Rubber calender is an essential equipment in the processing of rubber and plastic products. As a heavy-duty and high-precision machine in rubber and plastic machinery, it enables the production of high-quality rubber products. Below is a detailed introduction to the rubber calender, its structural composition, working principles, classification, parameter indicators, operation points, and maintenance requirements.

The rubber calender is made up of several components, including the working roller, frame, machine base, transmission device, speed and distance adjustment device, roller heating and cooling device, lubrication system, and emergency stop device. The working roller is the core component responsible for calendering rubber, and the frame supports and fixes other components. The machine base carries the entire calender equipment and ensures its smooth operation. The transmission device transmits power to the roller, while the speed ​​and distance adjustment device adjusts the speed and distance between rollers. The roller heating and cooling device helps to maintain the rubber's plasticity, and the lubrication system provides lubrication for various moving parts. The emergency stop device prevents accidents by stopping the equipment during abnormal conditions.

The rubber calender works by squeezing and stretching heated mixed rubber through the gap between two or more rollers that rotate relatively and are horizontally set. This process changes the molecular structure of the rubber and improves its plasticity, while controlling the thickness, width and other dimensions of the rubber.

Rubber calenders are classified according to the number of rollers, as well as by their process use. Two-roll calenders are simple and mainly used when calendering accuracy is not high. Three-roll calenders are widely used for producing sheets, rub textiles and other operations, while four-roll calenders produce thinner products and complete double-sided gluing operations. There are many form arrangements like L-type, Z-type and S-type. Other classification methods include: sheeting calender, rubber rubbing calender, general calender, profile calender, laminating calender, and steel wire calender.

Rubber calender parameter indicators include roller linear speed, speed range, and speed ratio. Roller linear speed is expressed in "m/min" and measures the production capacity of the calender. Speed ​​range must be about 10 times to meet the requirements of different processes. The speed ratio differs per the process needs of the rubber materials.

During operation, the equipment should be prepared and checked beforehand. The feeding of rubber material should be done moderately to avoid affecting the calendering effect. The roller speed, spacing, temperature, and other parameters should be adjusted according to the molding of rubber products. Finally, the equipment should only be stopped after all the rubber on the roller is discharged and cleaned.

Proper maintenance is critical for the longevity of the rubber calender. Daily maintenance, regular maintenance, and troubleshooting are essential. Daily maintenance entails regular checks of the equipment, addressing issues found. Regular maintenance, as per the equipment operating instructions, involves general maintenance tasks like changing lubricating oil, cleaning the rollers, and adjusting the gaps of various components. Finally, when troubleshooting, the problem must be identified and solved promptly.

1. Equipment Inspection:
   • Inspect various components of the calender such as rollers, transmission systems, spacing devices, and temperature control systems to ensure no looseness or damage.
   • Clean and smoothen the surface of the roller, and repair it whenever necessary.
2. Material Preparation:
   • Prepare accurate rubber raw materials and mix them uniformly.
   • Mix the rubber in advance to give it suitable plasticity.
   • Prepare auxiliary materials like additives and fillers according to the production's needs.
3. Parameter Setting:
   • Set the roller speed, roller spacing, working temperature and other parameters in the control system according to rubber products' specifications and production requirements.

1. Start the Transmission System:
   • Turn on the calender's transmission system and observe whether the roller rotates smoothly without any abnormality.
   • If any abnormality is found, immediately stop the machine and troubleshoot it.
2. Preheat the Roller:
   • Start the temperature control system to preheat the roller, and gradually heat it to the appropriate processing temperature range.
   • Continuously monitor the temperature changes to ensure the temperature rise is stable and uniform.

1. Feeding:
   • Feed the prepared rubber raw materials slowly and evenly into the feed port between the rollers.
   • Moderate the feeding speed to avoid accumulation or slow production efficiency.
2. Calendering Adjustment:
   • Adjust the spacing between the rollers through the spacing device to meet the thickness requirements.
   • Monitor the flow of rubber between the rollers to ensure even squeezing and stretching, adjust the roller's speed ratio and parameters if necessary.
3. Quality Monitoring:
   • Continuously check the quality of the calendered rubber products, including appearance, dimensional accuracy, and the presence of bubbles or impurities.
   • Analyze and take corrective measures in time when quality problems arise.

1. Stop Feeding:
   • Stop feeding the rollers and let the remaining rubber between the rollers continue to be calendered until the rollers are sent out.
2. Cooling Roller:
   • Turn off the heating function and on the cooling function to gradually cool the roller down and prevent it from being damaged.
   • Allow subsequent equipment maintenance and cleaning.
3. Stop the Transmission System:
   • Stop the transmission system to stop the roller from rotating.
4. Equipment Cleaning
   • Clean the calender thoroughly, remove debris, and prepare for the next start-up.