CN204196034U - 一种串联式橡胶连续混炼装置 - Google Patents
一种串联式橡胶连续混炼装置 Download PDFInfo
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Abstract
本实用新型属于橡胶生产设备技术领域，涉及一种串联式橡胶连续混炼装置，整体呈上下两层式结构，Ⅰ号机架和Ⅱ号机架分别通过螺栓固定连接在Ⅱ号底座上，Ⅰ号底座上通过螺栓固定连接有密炼机，异向双转子连续混炼机通过螺栓固定设置在Ⅰ号机架和Ⅱ号机架上，密炼机的下端与异向双转子连续混炼机的上端之间通过存料斗贯通式对接，存料斗的左侧上端与Ⅰ号底座通过螺栓连接，存料斗的右侧上端通过螺栓固定安装有Ⅱ号油缸，Ⅱ号油缸下端通过传动杆连接设置有压砣，用于将存料斗中由密炼机排出的初混胶压入异向双转子连续混炼机中；该装置结构简单，组建简便，可控性强，能耗低，技术成熟，便于加工应用。
Description
技术领域：
本实用新型属于橡胶生产设备技术领域，具体涉及一种串联式橡胶连续混炼装置。
背景技术：
随着橡胶工业的发展，现有技术中的密炼机和开炼机，暴露出了越来越多的缺陷：成本高、环境污染严重、高能耗，且不能进行连续式生产，整体设备占地面积大，而为了控制胶料在生产中的温度，所使用的新型转子和较为复杂的冷却***，使得生产成本也越来越高。为了解决这些问题，国内外纷纷把目光投向了能连续生产、便捷、低能耗的橡胶连续式生产装置，但它依然存在许多不可忽视的问题，例如中国专利201120086371.8公开了一种炼胶设备，在整个炼胶设备主体中贯穿设置输料平台，并配有控制器、电机和连接线，以实现连续供料，但是该设备无法真正意义上实现混炼工艺的连续化；中国专利201220225751.X和201210155837.4公开了一种炼胶设备，包括依次连接的原料输送装置、预压装置、炼胶装置和切断装置，从而实现了输料、预压、混炼和切断一体化操作，但也未能从根本上解决炼胶工艺的连续性问题。
另外，中国发明专利200710116412.1公开了一种双工位串联组合式密炼机，分为上工位和下工位两部分，上工位是一台完整的密炼机，下工位是一台去掉上顶栓的密炼机，通过联接段料筒将上工位的排料口与下工位的进料口联接，上工位采用普通型低温转子，下工位要采用快速吃料型低温转子，该设备将两台密炼机二合一有机搭配，充分发挥了密炼机的加工能力，大大提高了硅胶等温度敏感性胶料的加工效率，由于下工位无上顶栓、填充系数小，所以排汽性非常好，解决了单工位密炼机的排汽问题，同时也提高了胶料质量的稳定性，减少了用工数量和能耗；但是两台密炼机涉及的整个控制***极为复杂，转子加工成本高，从而使得整个设备的生产成本大大增加，限制了其投入生产实际；而且在针对同一个配方时，需要确定的工艺参数较多，对其连续化生产的实现增加了难度；中国专利201110026212.3公开了一种块状橡胶连续混炼方法及设备，其配置了一台块状橡胶连续塑炼机和一台连续混炼机，块状橡胶原料无需进行前期处理，直接投入块状橡胶连续塑炼装备塑炼，塑炼胶再经橡胶连续混炼装备混炼，从而实现连续的加料、卸料、连续塑炼、连续混炼的连续化生产，但是在上述双螺杆连续混炼生产工艺中，小料动态称量***的控制精度不够精确，并且塑炼胶条的质量均匀性存在偏差，导致最终配方的配比出现偏差而不利于终炼胶的混炼质量；因此本实用新型研究设计出一种新型的串联式橡胶连续混炼装置，真正意义上实现连续式混炼。
发明内容：
本实用新型目的在于克服现有技术存在的缺点，研究出一种串联式橡胶连续混炼装置，由密炼机进行初步混炼,再配合异向双转子连续混炼机进行二段混炼，从而实现串联式橡胶连续混炼。
为了实现上述目的，本实用新型设计的串联式橡胶连续混炼装置整体呈上下两层式结构，主体结构包括密炼机、Ⅰ号底座、Ⅰ号机架、Ⅱ号底座、异向双转子连续混炼机、Ⅱ号机架、压砣、存料斗和Ⅱ号油缸，Ⅰ号机架和Ⅱ号机架分别通过螺栓固定连接在Ⅱ号底座上，Ⅰ号底座上通过螺栓固定连接有用于进行胶料初混的密炼机，异向双转子连续混炼机通过螺栓固定设置在Ⅰ号机架和Ⅱ号机架上用于进行二段混炼，密炼机的下端与异向双转子连续混炼机的上端之间通过存料斗贯通式对接，存料斗的左侧上端与Ⅰ号底座通过螺栓连接，存料斗的右侧上端通过螺栓固定安装有Ⅱ号油缸，Ⅱ号油缸下端通过传动杆连接设置有压砣，用于将存料斗中由密炼机排出的初混胶压入异向双转子连续混炼机中进行连续式二段混炼；所述异向双转子连续混炼机的主体结构包括排料口、混炼机机头、混炼机转子、混炼机机筒、喂料口、Ⅰ号联轴器、Ⅰ号减速器、Ⅱ号联轴器和Ⅰ号电机，混炼机机头的左端开设有排料口用于排出制得的半成品胶片，混炼机机头的右端与内部配套安装有混炼机转子的混炼机机筒固定对接，混炼机机筒的右端上方开设有喂料口，喂料口与存料斗贯通对接用于异向双转子连续混炼机吃进密炼机排出的初混胶；从右往左依次串联的Ⅰ号电机、Ⅱ号联轴器、Ⅰ号减速器和Ⅰ号联轴器共同组成动力***，为异向双转子连续混炼机提供动力。
本实用新型中涉及的密炼机主体结构包括下顶栓、密炼机转子、密炼室、加料门、上顶栓、Ⅰ号油缸、Ⅲ号机架、Ⅲ号联轴器、Ⅱ号减速器、Ⅳ号联轴器和Ⅱ号电机，密炼室通过螺栓连接安装在Ⅰ号底座上，Ⅲ号机架左侧开设有可关闭式结构的加料门，加料门与密炼室贯通，密炼室内设置有密炼机转子，密炼室上部通过螺栓连接设置有Ⅲ号机架，Ⅲ号机架上固定安装有Ⅰ号油缸，Ⅰ号油缸下端通过传动杆结构连接设置有上顶栓，用于保证密炼机工作时密炼室中的压力，下顶栓通过铰链连接在Ⅰ号底座上用于卸料；从右往左依次串联固定在Ⅰ号底座上的Ⅱ号电机、Ⅳ号联轴器、Ⅱ号减速器和Ⅲ号联轴器共同组成动力***为密炼机提供动力。
本实用新型中涉及的混炼机机筒的主体结构包括四段结构和大小均相同的机筒，每段机筒的内部开设有圆形槽用于安装混炼机转子，每段机筒的内壁开设有冷却通道用于控制混炼机机筒的温度，四段机筒之间通过螺栓固定密封对接；最右端机筒的正上方开设有喂料口，喂料口边缘设置有加厚层，以防止通过螺栓与存料斗贯通式对接时穿透冷却通道；混炼机机头的内部设有冷却通道用于控制混炼机机头的温度，混炼机机头与混炼机机筒之间通过螺栓固定密封对接，冷却通道中可根据需要选用水或油等不同冷却介质。
本实用新型中涉及的混炼机转子由两根大小相同、结构相互对称的转子组成，转子的主体结构包括芯轴、加料混炼段、剪切段、Ⅰ号捏炼段、Ⅰ号混炼输送段、混炼段、Ⅱ号捏炼段、Ⅱ号混炼输送段、混炼挤出段和转子头部，加料混炼段为从右往左螺距保持不变的单头螺纹结构混炼元件，剪切段为前后两端带有长度不同的左右旋突棱的剪切型混炼元件，Ⅰ号捏炼段为相互对应的齿形盘结构元件，Ⅰ号混炼输送段为从右往左螺距逐渐减小的双头螺纹结构元件，其螺纹上开设有与螺纹相垂直的槽，混炼段是由三段长度不同的螺旋突棱组成的啮合型元件，Ⅱ号捏炼段是由厚度相同且在圆周方向均匀分布六个棱的捏合盘交错叠加而组成的捏合元件，Ⅱ号混炼输送段为制有单一螺旋角和螺旋方向的螺棱的混炼元件，混炼挤出段为从右往左螺距保持不变的双头螺纹结构混炼元件；加料混炼段、剪切段、Ⅰ号捏炼段、Ⅰ号混炼输送段、混炼段、Ⅱ号捏炼段、Ⅱ号混炼输送段和混炼挤出段分别通过花键连接在芯轴上，转子头部固定安装在芯轴的最前端，采用上述组合方式连接以便于安装、拆卸和维修；异向双转子连续混炼机运行时，两根转子呈异向、等转速且部分啮合状态旋转，以实现加料、剪切、捏炼、输送、混炼和挤出等综合功能。
本实用新型与现有技术相比，将密炼机和连续式混炼机进行有效的结合，解决了现有的连续混炼生产工艺中，小料动态称量***的控制精度不够的问题；所设计的连续混炼机转子的整体结构简单实用便于加工应用，配合使用的五段冷却通道，能够有效增大控温的范围，并能有效保证工作过程中其内部混炼胶温度的相对恒定，使得整体装置能够适用于不同配方橡胶的混炼；该装置结构简单，组建简便，可控性强，能耗低，技术成熟，自动化程度高。
附图说明：
图1为本实用新型的主体结构原理示意图。
图2为本实用新型涉及的密炼机的结构原理侧视图。
图3为本实用新型涉及的存料斗的立体结构原理示意图。
图4为本实用新型涉及的异向双转子连续混炼机中机头、机筒和内部五段冷却通道的横向结构剖视图。
图5为本实用新型涉及的异向双转子连续混炼机中转子的结构俯视图。
图6为本实用新型涉及的异向双转子连续混炼机中机头、机筒和转子三者组装后工作部分内部结构原理横向剖视图。
具体实施方式：
下面结合附图并通过实施例对本实用新型作进一步详细说明。
实施例：
本实施例中串联式橡胶连续混炼装置整体呈上下两层式结构，主体结构包括密炼机1、Ⅰ号底座2、Ⅰ号机架3、Ⅱ号底座4、异向双转子连续混炼机5、Ⅱ号机架6、压砣7、存料斗8和Ⅱ号油缸9，Ⅰ号机架3和Ⅱ号机架6分别通过螺栓固定连接在Ⅱ号底座4上，Ⅰ号底座2上通过螺栓固定连接有用于进行胶料初混的密炼机1，异向双转子连续混炼机5通过螺栓固定设置在Ⅰ号机架3和Ⅱ号机架6上用于进行二段混炼，密炼机1的下端与异向双转子连续混炼机5的上端之间通过存料斗8贯通式对接，存料斗8的左侧上端与Ⅰ号底座2通过螺栓连接，其右侧上端通过螺栓固定安装有Ⅱ号油缸9，Ⅱ号油缸9下端通过传动杆连接设置有压砣7，用于将存料斗8中由密炼机1排出的初混胶压入异向双转子连续混炼机5中进行连续式二段混炼；所述异向双转子连续混炼机5的主体结构包括排料口10、混炼机机头11、混炼机转子12、混炼机机筒13、喂料口14、Ⅰ号联轴器15、Ⅰ号减速器16、Ⅱ号联轴器17和Ⅰ号电机18，混炼机机头11的左端开设有排料口10用于排出制得的半成品胶片，混炼机机头11的右端与内部配套安装有混炼机转子12的混炼机机筒13固定对接，混炼机机筒13的右端上方开设有喂料口14，喂料口14与存料斗8贯通对接用于异向双转子连续混炼机5吃进密炼机1排出的初混胶；从右往左依次串联的Ⅰ号电机18、Ⅱ号联轴器17、Ⅰ号减速器16和Ⅰ号联轴器15共同组成动力***，为异向双转子连续混炼机5提供动力。
本实施例中涉及的密炼机1主体结构(如图1和图2所示)包括下顶栓19、密炼机转子20、密炼室21、加料门22、上顶栓23、Ⅰ号油缸24、Ⅲ号机架25、Ⅲ号联轴器26、Ⅱ号减速器27、Ⅳ号联轴器28和Ⅱ号电机29，密炼室21通过螺栓连接安装在Ⅰ号底座2上，Ⅲ号机架25左侧开设有可关闭式结构的加料门22，加料门22与密炼室21贯通，密炼室21内设置有密炼机转子20，密炼室21上部通过螺栓连接设置有Ⅲ号机架25，Ⅲ号机架25上固定安装有Ⅰ号油缸24，Ⅰ号油缸24下端通过传动杆结构连接设置有上顶栓23，用于保证密炼机工作时密炼室21中的压力，下顶栓19通过铰链连接在Ⅰ号底座2上用于卸料；从右往左依次串联固定在Ⅰ号底座2上的Ⅱ号电机29、Ⅳ号联轴器28、Ⅱ号减速器27和Ⅲ号联轴器26共同组成动力***为密炼机1提供动力。
本实施中涉及的混炼机机筒13的主体结构(如图4所示)包括四段结构和大小均相同的机筒30，每段机筒30的内部开设有圆形槽用于安装混炼机转子12，每段机筒30的内壁开设有冷却通道31用于控制混炼机机筒13的温度，四段机筒30之间通过螺栓固定密封对接；最右端机筒30的正上方开设有喂料口14，喂料口14边缘设置有加厚层，以防止通过螺栓与存料斗8贯通式对接时穿透冷却通道31；混炼机机头11的内部设有冷却通道31用于控制混炼机机头的温度，混炼机机头11与混炼机机筒13之间通过螺栓固定密封对接，冷却通道31中可根据需要选用水或油等不同冷却介质。
本实施例涉及的混炼机转子12由两根大小相同、结构相互对称的转子42组成(如图5所示)，转子42的主体结构包括芯轴32、加料混炼段33、剪切段34、Ⅰ号捏炼段35、Ⅰ号混炼输送段36、混炼段37、Ⅱ号捏炼段38、Ⅱ号混炼输送段39、混炼挤出段40和转子头部41，加料混炼段33为从右往左螺距保持不变的单头螺纹结构混炼元件，剪切段34为前后两端带有长度不同的左右旋突棱的剪切型混炼元件，Ⅰ号捏炼段35为相互对应的齿形盘结构元件，Ⅰ号混炼输送段36为从右往左螺距逐渐减小的双头螺纹结构元件，其螺纹上开设有与螺纹相垂直的槽，混炼段37是由三段长度不同的螺旋突棱组成的啮合型元件，Ⅱ号捏炼段38是由厚度相同且在圆周方向均匀分布六个棱的捏合盘交错叠加而组成的捏合元件，Ⅱ号混炼输送段39为混炼元件，其上有单一螺旋角和螺旋方向的螺棱，混炼挤出段40为从右往左螺距保持不变的双头螺纹结构混炼元件；加料混炼段33、剪切段34、Ⅰ号捏炼段35、Ⅰ号混炼输送段36、混炼段37、Ⅱ号捏炼段38、Ⅱ号混炼输送段39和混炼挤出段40分别通过花键连接在芯轴32上，转子头部41固定安装在芯轴32的最前端，采用上述组合方式连接以便于安装、拆卸和维修；异向双转子连续混炼机5运行时，两根转子42呈异向、等转速且部分啮合状态旋转，以实现加料、剪切、捏炼、输送、混炼和挤出等综合功能。
本实施例涉及的串联式橡胶连续混炼装置的运行过程为：橡胶配方的基体胶和配合剂经加料门22加入到已设定好相应工艺参数的密炼室21中，由Ⅱ号电机29运转通过Ⅳ号联轴器28将动力传给Ⅱ号减速器27，经减速后的动力通过Ⅲ号联轴器26传递给密炼机转子20，期间配合上顶栓23的运作，实现密炼机1对物料的初步混炼；经密炼机1混炼后制成的初混胶块沿存料斗8并在压砣7的作用下经过喂料口14进入已设定好相应工艺参数的异向双转子连续混炼机5中，由Ⅰ号电机18运转通过Ⅱ号联轴器17将动力传给Ⅰ号减速器16，经减速后的动力通过Ⅰ号联轴器15传递给混炼机转子12，从而实现异向双转子连续混炼机5对初混胶块的二段混炼，混炼完成后制成的半成品胶片沿排料口10挤出。
Claims (4)
1.一种串联式橡胶连续混炼装置，其特征在于混炼装置整体呈上下两层式结构，主体结构包括密炼机、Ⅰ号底座、Ⅰ号机架、Ⅱ号底座、异向双转子连续混炼机、Ⅱ号机架、压砣、存料斗和Ⅱ号油缸，Ⅰ号机架和Ⅱ号机架分别通过螺栓固定连接在Ⅱ号底座上，Ⅰ号底座上通过螺栓固定连接有密炼机，异向双转子连续混炼机通过螺栓固定设置在Ⅰ号机架和Ⅱ号机架上，密炼机的下端与异向双转子连续混炼机的上端之间通过存料斗贯通式对接，存料斗的左侧上端与Ⅰ号底座通过螺栓连接，存料斗的右侧上端通过螺栓固定安装有Ⅱ号油缸，Ⅱ号油缸下端通过传动杆连接设置有压砣；所述异向双转子连续混炼机的主体结构包括排料口、混炼机机头、混炼机转子、混炼机机筒、喂料口、Ⅰ号联轴器、Ⅰ号减速器、Ⅱ号联轴器和Ⅰ号电机，混炼机机头的左端开设有排料口，混炼机机头的右端与内部配套安装有混炼机转子的混炼机机筒固定对接，混炼机机筒的右端上方开设有喂料口，喂料口与存料斗贯通对接；从右往左依次串联的Ⅰ号电机、Ⅱ号联轴器、Ⅰ号减速器和Ⅰ号联轴器共同组成异向双转子连续混炼机的动力***。
2.根据权利要求1所述的串联式橡胶连续混炼装置，其特征在于所述密炼机主体结构包括下顶栓、密炼机转子、密炼室、加料门、上顶栓、Ⅰ号油缸、Ⅲ号机架、Ⅲ号联轴器、Ⅱ号减速器、Ⅳ号联轴器和Ⅱ号电机，密炼室通过螺栓连接安装在Ⅰ号底座上，Ⅲ号机架左侧开设有可关闭式结构的加料门，加料门与密炼室贯通，密炼室内设置有密炼机转子，密炼室上部通过螺栓连接设置有Ⅲ号机架，Ⅲ号机架上固定安装有Ⅰ号油缸，Ⅰ号油缸下端通过传动杆结构连接设置有上顶栓，下顶栓通过铰链连接在Ⅰ号底座上；从右往左依次串联固定在Ⅰ号底座上的Ⅱ号电机、Ⅳ号联轴器、Ⅱ号减速器和Ⅲ号联轴器共同组成密炼机的动力***。
3.根据权利要求1所述的串联式橡胶连续混炼装置，其特征在于所述混炼机机筒的主体结构包括四段结构和大小均相同的机筒，每段机筒的内部开设有圆形槽，每段机筒的内壁开设有冷却通道，四段机筒之间通过螺栓固定密封对接；最右端机筒的正上方开设有喂料口，喂料口边缘设置有加厚层；混炼机机头的内部设有冷却通道，混炼机机头与混炼机机筒之间通过螺栓固定密封对接，冷却通道中根据需要选用水或油作为冷却介质。
4.根据权利要求1所述的串联式橡胶连续混炼装置，其特征在于所述混炼机转子由两根大小相同、结构相互对称的转子组成，转子的主体结构包括芯轴、加料混炼段、剪切段、Ⅰ号捏炼段、Ⅰ号混炼输送段、混炼段、Ⅱ号捏炼段、Ⅱ号混炼输送段、混炼挤出段和转子头部，加料混炼段为从右往左螺距保持不变的单头螺纹结构混炼元件，剪切段为前后两端带有长度不同的左右旋突棱的剪切型混炼元件，Ⅰ号捏炼段为相互对应的齿形盘结构元件，Ⅰ号混炼输送段为从右往左螺距逐渐减小的双头螺纹结构元件，其螺纹上开设有与螺纹相垂直的槽，混炼段是由三段长度不同的螺旋突棱组成的啮合型元件，Ⅱ号捏炼段是由厚度相同且在圆周方向均匀分布六个棱的捏合盘交错叠加而组成的捏合元件，Ⅱ号混炼输送段为制有单一螺旋角和螺旋方向的螺棱的混炼元件，混炼挤出段为从右往左螺距保持不变的双头螺纹结构混炼元件；加料混炼段、剪切段、Ⅰ号捏炼段、Ⅰ号混炼输送段、混炼段、Ⅱ号捏炼段、Ⅱ号混炼输送段和混炼挤出段分别通过花键连接在芯轴上，转子头部固定安装在芯轴的最前端。
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| CN106956415A (zh) * | 2016-01-08 | 2017-07-18 | 华东理工大学 | 组合型双转子连续混炼挤出机 |
| CN112060388A (zh) * | 2020-09-22 | 2020-12-11 | 李冰 | 一种橡胶密炼机 |
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|---|---|---|---|---|
| CN104354236A (zh) * | 2014-11-14 | 2015-02-18 | 青岛科技大学 | 一种串联式橡胶连续混炼装置 |
| CN104354236B (zh) * | 2014-11-14 | 2016-11-23 | 青岛科技大学 | 一种串联式橡胶连续混炼装置 |
| CN106956415A (zh) * | 2016-01-08 | 2017-07-18 | 华东理工大学 | 组合型双转子连续混炼挤出机 |
| CN112060388A (zh) * | 2020-09-22 | 2020-12-11 | 李冰 | 一种橡胶密炼机 |
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