrument, which has dual channels, parameter self-tuning and heater break indication functions.
The host interlocking protection function is twin-screw host and Gear box oil pump interlock
, single screw and feeder interlock protection. When the feeder fails, the host will delay shutdown. If the host stops for any reason, the feeder will stop
. Single screw machine The head is equipped with melt pressure and melt temperature displays, in which the melt pressure is interlocked with the host to achieve over-pressure protection.
, Electrical control cabinet control includes temperature control system, drive system, interlocking and joint control system
Air-cooled die surface cutting system
) Air-cooled die surface cutting granulator, motor power. 1 Taiwan, INVT variable frequency speed regulation
) Hot-heating pellet hood blowing type, made of stainless steel
) First-level cyclone separator, made of stainless steel, made of stainless steel. The connection method is a snap connection. Material transportation One high-pressure fan
) Two-stage cyclone separator, made of stainless steel. One piece of stainless steel pipe connection is used for buckle connection to transport materials. One high-pressure fan
) One extended vibrating screen. The screen mesh is Made of stainless steel, cooling fan.
) Silo, one piece, stainless steel blower, stainless steel pipeline transportation, connection method is snap connection.
Equipment Instructions Edit
New energy charging pile low-smoke halogen-free cable material granulator start-up preparation
Whether the electrical wiring is accurate and whether there is any looseness.
Use a megohmmeter to measure the motor. The insulation resistance of the cast aluminum heater shall not be less than.
Whether the detection components such as thermocouples and melt sensors are installed properly.
, main motor voltage, frequency range. Screw speed/.
. Check the lubrication system
Add lubricating oil to the gear transmission box to the oil level indicated by the oil mark.
Check the oil circulation system and the oil supply status of each point. After the point-to-point oil pump turns correctly, turn on the oil pump and set the pressure relay to protect the pressure lower than the alarm. Then check and adjust the oil volume and injection status of each oil supply point.
Check all water pipes and oil pipes up and down. They should be smooth and free of leaks. All control valves should be flexible to adjust.
, manual turning safety coupling, check the transmission system, screw and other moving parts, if there is no abnormal sound, it is qualified. When looking at the turning direction from the machine head, the screw turns clockwise and the screw rotates no less than three times.
Whether the combination configuration of the main screw and cylinder is suitable for the type of materials to be processed. If it is obviously not suitable, it should be reassembled and adjusted.
After cleaning the storage silo and hopper and confirming that there are no impurities and foreign matter, fill the storage silo with materials and start the automatic feeding machine. When the material in the hopper reaches the predetermined level, the loading machine will automatically stop loading. Various metering and feeding devices should be calibrated on-site according to process requirements, the feeding curves of each feeding device should be given, and a commissioning plan should be agreed upon.
, Check the feeding device
Add an appropriate amount of calcium-based lubricating oil to the cycloidal pinwheel reducer, and add it regularly (monthly) in the future.
Check to make sure the hopper is clean and free of dirt.
Low-speed operation (clockwise when viewed from the discharging direction) and brisk operation, and no sound are considered qualified.
. For operations that require vacuum exhaust, clean tap water should be added to the condensation tank to the specified water level, the vacuum pipeline and the valves of the condensation tank should be closed, and check whether the sealing ring of the exhaust chamber is in good condition.
The main unit is cooled by soft water cooling. Open the return water manual valve and press the start button to start the circulation system. Adjust the working pressure regulating valve to make the system pressure meet the requirements and be stable.
For materials with large internal heat or materials that are too sensitive to shear heat, the soft water cooling circulation system matched with this unit should be used. Before use, soft water should be added to the water tank to the specified level. When used for the first time, an appropriate amount of soft water should be added to the normal level after the system is put into operation. The cooling pipeline valves of each cylinder section must be tightened and closed before use.
Only after the above items have been carefully and comprehensively checked and confirmed to be correct, can the unit be ready for start-up testing.
Start-up operation of the new energy charging pile low-smoke halogen-free cable material granulator
Push the switch up to start.
, push the heating control switch up to start.
, preheating and heating. Set the heating temperature value of each section according to the process requirements. When the heating temperature of each section reaches the set value, keep the temperature constant for several minutes, and then check whether the temperature control table of each section and the solenoid valve of the cooling pipe of each section are normal.
, Push up the solenoid valve switch to start.
. Start the lubricating oil pump switch and observe the oil pressure gauge at the rear of the main engine. It should be at. (Always keep it below . The machine should be stopped immediately to check the oil circuit, oil pump, oil pump motor and wiring)
, turn on the switches of the lubricating oil pump, cooling water, granulator, etc.
. Manually turn the main engine and turn it three times. After there are no abnormalities, start the main motor control system and turn the main engine speed control knob clockwise (note that the knob should be turned counterclockwise to the zero position before starting the main engine. ), slowly increase the screw speed (see Figure, Figure). When the screw is idling, the speed should not be higher than the time for less than 1 minute, and check the machine operation and whether the no-load current is normal.
If there is no abnormality in the operation of the host machine, you can start feeding (such as side feeding, the feeding devices should be started in sequence according to the process requirements), and start feeding at the lowest possible speed (please pay attention to the setting of the speed control knob before starting the machine) in zero position, see figure). Wait for the material to be discharged from the machine head and then gradually and slowly increase the screw speed and double-wrist feeder speed. When increasing the speed, wait until the current has stabilized and then increase the speed of the feeder to match the speed of the feeder and the host machine, and adjust the granulation speed in time to ensure that the particles produced meet the requirements. At the same time, pay attention to the operation of each part of the entire unit, such as noise, vibration, bearing temperature rise, heating temperature, host current and other main operating data must be within the normal range. If there is any abnormal sound, stop the vehicle immediately and deal with it immediately. Every time the host and feeder speed up, the current indicators of the host should be closely observed at any time during the speed-up adjustment process. In principle, it is better to control the host current to not exceed % of the rated current. For a certain screw combination, the machine's production capacity and load (host current) mainly depend on the amount of feed. The plasticizing and mixing effect depends more on whether the screw combination is reasonable and the host screw speed, Heating temperature, exhaust effect, etc. When commissioning, it is essential to adjust these parameters multiple times.
, Soft water cooling circulation system. Each section of the cylinder cooling pipeline is equipped with a manual shut-off valve and a solenoid valve. The former controls the flow of soft water, and the latter is linked with the temperature control instrument to automatically control the on-off of soft water. During the start-up phase, the soft water circulation system does not need to be used. After the host runs smoothly, if the test temperature of a certain section of the cylinder is significantly higher than the set temperature, the soft water system pump can be started and the bypass overflow valve at the pump outlet can be adjusted. Control the pump outlet pressure at and then slightly open the shut-off valve of the cylinder section that needs to be cooled (do not open it suddenly and fully). Wait for a few minutes to observe the temperature changes in this section. If there is no obvious downward trend or it drops to a certain new equilibrium temperature, but it exceeds When the allowable value is reached, the pipeline valve can be increased or decreased appropriately. The barrel of the feeding section is only equipped with a manual shut-off valve. For materials that have no tendency to melt and accumulate at the feeding port, the cooling section does not need to be opened. This process often needs to be repeated to meet the requirements. After the valve opening adjustment is determined, no further adjustment is generally required for the same material operation. The water temperature of the soft water tank is controlled by adjusting the water tank cooler.
For the exhaust operation, the vacuum pump should generally be started after the host enters a stable operating state (before starting, open the vacuum pump water inlet valve, adjust and control the appropriate working water volume, and take a small amount of water spraying out from the vacuum pump exhaust port as the allow). Observe the plasticization and filling of the material in the screw channel from the exhaust port. If it is normal, you can open the vacuum pipeline valve and control the vacuum degree. If there is material ejection from the exhaust port, you can adjust the screw speed of the host and feeder, and change Screw combination configuration, etc. to eliminate. When cleaning the material that has emerged from the exhaust chamber, do not touch the cleaning tool to the rotating screw. Before closing the vacuum chamber, you should first close the vacuum pipe valve and then turn off the vacuum pump to prevent air from flowing back in the vacuum pipe.
After the test run, return to %% load trial production hours, so that all moving parts can be run-in before being put into normal production.
Precautions for the operation of the host of the low-smoke halogen-free cable material granulator for new energy charging piles
The rated current of the host is the rated current of the motor. During normal operation, it should be controlled below % of the rated current, leaving room for Prevent overload (for rated current, please refer to the motor nameplate). The rated voltage and frequency of the host should be controlled above % of the rated voltage and frequency during normal operation.
. Operators should regularly check the tail lubricating oil pressure gauge (value.). If it is lower than ., the machine should be stopped immediately to check the oil circuit, oil pump motor and oil pump to protect the normal operation of the transmission box gear.
The machine head pressure sensor is equipped with a digital display. In normal operation, the digital display number should be below. The operator should always monitor the digital display number. If it exceeds the above number, then check whether the flow channel is blocked, stop feeding immediately, and gradually reduce the host screw speed and adjust The number on the sensor's digital display is below. If the number on the digital display is still high, the machine should be shut down manually for inspection.
During normal operation, there should be operation records.
, normal stop
Adjust the screw speed of the feeder to zero and press the stop button of the feeder.
Gradually reduce the screw speed of the main engine and drain the remaining material in the barrel at low speed. After the material is basically discharged, adjust the screw speed to zero and press the main motor stop button to stop the machine. At the same time, close the valve next to the vacuum chamber and open the vacuum chamber cover.
Close the vacuum line valve.
Stop all auxiliary power supplies.
Press the stop buttons of the main motor, oil pump, water pump and the heating power switch of each section on the electric control cabinet in sequence.
Clean up the remaining materials inside and outside the machine head, clean the entire unit working area, and keep the site clean.
, Emergency Stop
When you need to stop the host in an emergency, you can quickly press the red emergency stop button of the electric control cabinet. And turn the main machine, double-wrist feeder, and hot-heating speed control knob back to the zero position, and then cut off the main power switch. After the fault is eliminated, the vehicle can be driven again according to normal driving procedures.
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New energy charging pile low smoke halogen-free cable material granulator, cable material granulator manufacturer