PLC Controlled Rubber Calendering Machine with 200-500mm Diameter Rollers

Product Description:

Features:

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:

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.

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.

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.

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.

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:

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.