郑州巴特熔体泵中英文对照说明书.doc

公司简介部分 Company IntroductionBATTE公司自专业生产高温容体泵以来，在熔体泵应用技术方面积累了丰富经验。近年来，根据世界熔体泵应用技术的发展趋势，特别是在塑料.橡胶精密挤出领域里，对熔体泵的工作基础.使用性能.设备结构研制.控制技术等开展了多方面的研究并取得了一定成果。 BATTE公司的政策是以一直持续不断的研究与开发为基础，使巴特公司得以制造出高科技高效率的产品，具有卓越的产品可靠度，这些产品是通过精心挑选原材料与零部件，于整个机械加工过程中，仔细检查每一个部分，最后再以熟练的经验来装配完成。出厂前的调试，是每一个BATTE高温熔体泵离开工厂前最好的品质保证。BATTE公司的目标是以提高客户的使用价值，通过持续不断的努力，提供更好的服务品质，从而获得客户的认同，惠于更多的订单。Batte has accumulated abundant experiences on the application technique of melt pumps since we manufacture pumps professionally. Recently, according to the development trend of melt pumps application all over the world, especially in the field of precise plastic extrusion, we have done extensive research on the pump operation performance, practical function, equipment structure and control technology and achieved regular achievements. Battes policy is to be based on continuous researches and exploitations. That makes us manufacture high-tech and high efficient products which have excellent reliability.All raw materials and spare parts of products are selected carefully and assembled with skilled experience. Pre-delivery debugging of melt pumps is the best quality assurance before they are leaving the factory.产品概述部分一 概述 General Information熔体泵主要用于高温高粘度聚合物熔体的输送、增压、计量.容体泵将来自挤出机的高温塑料熔体增压.稳压后流量稳定地送入挤出机头。其稳定熔体压力、流量的能力优于各种类型的挤出机。国外广泛应用于塑料、树脂、橡胶制品的挤出成型。如：造粒、薄膜、管材、板材、片材等行业。随着机械工业的日益发展，熔体泵在国内市场也逐渐地被行业人士所采纳、应用。Melt pump is mainly used in high temperature and high viscosity polymer melt transportation, pressurization, metering. The melt pump pressurizes and stabilizes pressure of hot melt polymers coming from the extruder, then send them into extruder dies. The pumps ability of stabilizing the pressure and flow is better than all kinds of extruders. Foreign countries widely apply in plastic, resin, rubber extrusion, such as pelletizing, film, pipes, plate, etc. With the increasing development of mechanical industries, melt pump is increasingly accepted and applied by domestic.双曲线齿形设计Hyperbolic tooth shape design压力脉动率更低 Lower pressure pulsation rate防止剪切热产生Preventing shear heat非接触免维护 Non-contact Free maintenance螺旋密封设计Helical sealing design无后顾之忧Free from any worries先进的流道设计Advanced flow design熔体停留时间短 Short residence time of melt stream适用热敏性材料Suitable for heat-sensitive material专业辅助设计软件 Professional auxiliary software design优化轴承润滑设计 Advanced bear lubrication design有效延长使用寿命 Prolonging the service life二 使用范围 Application熔体泵属于容积式齿轮泵，采用一对外齿合的圆柱齿轮（直齿、斜齿、人字齿）相对转动来运输送高黏度的流体。所有齿轮和配合面都经过精磨、并严格控制装配间隙来获得精确的流量。齿轮和泵体根据不同的共况，ZB-B系列采用铬镍合金钢、高温工具钢材料;ZB-H系列采用进口CPM工具钢或钛钽合金材料，整体淬火，硬度HRC62-68，耐磨性好。 1.ZB-B系列：工作温度：400(750)，清洗温度：450(850)，出口压力40Mpa(6,000psi)，黏度：30000Pa.s 2.ZB-H系列：工作温度：510(950)，清洗温度：590(1100)，出口压力70Mpa(10,000psi)，最大压差：50Mpa(7,000psi), 黏度：20000Pa.s 3.密封 一般采用螺旋密封和填料密封，也可根据客户要求采用其他机械密封形式。 4.驱动 电机+减速机+万向联轴器+泵体，电机采用变频调速或伺服调速，可以随意调至所需流量。对于产品看、精度要求高的，建议采用伺服电机调速。 5.加热 熔体泵采用电加热棒加热或热传媒加热，可以精确控制熔体温度。Melt pump belongs to positive displacement gear pump, adopt a pair of external gearing cylindrical gears(straight gear, helical gear, herringbone gear) with relative turning to deliver high viscosity fluid. All gears and fitting surfaces are accurate grinded, and obtain precision flow by controlling the assembling clearance strictly. Gear and pump body varies to different materials. ZB-B series are produced by nickel-chrome alloy steels and high temperature tool steels. ZB-H series are produced by import CPM tool steels or titanium-tantalum alloys, the rigidity is HRC62-68 and they are wear-resistant.1. ZB-B series: working temperature: 400(750), cleaning temperature:450(850), outlet pressure:40Mpa(6000psi), visocity:30000pa.s2. ZB-H series: working temperature: 510(950), cleaning temperature:590(1100), outlet pressure:70Mpa(10.000psi), max. Differential pressure: 50Mpa (7.000psi), visocity: 20.000pa.s3. Sealing: Helical sealing and packing sealing. Mechanical seal can be adopted according to customers needs.4. Drive motor+reducer+universal coupling+pump body, you can use frequency control or direct current governor for the motor and adjust the flow to your need optionally. We suggest using servo motor for speed governing if the products are high precision.5. Heating melt pump adopts electric heating or heat medium heating and the temperature of the melt can be controlled accurately.三 熔体泵的代号及标志 Code and Sign of melt pumpRotation Assemble Sealing TemperaturePressurecc/rpmSeriesModel四 熔体泵的外型尺寸 Dimension of melt pump ZB-B SERIES五 运用范围 Scope of application将熔体泵与单螺杆或双螺杆挤出机串联使用时，能使整条生产线的效益显著增加，应用熔体泵的主要好处是：1.稳定输出压力能有效的降低挤出机参数引起的物料输出不稳定及压力脉动。2.提高产品质量将挤出制品的尺寸公差降至最小，减少废料和降低废品率。普通挤出机也能生产出高精度产品。3.提高挤出产量降底了对螺杆的压力要求，由原来的螺杆向模头建压，改为熔体泵向模头建压，螺杆可以高速高效的挤出，且可以调节挤出机背压，减少熔体在螺筒内驻留时间，稳定塑化过程，降低熔融温度，提高制品产量和质量。4.降低单位能耗有数据表明将挤出与熔体泵组合，其混炼质量和产量比单独的挤出机大幅提高。加工每公斤物料一般可降低四分之一左右。5.延长整机寿命使用熔体泵后挤出机螺筒内压力降低，能大大降低螺杆和螺筒之间的磨损，减轻齿轮箱推力轴承的负荷，延长挤出机寿命，挤出机在生产工艺中需要排气的冒料问题也可迎刃而解。When melt pump and single screw or twin screw extruder are put into use with series connection, the benefit of whole extrusion line will be improved significantly. The main advantages of using melt pump:1. Stabilizing the output pressure-reducing the unstable output of material causing by the parameters of extruder and pressure pulsations.2. Improving the product quality-reducing the dimensional tolerance of extrusion product into minimum and reducing the rate of scraps and rejects.3. Increasing the extrusion output-reducing the screw pressure, changing the building pressure style from “screw to die” to “melt to die”, so the screw can extrude the products with high efficiency, meanwhile the back-pressure of extruder can be adjusted, reducing the melt residence time in screw cylinder, stabilizing the plasticizing process and reducing the melting temperature, improving the product quality and quantity.4. Reducing the unit energy consumption-some dates show that the combination of the extruder and melt pump, comparing with the extruder alone, can improve the milling quality and quantity remarkably. Energy consumption of per kilogram material can be reduced one-quarter.5. Prolonging the service life-the pressure of extruder screw cylinder can be lowered after using the melt pump. So the wear and tear between the screw and screw cylinder can be reduced consumedly.六 熔体泵安装和使用 Installation and Usage1、熔体泵运输、存放时应轻拿轻放。到货后如三个月内不安装，应重新清洗轴封。起吊ZB-100CC以上系列的熔体泵时，应使用吊环螺钉。2.安装前用测具检查、调整泵座与电机传动轴的同心度应确保熔体泵轴在工作时按订货时标明的方向旋转，否则会引起输入轴断裂、泵体损坏。熔体泵安装的底座要平整，并有足够的强度和刚性。在螺栓均匀紧固的情况下，应保证输入轴能无卡滞地均匀回转。万向联轴器的安装误差应不超过其允许的偏差值，以免引起附加力，缩短轴的寿命。安装中旋紧螺钉时用力要均匀。3.熔体泵在交货前均经过严格的试运转检验，各项指标符号要求，交货后可以直接投入使用。无论那种规格的熔体泵启动使用加载负荷时应低速（5rpm左右）运转一段时间，待各轴承处充分润滑后可加载运转，缓慢的提升工作压力，当整体运行状况较为稳定后，则可逐步将泵及整个系统调整至正常的工艺速度与压力。4.熔体泵在加载前，应先均匀预热，温升不得超过120度每小时。在泵没有达到工作温度前不要启动泵，冷启动是最容易引起泵损坏的时候。5.对于采用填料密封形式的熔体泵，应及时调整密封压盖的位置，保证最佳的密封状态。对于采用螺旋密封的泵，如果需要使用冷却水辅助密封，应在螺旋密封组件上安装1/8或1/4NPT接头，然后通上水源。对于小排量的泵不要让冷却水影响到泵体的加热。1、You should be careful of transporting and storing melt pump. You should clean the shaft seal when you dont install it within 3 month of arrival. Use rings screws when you lift melt pump of ZB-100 above series. 2、Before installation, test with testing tools, adjust concentricity between pump seat and motor shaft. Ensure the melt pump shaft rotates in ordering indicated direction, otherwise that will cause input shaft rupture and the pump body damage. Mounting base of melt pump should be smooth and has enough intensity and rigidity. Under the holding down bolt with is tightened evenly, make sure the input shafts rotate evenly without clamping stagnation. Deviation of universal coupling installation shouldnt exceed the allowing deviation in order to avoid causing additional force and shortening the shaft life. You should tighten the screws evenly during the installation. 3、The melt pumps have past strict test-turn inspection, each indications meet the requirements, you can put them into use directly. Any kinds of melt pumps should run in low speed (about 5 rpm) when you start the pumps. When each bearing has sufficient lubrication the pump can have load operation and the working pressure can be improved slowly. When there is a steady running of the whole line, you can adjust the pump and the whole system into normal operation speed and pressure.4、 Before loading the pump, there should be a even preheating for the pump. The rising temperature shouldnt exceed 120 (250) per hour. Dont start pump before it reaches the operation temperature, cold start is the most likely time to damage the pump. For melt pump with packing seal form, you should adjust the position of the sealing gland promptly to make sure the best sealing condition. 5、For melt pump with packing sealing form , you should adjust the position of sealing cover to ensure the best sealing state. For melt pump with helical sealing form, if it is necessary to use cooling auxiliary seal, you should install 1/8 or 1/4 NPT joint on the helical sealing component, then connecting water. For the small delivery capacity pump, dont let the cooling water influence the heating of pump body.七 清洗 Cleaning1.将泵从设备上卸下来，放入真空加热炉内，缓慢增加温度至400-450度，升温过程不得少于两个小时。要注意温度的控制，如果过热，会造成泵体的材料硬度下降，影响尺寸的稳定性。2.完全炭化物料的时间为3-12小时，这取决于物料本身，泵的大小，加热温度及炉子的负荷。泵需要自然冷却至室温，不得强制冷却。3.必要时可将泵送回我公司进行彻底修复。1. Remove the pump from the equipment, then put it into vacuum heater, increasing the temperature from 400-450 (750-850), the process of rising temperature shouldnt be less than 2 hours. Give your attention to control temperature, if it is too hot, that will reduce the hardness of pump body and influence the dimension stability.2. The time for complete carbonized materials is 3 to 12 hours that depends on the material itself, the pump size, heating temperature and load of the heaters. Cooling the pump to room temperature naturally, its forbidden to cool the pump by force.3. You can return the pump to us for a complete repair when it is necessary.八 拆卸 Disassembly如果对泵作定期维护，应通读并理解本说明，要确保正确的拆卸，应遵守下述要点：1.拆卸时要注意所有部件的位置和方向，以保证组装时正确归位，存放零件的场地应干净整洁。2拆卸时要使用软口台钳夹持泵体。进行维护时，要小心拿放部件，避免坠落及碰撞。因为最轻微的划痕或毛刺都会使装配困难，并引起对泵的损坏。3.小心取出密封组件，注意不要损坏密封沟槽和轴，否则泵工作时，可能会导致物料泄漏。然后检查冷却水进出口，确认无堵塞。密封组件是有两个部件并通过紧固螺钉组合在一起的。如有堵塞，可将其拆开，用机械或化学方法进行清洁。4.将端盖板上所有的螺栓松开一圈，然后全部旋松并取出。取下端盖板，并将其放在安全的地方，以防损坏。这时要记住每个轴承上的沟槽对应于泵进口的方位。组装时必须按照原方位装回，否则，当启动时泵会被严重损坏。5.将齿轮轴与轴承从中板中取出，由于泵内留有残余物料黏度，它们有时很难被取出。因此取出时要特别注意，不要敲打或损坏齿或轴承的边角，可用塑料或软铜锤，轻轻敲打，将其取出，不要用铁锤。6.将轴承从齿轮轴上取下，注意不要损坏齿，轴承边角及轴。如果不易拆开，（由于有残留物料黏度），可用塑料或软铜锤敲打轴承使其松动，不可用铁锤。不要用螺丝刀或其它工具将其撬开，因为这容易将齿损坏。要记住所拆下的轴承来自于哪根轴，然后将其放在一旁安全的地方。7.泵被解体以后，所有部件都应仔细检查，确认是否有磨损，裂纹，毛刺及划痕等。端盖板，D型轴承可用600#砂纸打磨，如有毛刺，划痕或其它尖角出现，可用磨石轻轻打磨。计量齿轮，中板及D型轴承之间的关系对保证计量性能是非常重要的，因而打磨时要特别小心，只需将表面抛磨干净，而不能去除金属。在任何情况下，都不能对这些部件进行磨削。If you want to do regular maintenance for the pump, you should read and understand the instruction and ensure the correct disassembly. Observe the following points:1.Notice the position and direction of all parts during disassembly, so as to return the correct position during assembly. Place the parts in a clean and tidy place.2. Hold the pump with soft mouth clamp during disassembly. Take and put the parts carefully during maintenance, avoid falling and colliding. The slightest nick or burr will cause trouble for assembly and damage the pump.3. Remove the seal components carefully, dont damage seal grooves and axis, otherwise that will cause the material leakage when the pump is working. Check the inlet and outlet of cooling water, ensure there is no jam. Seal components are assembled by two parts through tightening bolts. If there is jam, you can unpack them and clean them by mechanical or chemical method.4. Loosen one circle of all bolts on the cover, then loosen and remove all of them. Remove bottom cover; place it in a safe location. Remember each bearing on the groove corresponds to the inlet direction of the pump. Reinstall them in original location; otherwise the pump will be damaged seriously when you start it.5. Remove the gear axis and bearing from middle plate. It will be difficult for you to remove them owing to the remnants of viscous materials. Dont knock or damage gear or bearing angel. You can remove them by using plastic or soft copper hammer, but iron hammer is not allowed to be used here.6. Remove the bearing from gear axis; take care of gear, bearing angel and axis. If its hard to remove (dueling to the remnants of viscous materials), you can loosen the bearing by using plastic or soft copper hammer, also iron hammer is forbidden. Dont pry it with screwdriver or other tools, because that will damage the bearing. Remember which axis do the bearings come from, and then place them in a safe location.7.After breaking up the pump, check all parts and see if there is abrasion, crack, burr, and nick or not. The cover and D shaped bearing can be burnished by 600# sandpaper. If there is burr, nick or other sharp angle, you can burnish them with grindstone. The relationship among metering gear, middle plate and D shaped bearing is important to assure the metering performance, so you should be careful when burnishing them. You should only burnish the surface clean, dont remove the metal. You cant grind these parts under any conditions九 组装 Assembly1.使用三氯乙烷或氯乙烯熔剂，清洗所有要装配的零部件。2.在组装过程中，要经常用手转动齿轮，以确认它们可自由旋转。组装过程中，任何时候出现卡死现象，都要在进行下一步前，找出原因，将其解决。任何微小的划痕、毛刺或外部杂物，都可能引起重要部件的损坏。在装配过程中，绝不能强力组装或转动泵；如果转配正确，所有部件都会很容易的装入泵内，轴的转动也会很灵活。3.在装配时，应使用软口台钳夹持泵体。4.安装螺栓前，用DAG154或相似的耐高温润滑脂涂抹螺纹部分，按对角线的方式拧紧端盖板上的螺栓，首先用所建议扭矩值达到1/4将其拧紧，然后1/2，再然后3/4，最后用全部力矩将其螺栓拧紧。5.将密封腔装到轴上，不要拧紧密封腔上的螺栓，应使其略为松动，这将使密封对中。6.将密封盖板装到轴上，将盖板的螺栓孔与密封组件上的螺栓对准，装上螺栓，以对角线的方式均匀的将其拧紧，封件被平稳的压入密封腔内，当盖板全面接触到密封组件上时，将盖板取下，拧紧密封组件的螺栓，并将其拧紧1、Cleaning all assembly parts with methyl chloroform or vinyl chloride solvent. 2、Turn the gear with hands regularly during assembly to ensure they can rotate freely. Any jammed phenomenon should be solved before going into the next step during assembly. Any slight nick, burr or sundries will cause the important parts damaged. It is not allowed to assemble or turn pump by powerful strength. If you assemble them in a correct way, its easy to put all parts into pump. The axis will turn flexibly. 3、You should use soft mouth-grip to hold the pump body when assembling it 4、Before installing screws, daub the screw thread with DAG154 or similar high temperature resistant grease. Tighten bolts on the cover by diagonal way. First tighten them with 1/4 torque value, then 1/2 torque value, 3/4 torque value; finally tighten the bolts with the full torque value. 5、Put the seal components on the axis, dont tighten the bolts in seal cavity, you should loosen them little. That will make the seal components centered. 6、Install the seal cover to the axis, make the bolt hole on the cover and the bolt on the seal component aligning, install the bolts and tighten them evenly by diagonal way. The components are pressed into sealed cavity smoothly. When the cover touches the seal component completely, tighten the bolts on the seal component.熔体泵控制系统 Melt Pump Control SystemS系列控制系统是我公司专为针对熔体泵工作特定，专门开发的新一代PLC控制系统。* 行业标准领导者 * 降低维护要求* 人机界面友善* 操作简易可靠* 运行成本低S series control systemis new generation of PLC control system which is specially designed for melt pumps.* Industry leader* Lower maintenance requirements * Friendly human-machineinterface * Simple and reliable operation * LowcostS60 控制系统*2-4个压力闭环控制*压力上下限报警*20-30个独立的温度控制区*流量控制*自动启动和停机*触摸屏人机界面*过程值的连续监控*运行监控和故障检修*适合更复杂的挤出或复合系统S60 Control System* 2-4 closed-loop pressure controls* Top and bottom Limitatio