WBZD100/65-900臥式三層共擠片材機組

一、工藝流程

擠出→換網

共擠分配器→成型擠出→兩輥壓片→冷卻切邊→牽引→卷取

擠出→換網

 

二、制品參數

1、制品形式：三層片材

2、適應原料：PP、HIPS、KPS

3、制品規格：寬度≤760mm、厚度0.18-2mm

4、制品厚度誤差: ±0.01mm

5、分層形式:  AB、ABA

6、分層比例：A層25% 、B層75%

7、生產能力：≤220Kg/H

8、整機功率：約200kw

 

三、機組組成

1、SJ100/33：1擠出機                     1臺

2、SJ65/33：1擠出機                      1臺

3、液壓快速換網器                        2套

4、二擠出三層分配器                      1套

5、推拉式共擠模頭                        1個

6、風刀                                  1套

7、臥式兩輥壓光機                        1臺

8、恒溫機                                1臺

9、冷卻切邊裝置                          1套

10、牽引裝置                             1套

11、中心翻轉三工位收卷機                 1臺

12、電氣控制柜                           1屏

 

四、機組配置

 

1、擠出主機B

（1）螺桿直徑φ100，長徑比33：1

（2）機筒螺桿材料38CrMOALA，氮化處理，氮化層厚度0.4-0.6mm表面硬度HV865-920

（3）螺桿最高轉速：98r/min

（4）電機功率：型號280M-55kw-6

（5）電機調速形式：55kw變頻調速（歐瑞）

（6）減速箱：立式高強度硬齒面減速箱帶油冷卻器ZLYJ-280-10-V(國茂)

（7）電機傳動形式：電機通過聯軸器同減速機聯軸傳動

（8）加熱器：擠出機筒采用五區陶瓷加熱器，不銹風機外罩，五組冷卻風機

（9）加熱功率：5×7.2kw=36kw（三相星型接法）

冷卻風機：5×0.3kw=1.25kw（三相380V）

 

2、擠出輔機A

（1）螺桿直徑φ65，長徑比 33：1

（2）機筒螺桿材料：38CrMOALA，氮化處理，氮化層厚度0.4-0.6mm,表面硬度HV865-920

（3）螺桿最高轉速：98r/min

（4）電機功率：200L-22kw-6

（5）電機調速形式：22kw變頻調速(歐瑞)

（6）減速箱：立式高強度硬齒面減速箱ZLYJ-200-10-V (國茂)

（7）電機傳動形式：聯軸器直連

（8）加熱器：擠出機筒采用四區陶瓷加熱器，不銹風機外罩、四組冷卻風機

（9）加熱功率：4×4kw=16kw（三相星型接法）

冷卻風機：4×0.25kw=1kw（三相380V）

 

3、板式雙工位液壓快速換網器

（1）帶儲能罐液壓站，油泵電機功率2.2kw

（2）液壓系統元件采用臺灣品牌

（3）換網器采用柔性膨脹環密封，可靠不漏料，配壓力傳感器及壓力顯示

（4）換網器采用不銹加熱棒加熱，A換網加熱功率3.6kw，B換網加熱功率6kw

 

4、兩擠出三層分配器

（1）兩擠出三層共擠分配器，帶AB、ABA芯棒各一條

（2）獨立溫控區，加熱功率4Kw

 

5、推拉式共擠模頭

（1）模頭形式：推拉式兩片可調精密模頭，有效寬度800，內置加熱器，帶可調擋料板

（2）模頭材料采用優質合金鋼材，經調質定型，表面氮化，鍍硬鉻拋光等精工制作，具有流道光滑，模唇開合均勻，分流調節平滑，能耗低

（3）模頭加熱功率：12kw

 

6、風刀

（1）鋁合金材質，兩片式結構，風口有效寬度850mm，可手動微調

（2）風刀高度及角度可調

（3） 配置5.5Kw高壓氣泵及管道

 

7、臥式兩輥壓片機

（1）壓光機形式：輥筒渦輪蝸桿壓合，開啟；擺動輥為手輪調節擺動角度

（2）輥筒規格：Φ400×850鏡面輥2條，Φ250×900擺動輥1條

（3）輥筒結構：三層結構，冷卻流道為交叉對流形式，單頭進出水，外輥經調質中頻處理，輥面硬度HRC52～56

（4）輥筒表面：鍍硬鉻，壓光后鍍層厚度，0.08～0.10mm，鏡面粗糙度，Ra≤0.01μm

（5）輥筒精度：徑向跳動≤0.005，圓柱度≤0.005

（6）三輥軸承，日本NSK品牌

（7）電機功率： 2.2kw×2=4.4 kw

（8）調速形式：變頻調速控制（歐瑞）

（9）傳動形式：GKAF斜齒輪-弧齒錐齒減速機（國茂）與輥筒直聯，可單獨調速或聯動

減速機型號：GFA77 –Y2.2-4P-58.32，2臺；擺動輥為無動力輥，用于調整膜片平整度

（10）輥筒調距：絲桿斜塊微調結構

（11）縱向行走：電動行走定位裝置，配減速器帶電機，0.37 kw

減速機型號：RVE040/075-300-0.37

（12）壓光機垂直升降裝置：配JX-5T -1/30升降機4臺，配RV50-7.5-0.75減速電機 1臺

 

8、恒溫機

（1）恒溫形式，加熱器，冷卻器串聯式封閉系統，加熱/冷卻介質：水

（2）配高效特種泵，功率1.1kw×2=2.2kw，流量6m³/h臺，揚程27M，公稱直徑DN40

（3）加熱器功率：12kw×2=24kw

（4）獨立溫度控制柜

 

9、冷卻帶切邊裝置

（1）冷卻部分由Φ200×900助冷輥及Φ80×900鋁合金導輥組成

（2）手調切邊裝置一套，配置3把切刀

 

8、牽引機帶卷邊裝置

（1）牽引裝置動力：減速機GR67-Y2.2KW-4P-17.95,可與三輥統一聯控

（2）牽引鋼輥Φ200×900一根，硅膠輥Φ200×900一根

 

10、三工位中心翻轉收卷機

（1）采用斜齒輪-傘齒輪（SK67-22.77-Y100M4）與力矩電機直接傳動

（2）配Φ74×900mm氣漲軸3根

（3）卷取的最大直徑≤600mm

 

11、電氣控制系統

（1）擠出機、壓光三輥及牽引由歐瑞變頻器控制

（2）加熱溫控區設置：B擠出機設置5區，A擠出機設置4區，換網器設置2區，過度彎頭設置2區，分配器1區，模頭設置5區，總共19溫控區

（3）日本三菱PLC，10寸威倫觸摸屏

（4）溫控儀采用富士溫控表帶PID調節，有自定記憶抗干擾功能，控溫精度±1^O C

（5）中間繼電器采、接觸器、按鈕開關、行程開關采用國產名牌

（6）空氣開關、電流表、電壓表、K型熱電偶、互感器、接換開關等采用國產名牌

WBZD100/65-900Horizontal three - layer co-extrusion sheet unit

 

I. technological process

Extrusion → net change

Co-extrusion distributor → molding extrusion → two-roll lamination → cooling cutting edge → traction → coiling

Extrusion → net change

 

Product parameters

1. Product form: three-layer sheet

2, adapt to raw materials: PP, HIPS, KPS

3. Product specification: width ≤760mm, thickness 0.18-2mm

4. Product thickness error: ±0.01mm

5. Layered form: AB and ABA

6. Layering ratio: 25% of layer A and 75% of layer B

7. Production capacity: ≤220Kg/H

8. Machine power: about 200kw

 

Iii. Unit composition

1. Sj100/33:1 extruder                    1set

2. Sj65/33:1 extruder                     1set

3, hydraulic quick net changer             1set

4, two extrusion three layer distributor       1set

5. Push-pull co-extrusion die head          1set

6, wind knife                             1set

7. Horizontal two-roll calender              1set

8. Thermostat                            1set

9. Cooling edge cutting device              1set

10. Traction device                        1set

11. Rewinding machine with three working positions of center turnover          1set

12. Electrical control cabinet                 1set

 

Machine  configuration

 

1. Extrude host B

(1) screw diameter 100, length-diameter ratio 33:1

(2) barrel screw material 38CrMOALA, nitriding treatment, nitriding layer thickness 0.4-0.6mm surface hardness hv865-920

(3) maximum rotation speed of screw: 98r/min

(4) motor power: model 280m-55kw-6

(5) motor speed regulation form: 55kw frequency conversion speed regulation (ourui)

(6) reducer: vertical high-strength hard-toothed reducer with oil cooler zlyj-280-10-v (guo mo)

(7) motor transmission: the motor is driven by coupling and reducer

(8) heater: the extruder cylinder is equipped with a five-zone ceramic heater, a stainless fan cover, and five groups of cooling fans

(9) heating power: 5×7.2kw=36kw (three-phase star connection)

Cooling fan: 5×0.3kw=1.25kw (three-phase 380V)

2. Extrusion auxiliary machine A

(1) screw diameter 65, length-diameter ratio 33:1

(2) barrel screw material: 38CrMOALA, nitriding treatment, nitriding layer thickness 0.4-0.6mm, surface hardness hv865-920

(3) maximum rotation speed of screw: 98r/min

(4) motor power: 200l-22kw-6

(5) motor speed regulation form: 22kw frequency conversion speed regulation (ourui)

(6) reducer: vertical high-strength hard tooth surface reducer zlyj-200-10-v (guo MAO)

(7) motor transmission: coupling is connected directly

(8) heater: the extruder cylinder adopts four-zone ceramic heater, stainless fan cover, and four groups of cooling fans

(9) heating power: 4×4kw=16kw (three-phase star connection)

Cooling fan: 4×0.25kw=1kw (three-phase 380V)

3. Plate type double station hydraulic quick net changer

(1) hydraulic station with energy storage tank, the power of oil pump motor is 2.2kw

(2) hydraulic system components adopt Taiwan brand

(3) the net changer adopts flexible expansion ring seal, reliable and no leakage, equipped with pressure sensor and pressure display

(4) the screen changer is heated with an stainless heating rod. The heating power of A screen changer is 3.6kw, and that of B screen changer is 6kw

4. Two extrusion three layer distributor

(1) two extrusion three-layer co-extrusion distributor with one AB and one ABA mandrel

(2) independent temperature control zone, heating power is 4Kw

 

5. Push-pull co-extrusion die head

(1) form of die head: push-pull two adjustable precision die head, effective width of 800, built-in heater, with adjustable baffle plate

(2) the material of die head is made of high-quality alloy steel, which is made by finalizing and tempering, nitriding on the surface, polishing with hard chromium plating, etc. It has smooth flow passage, even opening and closing of die lip, smooth flow regulation and low energy consumption

(3) heating power of die head: 12kw

6. Wind knife

(1) aluminum alloy, two-piece structure, tuyere effective width of 850mm, can be manually adjusted

(2) adjustable air knife height and Angle

(3) 5.5kw high-pressure air pump and pipeline are configured

7. Horizontal two-roll tablet press

(1) form of calender: roller turbine worm press and open;

Swing roller adjusts swing Angle for hand wheel

(2) roller specification: 400 x 850 mirror roll Φ article 2, article 250 x 900 floating roller Φ 1

(3) roller structure: three-layer structure, the cooling passage is in the form of cross convection, the single head is in and out of water, the outer roller is treated with medium frequency of quenching and tempering, and the surface hardness HRC52 ~ 56

(4) roller surface: hard chromium plating, coating thickness after pressing, 0.08 ~ 0.10mm, mirror roughness, Ra≤0.01 micron

(5) roller precision: radial runout ≤0.005, cylindrical ≤0.005

(6) three-roller bearing, Japanese NSK brand

(7) motor power: 2.2kw×2= 4.4kw

(8) speed regulation form: frequency conversion speed regulation control (orui)

(9) transmission mode: GKAF helical gear -- arc tooth taper gear reducer (guomao) is directly connected with the roller, which can be adjusted independently or linkage

Deceleration type: GFA77 -- y2.2-4p-58.32, 2 sets;

The swing roller is a non-powered roller used to adjust the flatness of the diaphragm

(10) roller distance adjustment: fine-tuning structure of screw diagonal block

(11) longitudinal walking: electric walking positioning device, with reducer with motor, 0.37kw

Deceleration model number: rve040/075-300-0.37

(12) vertical lifting device of polisher: equipped with 4 jx-5t-1/30 lifts and 1 rv50-7.5-0.75 reducer motor.

8. Thermostat

(1) constant temperature form, heater, cooler series closed system, heating/cooling medium: water

(2) equipped with high-efficiency special pump, power 1.1kw×2=2.2kw, flow 6m3/h, head 27M, nominal diameter DN40

(3) heater power: 12kw×2=24kw

(4) independent temperature control cabinet

 

9. Cooling belt edge cutting device

(1) cooling part by Φ 200 x 900 help cold roll and Φ 80 x 900 aluminum alloy guide roll

(2) a set of manual trimming device, equipped with 3 cutting knives

8. Tractor with edge winding device

(1) traction device power: reducer gr67-y2.2kw-4p-17.95, unified linkage control with three rollers

(2) the traction steel roller Φ 200 x 900 a, 200 x 900 a silica gel roller Φ

 

10. Three-station center rollover and rewinding machine

(1) helical gear - bevel gear (sk67-22.77-y100m4) and torque motor direct drive

74 x 900 mm (2) with Φ gas rose axis 3 root

(3) the maximum diameter of coiling ≤600mm

 

11. Electrical control system

(1) the extruder, three rollers and traction are controlled by ourui frequency converter

(2) setting of heating temperature control zone: set 5 zones for the extruder, 4 zones for the extruder, 2 zones for the net changer, 2 zones for the excessive elbow, 1 zone for the distributor, 5 zones for the die head, and A total of 19 temperature control zones

(3) mitsubishi PLC of Japan, 10-inch willen touch screen

(4) temperature controller adopts Fuji temperature control band PID adjustment, with self-determining memory anti-interference function, temperature control accuracy ±1O C

(5) the intermediate relay, contactor, button switch and travel switch adopt domestic famous brand

(6) air switch, ammeter, voltmeter, k-type thermocouple, mutual inductor, change-over switch and so on adopt domestic famous brand