挤出机说明书30-25（英）.doc

浙江金湖机械集团有限公司浙江省舟山经济开发区B区 邮编：316001TELFAXmail: jinhuzjjinhu-china. ComJHS30/25Single Screw ExtruderOperation Manual Zhoushan Jinhai Machinery Co., LTD.Zhejiang Jinhu Machinery Co., LTD.15l 第 页Table of Contents1. General Description1.1 General Remarks on the Operating Manual1.2 Specifications1.3 Ancillary Equipment1.4 Range of Rotation Rate2. General Information2.1 Layout of the Assembly Units3.0 Installation3.1 General3.2 Convey of the Extruder3.3 Requirements of the Working Place3.4 Adjustment of the Extruder3.5 Laying of the Cooling Water Pipe3.6 Filling the Gear Oil3.7 Installation and Pretension of the Triangle Belt3.8 Installation of the Screw3.8.1 Cleaning3.8.2 Installation3.9 Connection of the Barrel4. Operation4.0 General Description4.1 Warm-up to Working Temperature4.2 Starting the Extruder4.3 Interrupt Operation5. Maintenance and Repairs5.1 Emptying the Extruder5.2 Disassembling the Screw5.2.1 Overview5.2.2 The function of mandrel 5.3 Cleaning the Screw5.4 Cleaning the Sleeve Barrel5.5 Illustration of Lubrication5.6 Gear Reducer and Its Sealing Member and Bearing1. General Description1.1 General Remarks on the Operating ManualThis Operating Manual provides the basic parameters and performance of the extruder for users so that they can fully understand the operation, maintenance and repairs of the machine.The Operating Manual is an aid to the users to keep the extruder in high efficiency during its lifetime service and is also conducive to avoiding accidents. Therefore, the users should grasp the requirements in the Operating Manual and strictly comply with the operating rules during their operation, periodical inspection and maintenance of the machine.In the process of operating, special attentions should be paid to the followings:A. High Temperature B. Rotatable Parts C. VoltageBefore maintenance, it is required that the power supply of the whole extruder, including the control box, should be cut off, and time is set apart for discharging material from the extruder and cooling of the heating zone during repairs. 1.2 Specifications:Screw Diameter: 30L/D: 25:1Model of Motor: Z4-112/4-2Power of Motor: 7.5KWMax Speed of Motor: 1500rpmReduce ratio: 1:8Heating power and Voltage: 4.0KW/230VZone of Heating: 3 ZonesSpeed of Screw: Max. 125rpmPower of blower: 60W/400VNo. of blower: 31.3 Ancillary EquipmentHeavy load is not allowed to put on the extruder. The heavy ancillary equipment is also required to be supported or fixed. A set of handling tools for the screw is provided. 1.4 Range of Rotation RateSince the bearing lubrication inside the gearbox is supplied by a definite rotate speed, the lowest speed of revolution is stipulated during operation of the extruder. If a special processing condition requires keeping the rotation speed lower than the minimum velocity, a mandatory lubricating device must be attached to the gearbox. The stipulated minimum speed of rotation is 20r/min.2. General Information2.1 Layout of the Assembly Units The basic facilities in the extruder is listed as follows:a. frameb. gear reduction unitc. drive unitd. feed inlet and cooling water jacket e. special screwf. barrelg. heating elements and temperature sensors 3. Positioning and Installation3.1 OverviewThe positioning and installation of the extruder is conducted simultaneously with other facilities of the production line. The relevant installation diagram and underlying graph are essential in the process of mounting. (See fig.1&fig.2)3.2 Conveying of the ExtruderTwo strong round bars are insert into the openings of the mounting rack so that the extruder can be lifted by a crane. At the same time, a plank is placed between the sling ropes to avoid the damages to the machine parts and attemperator by friction. To prevent sliding of the sling ropes in lift hook caused by the unevenness of the extruders weight, the sling ropes should circle the hook once more. (see fig. 3)3.3 Requirements of the Working PlaceA sufficient space should be kept in the direction of longitudinal shaft and back and forth so that the screw can be easily pushed out and the pushing-off device of the screw can be positioned. 3.4 Adjustment of the ExtruderMake sure that the extruder is in horizontal position. The surface of the sleeve port and feed inlet can be used as the measuring basis. 3.5 Laying of the Cooling Water PipeThe shell of the feed inlet is equipped with an interface of ZG 1/2” water pipe, which is used for cooling the inlet. The cooling water must be in accordance with the following requirements:Water purity: non-contaminated and lime-freeWater pressure: 0.5Mpa common pressure of tap waterWater temperature: 18-30C3.6 Filling the Gear OilType of oil: N150# gear lubricant. Using oil by mixing different brands of lubricant are forbidden. Volume of oil: up to the upper mark of the oil scale. 3.7 Installation and Pretension of the Triangle BeltThe belt pulleys of the electric motor and reduction box should be precisely adjusted until they are in the same plane. All the triangle belts are of the same quality and the length variation of the different belts should be smaller than 1.5%. It is suggested that the belts be replaced in pairs. After the first 0.54 hrs of operation at full load, the belts need to be tightened. Thereafter, the belts are to be tightened again every 20003000 hrs of operation. According to the design, the number of imported A-1676 in the extruder is 6 with pretension force of 60N and depth of 10mm (See fig. 4). 3.8 Installation of Screw3.8.1 CleaningFirstly, clear away the anticorrosive agent covering the screw and inner bore of the sleeve, especially the hole of transmission shaft. Then spray a thin layer of silicon oil on the wall of the inner bore of sleeve and on the screw shaft. 3.8.2 InstallationCover the feed inlet before installation.Soft ropes, instead of iron or steel cables, is used in the conveying of the screw. To avoid damages to the screw, the head and handle of the screw should not be knocked or stricken directly by a hammer or other hard metal tools. During installation, the linchpin of the screw is firstly connected with the inner bore slot groove located in the low-speed shaft of reduction box. Carefully push the screw into the sleeve in a proper position. This operation can also be finished by using the special installation tools. That is, slowly revolve the shaft center into the M12 bolt hole in the rear end of the screw and embed it in the screw by rotating the nut. The aligning method of slot is explained as follows: After the handle of screw touches the bottom of reduction box, gently pull the belt until the linchpin is connected with the bore of the transmission shaft. Then lightly revolve the turntable of the leadscrew and pull the belt continuously. If the screw rotates slowly, the linchpin is aligned to the slot groove of the transmission shaft. At this point, rotate the turntable until the screw is positioned properly (the turntable can not move any more).Cautions: To avoid damages to linchpin and slot groove, the brute force is forbidden in the process of screw installation. If any problem exists, take out the screw and reinstall it. Push the screw until it can not move further. You can also determine if the screw is in the right position according to dimension. The distance between the head of screw and the inner rabbit of the discharge port is about 3 mm. (The details are shown on Fig.5). 3.9 Connection of Barrel Before the subsequent equipment is attached to the outlet of sleeve barrel, be sure that the joint is not contaminated and sealing surface is damage free. Before revolving into the screw bolt, spread supramoly, which can resist temperature as high as 350C, on the surface of the screw bolt.The installation of ancillary facilities should be in accordance with the requirements mentioned in Section 1.3 of this Operating Manual. 4 Operation4.1 General DescriptionThis extruder is usually operated in company with other machines and facilities on the whole production line. Therefore, the Operating Manual is only applicable to the above-mentioned situation. 4.2 Warmup to Working TemperatureFirst, turn on the water cooling system built in the shell of feed inlet and reduction box. Then switch on the heating elements in all heating zones, adjust the temperature control system so that the temperature of extruder increases at the rate of 50C per hour. In order to heat the screw evenly, conduct hand turning for 3 minutes every one hour (The fan will start to work automatically. Pay attention to the rotation direction of the blower fan.)4.3 Starting the ExtruderAfter 30-minute heat preservation, start the electric motor (from zero to 56 rpm). During its idle run, observe the screws direction of rotation. If the direction is wrong, stop the motor immediately and rewire. In the test run at a low speed, monitor if there is any abnormal sound existed between the screw and sleeve and inside the reduction box (The test run can not exceed one minute). If not, add some stuff into the machine sporadically. Then increase the stuff until molten material appears in the exit of the machine barrel. If you feel the machine in normal conditions, stop and clear the extruder. Equip the die head in the discharge end and restart test run at full load (During the test run, be careful with the temperature). Continuously add the stuff and increase the speed of rotation gradually until molten material appears on the die head. Finally, raise the speed to that of technological requirements and inspect such circumstances as the electric current of the motor, temperature control and abnormal sound inside the barrel. Turning back the extruder is forbidden in any case. 4.4 Interrupt Operation4.4.1 Adjust slowly the rotation speed to the low level and stop the drive unit of the extruder. The extruder will stop in a short time. The length of outage time is based on the condition that the stuff will not be decomposed by heat or condensed. The heating system is not necessary to be cut off during short-time interruption.But the cooling system in the shell of feed inlet and reduction box should be kept in running order. 4.4.2 A long interval of interruption. If the interruption interval exceeds the allowed time for short-time stopping, the operation should comply with the operating rules of long interval of interruption. During the long interval of interruption, empty the molten stuff inside the extruder, switch off the heating system and stop the drive unit of the extruder.Cautions: The cooling water system can not be closed until the heating system is cut off for over 30 minutes. 5 Maintenance and Repairs5.1 Emptying the ExtruderBefore maintenance or repairs, the extruder should be emptied. Then switch off all power supply of the extruder.5.2 Disassembling the Screw5.2.1 OverviewThe special set of tools provided with the extruder is useful in disassembling the screw. By using it, the screw can be dismantled directly after exhaustion of the extruder. Then, the remained molten stuff has not been condensed. So the screw can be easily ejected. The details are shown on Fig.6If the extruder is cooled, it is required to turn on the heating zone before ejecting the screw. When the machine is heated up to working temperature, turn off the power supply again. A lifting appliance is used to support the screw after pullout. 5.2.2 The Function of mandrelSee fig.65.3 Cleaning the ScrewIn order to avoid damages to the screw, it is demanded that such tools as the brass wire brush, the scrapers made of brass or aluminum be used in cleaning the screw. 5.4 Cleaning the Sleeve BarrelThe inner bore of the sleeve barrel should be cleaned in a warming state. During the cleaning, a semicircular scraper fixed on the pullrod, whose diameter is the same as that of the inner bore, is utilized in the operation. Firstly, insert the scraper upward into the barrel. Then turn the semicircular surface downward to remove the remains. Repeat the above operation if necessary. Finally, use the brush to clean the barrel. 5.5 Illustration of Lubrication See table 15.6 Gear Reducer and Its Sealing Member and BearingThe construction of the gear reduction box is shown on the general assembly drawing. (fig. 7)Special attentions should be paid in the installation and dismantling of the gear reduction box: a. In the wheel box, the sealing material like No.515 anaerobic glue must be spread in the dividing slit and bearing cap. b. The sealing material must be changed after each unpacking.c. Make sure that all locating holes and surfaces are clean and intact when fastening and installation of assembly units.Table 1Oil SiteLubricantInterval of lubrication and remarksGear reduction b