Product Description:
Rubber Calender: Introduction, Composition, Principle, Classification, Parameters, Operations, and Maintenance
Rubber calender is one of the most important equipment used in the processing of rubber and plastic products. It is heavy-duty and high-precision machinery used in the rubber and plastic industry. This detailed guide will cover the structural composition, working principle, classification methods, parameter indicators, operation points, and maintenance of rubber calenders.
Composition of Rubber Calender
Rubber calender consists of several key components:
- Working Roller
- Frame
- Machine Base
- Transmission Device
- Speed and Distance Adjustment Device
- Roller Heating and Cooling Device
- Lubrication System
- Emergency Stop Device
Working Principle of Rubber Calender
The heated and mixed rubber is squeezed and stretched through the gap between two or more rotating rollers placed horizontally, forming semi-finished products such as films. During this process, the molecular structure of the rubber changes, improving its plasticity, and the rubber's dimensions are fully controlled.
Classification Methods of Rubber Calender
Rubber calender can be divided into different types:
- Classification by the number of rollers:
- Two-roll calender
- Three-roll calender
- Four-roll calender
- Classification by process use:
- Sheeting calender
- Rubber rubbing calender
- General calender
- Profile calender
- Laminating calender
- Steel wire calender
Parameter Indicators of Rubber Calender
There are several parameter indicators of rubber calender:
- Roller Linear Speed
- Speed Range
- Speed Ratio
Operation Points of Rubber Calender
Some important operation points of rubber calender:
- Preparation before starting
- Feeding operation
- Adjustment of the calendering process
- Stop operation
Maintenance of Rubber Calender
The maintenance of rubber calender can be divided into three parts:
- Daily maintenance
- Regular maintenance
- Troubleshooting
Features:
The Main Features of Rubber Calenders
The rubber calender is a machine used in the production of various rubber products. Its main features are:
- Working Principle: The rubber material is stretched and thinned by the pressure applied through the relative rotation of multiple rollers, resulting in uniform thickness control.
- Structural Features: The roller is a key component, usually made of high-quality steel with high hardness, strength, good thermal conductivity, and high surface accuracy to ensure the quality of the calendered products. It is also equipped with a complete transmission system that can accurately control the roller speed and achieve different calendering speeds and speed ratios.
- There is a reliable spacing device that can flexibly adjust the spacing between rollers to adapt to the calendering of rubber materials of different thicknesses.
- Precision Control: The rubber calender can accurately control 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.
- Temperature Regulation: Most rubber calenders have roller heating or cooling functions. The temperature control system can keep the roller at a suitable working temperature, generally between 50℃ and 150℃, which is conducive to the plasticization and molding of rubber.
- Production Efficiency: The rubber calender has high production efficiency and can operate continuously. It can quickly calender a large amount of rubber raw materials into products of required specifications. The hourly output varies according to the machine model and process. Small ones may be several tons per hour, and large industrial ones can reach tens of tons.
- Scope of Application: The rubber calender is widely used in the production of various rubber products, such as tires, conveyor belts, rubber sheets, seals, etc. Raw material processing links.
Technical Parameters:
Model Specifications for Roller Calender Machine
Model XY-2I Series
The XY-2I Series roller calender machine comes in different sizes with various specifications:
| Item | XY-2I()320 | XY-2I()620 | XY-2I()1120A | XY-2I()1500 | XY-2I()1830 | XY-2I()1730 | XY-2I()2430 |
| Roll diameter (mm) | 160 | 250 | 360 | 450 | 550 | 610 | 810 |
| Roll working length (mm) | 320 | 620 | 1120 | 1500 | 1830 | 1730 | 2430 |
| Roll ratio | 1:1 | 1:1 | 1:1 | 1:1 | 1:1.08 | 1:1 | 1:1 |
| Roll linear speed (r/min) | 7.79 | 14.8 | 3-20.2 | 2.5-24.8 | 2-18.7 | 4-36 | 2-20 |
| Adjusting nip range | 0-4.5 | 0-5.5 | 0-10 | 0-10 | 0-12 | 0-15 | 0.5-25 |
| Min.calendering product thickness (mm) | 0.2 | 0.2 | 0.2 | 0.2 | 0.2 | 0.2 | 0.5 |
| Calendering product width (mm) | 250 | 580 | 920 | 1250 | 1600 | 1500 | 2150 |
| Motor power (kW) | 5.5 | 15 | 37 | 45 | 75 | 90 | 160 |
| Overall dimensions L x W x H (mm) | 2200 x 530 x 1470 | 3100 x 770 x 1590 | 5400 x 1542 x 1681 | 7113 x 1595 x 2446 | 7420 x 1760 x 2760 | 5987 x 1860 x 2988 | 8690 x 3139 x 4270 |
| Weight (t) | ~1.2 | ~3 | ~14.5 | ~22 | ~24 | ~30 | ~62 |
Model XY-3I Series
The XY-3I Series roller calender machine comes in different sizes with various specifications:
| Item | XY-3I 630 | XY-3I 1120A | XY-3 1120A | XY-3l1120A | XY-3I 1400 | XY-3I 1200 | XY-3I 1500 | XY-3I 1730 | XY-3I 2130 |
| Roll diameter (mm) | 230 | 360 | 400 | 450 | 610 | 710 | – | – | – |
| Roll working length (mm) | 630 | 1120 | 1120 | 1120(1500) | 1400 | 1200 | 1500 | 1730 | 2130 |
| Roll ratio | 1:1:1 | 1:1.42:1 | 1:1:1 | 0.733:1:1
0.733:1:0.733 | 1:1.383:1.383
1:1.383:1 | 1:1.5:1 | 1:1.4:1 | 1:1.48:1 | 1:1.5:1 |
| Middle-roll linear speed (m/min) | 7.97 | 7.0-21.06 | 8.8-26.39 | 8.36-25.08 | 5.4-54 | 8-50 | 2-20 | — | — |
| Adjusting nip range (mm) | 0-7 | 0-10 | 0-10 | 0-6 | 0-20 | 0-20 | 0.5-25 | — | — |
| Min.calendering product thickness (mm) | 0.2 | 0.2 | 0.2 | 0.15 | 0.15 | 0.15 | 0.5 | — | — |
| Calendering product width (mm) | 100-500 | 500-920 | 1200 | 1100(1400) | 1500 | 1900 | 2150 | — | — |
| Motor power (kW) | 7.5 | 40/13.3 | 55/18.3 | 75/25 | 132 | 185 | 220 | — | — |
| Overall dimensions L x W x H (mm) | 2570 x 740 x 1500 | 5550 x 1640 x 2120 | 6500 x 1500 x 2440 | 7120(7420) x 2200 x 2900 | 7010 x 3950 x 3730 | 7650 x 4560 x 4080 | — | — | — |
| Weight (kg) | about 4200 | about 12750 | about 26000 | about 27000 | about 52000 | about 67000 | — | — | — |
Model XY-4I Series
The XY-4I Series roller calender machine comes in different sizes with various specifications:
| Item | XY-4I 630 | XY-4L 630 | XY-4630 | XY-41120A | XY-41400 | XY-41500 | XY-41730 | XY-42130 | XY-42430 |
| Roll diameter (mm) | 230 | 360 | 400 | 450 | 610 | 710 | 810 | – | – |
| Roll working length (mm) | 630 | 1120 | 1400 | 1500 | – | – | 1730 | 2130 | 2430 |
| Roll ratio | 1:1:1:1 | 0.73:1:1:0.73 | 1:1.38:1.38:1 | 1:1.5:1.5:1 | 1:1.4:1.4:1 | 1:1.4:1.4:1.4 | 1:1.5:1.5:1 | 1:1.5:1.5:1 | 1:1.5:1.5:1 |
| Middle-roll linear speed (m/min) | 2.1-21 | 2- |
Applications:
The Operation Process of Rubber Calender
The operation process of the rubber calender involves preparation before starting, start-up operation, calendering process operation, and shutdown operation. Here's a detailed breakdown of the process:
Preparation before Starting
Before starting the calender, some essential preparations must be taken:
- Equipment inspection:
- Check the various components of the calender, such as rollers, transmission systems, spacing devices, temperature control systems, etc. Ensure that the components are well-connected, and there is no looseness or damage.
- Check the surface of the roller and clean it if there is debris or damage.
- Material preparation:
- Prepare the rubber raw materials to ensure that their formula is accurate and mixing is uniform.
- Prepare auxiliary materials such as additives and fillers required for production.
- Parameter setting:
- Set 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, and the appropriate working temperature needs to be determined for different types of rubber.
Start-up Operation
The start-up operation involves:
- Starting the transmission system: This is done to ensure that the roller starts to rotate slowly. It is essential to observe whether the roller rotates smoothly and detect any abnormal sounds or vibrations.
- Preheating the roller: The temperature control system is started to preheat the roller according to the set working temperature. During the preheating process, the temperature changes are monitored to ensure that the temperature rise is uniform and stable.
Calendering Process Operation
The main operations to be carried out during the calendering process are:
- Feeding: Prepared rubber raw materials are fed slowly and evenly into the feed port between the rollers. The feeding speed should be moderate to avoid any issues.
- Calendering adjustment:
- Check the molding of rubber products, observe the flow of rubber between the rollers and adjust the speed ratio of rollers, and other necessary parameters.
- Continuously check the quality of the calendered rubber products, including appearance, and dimensional accuracy, among others.
Shutdown Operation
The shutdown operation process entails:
- Stop feeding: When current production tasks are completed or production needs to be suspended, first stop feeding the rollers, and let the remaining rubbers be calendered until all rollers are sent out.
- Cooling Roller: Turn off the heating function of the temperature control system and allow the roller to gradually cool down; the cooling function can be turned on as necessary.
- Stop the transmission system: After the roller has cooled down and the rubber has been fully delivered, stop the transmission system of the calender to stop the roller from rotating.
- Equipment cleaning: 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 in preparation for the next start-up.
Customization:
- Brand Name: Beishun
- Model Number: 4-roller, 3-roller, 4-roller
- Place of Origin: QINGDAO, CHINA
- Certification: CE, ISO, SGS
- Minimum Order Quantity: 1pcs
- Price: 10000usd-150000usd
- Delivery Time: 45day
- Payment Terms: L/C, T/T
- Supply Ability: 50 set/year
- Max Temperature: 200℃
- Heating Method: Steam/Oil/Electric
- Control System: PLC
- Material: Rubber
- Cooling System: Optional
These customization services are available for various applications, including Rubber roller machinery, Rubber sheet manufacturing machine, and Conveyor belt calender.
Packing and Shipping:
Product Packaging:
- One Rubber Calender Machine
- Instruction Manual
- Spare parts
Shipping:
- Shipping cost will be calculated based on the destination
- Shipping time may vary depending on the location
- Tracking number will be provided once the product is shipped
FAQ:
Q1: What is the brand name of the Calender Machine?
A1: The brand name of the Calender Machine is Beishun.
Q2: What are the available models of the Calender Machine?
A2: The available models of the Calender Machine are 4-roller, 3-roller, and 4-roller.
Q3: What is the place of origin of the Calender Machine?
A3: The Calender Machine is manufactured in QINGDAO, CHINA.
Q4: What certifications does the Calender Machine have?
A4: The Calender Machine has CE, ISO, and SGS certifications.
Q5: What are the payment terms for the Calender Machine?
A5: The payment terms for the Calender Machine are L/C and T/T.
