Steel cord conveyor belt curing press line Technical specification

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2600 10600 1 Steel cord conveyor belt curing press line Technical

1 Steel cord conveyor belt curing press line Technical specification Qingdao Doublestar Rubber & Plastic Machinery Co., Ltd Feb. 21, 2013

2 1. Scope of supply 2. Technological process 3. Machine structure 4. Technical parameter 青岛双星橡塑机械有限公司 Index Tel: /29

3 Ⅰ. Scope of supply set. No. Equipment Unit Qty. Note 1 Creel Set 1 2 Tension station Set 1 3 Fixed comb device Set 1 4 Building machine Set 1 5 Inspection device Set 1 With motor 6 Belt releasing device Set 2 7 Curing press Set 1 8 Centering device Set 2 9 Supporting roller Set 2 10 Belt pulling device Set 1 11 Belt repairing press Set 1 12 Hydraulic belt cutting device Set 1 13 Centering and encoder device Set 2 14 Double ground rollers type belt wind-up and packing device Set 1 15 Shaft type wind-up and packing device 16 Hydraulic system Set 1 Contain pipeline and valve 17 Electric control system Set 1 18 Heating balance system of the upper/lower platform Set 1 19 Foundation bolts Set 1 20 Steam and water escape system Set 1 21 Electric wire Set 1 The following items are not included in scope of supply: a. Workshop and external power supply wire. b. Wire between main power and control cabinet. c. Connecting pipeline and valves between external power supply(cooling water)and machine d. Lubricating oil, hydraulic oil Tel: sheldon@doublestar.cc 2/29

4 Ⅱ.Technological process Creel Tension station Fixed comb device Building machine Inspection device Centering device Belt releasing device Curing press Belt releasing device Centering device supporting rollers (2sets) Belt pulling device Belt repairing press Hydraulic belt cutting device Centering and encoder device Double ground rollers type winding-up and packing device Centering and encoder device Shaft type winding-up and packing device. Equipment center height is 1300mm(The lower surface of upper heating platen to the floor). Tel: /29

5 Ⅲ. Machine structure 1. Creel The creel is frame structure that has 196 spindles. There are 3 layers, each layer has 2 lines. Every spindle is equipped with a torque motor and reducer to apply initial tension and back tension for steel cord. Steel spindles are loaded and unloaded by 3 sets electrical cranes (load capacity: 1000kg) and loading cassette. Steel wire deflection guiding devices made of abrasion resistant and self lubricating ceramic are installed at steel wire exits, which can guarantee steel wires in order and reduce abrasion. Tel: sheldon@doublestar.cc 4/29

2. Tension station The tension station consists of clamping, tension moving, tension cylinder, pull-back cylinder, pulley group and hydraulic system etc.

6 2. Tension station The tension station consists of clamping, tension moving, tension cylinder, pull-back cylinder, pulley group and hydraulic system etc. The frame is welded and assembled by steel plates. All the tension cylinders are separate from each others that convenient for maintain. The station is controlled by same working hydraulic pressure to guarantee same and constant tension cylinder ejecting force. The control system adopts PLC. The steel cord pulleys use self lubricating bearing, so there will be no oil drip. The steel cord surface can keep good adhesive performance. Tel: /29

7 Tel: /29

The comb plate can complete R&L adjustment and can turn forward 90 degree, this design is convenient to make the steel cord cross and change the

8 3. Swing comb device The swing pin structure is used for accurate positioning of steel cord. This device consists of comb frame, supporting roller and fixed comb etc. The comb plate can complete R&L adjustment and can turn forward 90 degree, this design is convenient to make the steel cord cross and change the comb plate. The comb plate is square steel tube with spring steel pin. One kind of comb plate is supplied with the curing press line. 4. Inspection device This device is used for checking green belt. Moved by motor. Tel: /29

5. Building machine 青岛双星橡塑机械有限公司 The building machine consists of upper rubber let-off device, lower rubber let-off device, refining comb device, cold pressure plate, edge-rubber cutter(trimming

9 5. Building machine 青岛双星橡塑机械有限公司 The building machine consists of upper rubber let-off device, lower rubber let-off device, refining comb device, cold pressure plate, edge-rubber cutter(trimming knives), hydraulic driving system, hydraulic system, back traction cylinder and centering device. The machine frame is assembled by welded profile steel; there is one set refining comb device which can keep even distribution of steel-cord rope during building. The comb plate can be equipped from the side. One kind of comb plate is supplied when we supply the curing press line. The movement of building machine is driven by 4 hydraulic motors, and there is a centering device on the building machine center line that can ensure the movement reliable and stable. There re four rounded cutting knives(trimming knives) are equipped on the outlet of cold pressure plate to ensure accurate cutting. The design is suitable for curing two belt at the same time. The control system adopts PLC. The surface of cold pressure plate adopts tire mold design, it uses Thermal spraying teflon. Tel: sheldon@doublestar.cc 8/29

10 6. Curing press The curing press is designed according to standard HG/T (1) Frame This part is made of Q235 steel plate in welded structure. It s treated by mechanic shot-blasting Tel: sheldon@doublestar.cc 9/29

6, and double cooling ends are 300mm x 2. Each platen has 6 heating zones which have one point for temperature measuring.

11 and spraying with zinc-rich paint. The mechanical processing will be done after shock eliminating stress. (2) Heating platen Heating platens are made of 35# steel plate which is treated by normalizing on the double fixed rule. The heating platen surface roughness is Ra1.6, and double cooling ends are 300mm x 2. Each platen has 6 heating zones which have one point for temperature measuring. Totally there are 12 points for temperature measuring. There is a group of electrical valves at the steam entrance of each platen, which can adjust temperature automatically. There s a manual adjusting valve to control Tel: sheldon@doublestar.cc 10/29

The material is cutting automatically. The parts adopt carbon dioxide welding with alloy welding wire.

12 temperature at the steam entrance of each heating zone, and the temperature of each heating zone can show at the general control panel. The cured belt cooling area can exchange by cooling and heating. (3) Top and bottom platform They re made of Q235 steel plate, to make sure the production accuracy. The material is cutting automatically. The parts adopt carbon dioxide welding with alloy welding wire. After welding, the complete part will undergo heating treatment to eliminate stress thoroughly. In this way, there ll be no deformation during mechanical processing. There s double direction heat balancing device on the upper/lower platforms to eliminate heat deformation during curing. (4) Hydraulic cylinder Tel: sheldon@doublestar.cc 11/29

Hydraulic cylinder is made of ZG270-500, and the plunger is made of chilled cast iron.

(5) Hydraulic automatic side edge iron device There is one set of hydraulic automatic side edge iron device at each side of lower platform.

13 Hydraulic cylinder is made of ZG , and the plunger is made of chilled cast iron. The double-sealing ring and the dust-proof ring structure can guarantee a long life time. (5) Hydraulic automatic side edge iron device There is one set of hydraulic automatic side edge iron device at each side of lower platform. With help of four hydraulic cylinders, the side edge iron can hold on line before mold-closing through PLC, operation of front & middle clamping device to guarantee belt centering and same width. (6) Hydraulic type lifting balance device Tel: sheldon@doublestar.cc 12/29

There are 2 pairs of hydraulic type lifting balance devices at both sides of lower platform to guarantee lower horizontal lifting of platform with help of hydraulic cylinder uniform devices.

14 There are 2 pairs of hydraulic type lifting balance devices at both sides of lower platform to guarantee lower horizontal lifting of platform with help of hydraulic cylinder uniform devices. (7) Heat insulation plate There are no asbestos in the heat insulation plate. Pressure resistance 400kg/cm2, thermal conductivity is 0.022w/m.h, temperature resistance is 220 ~250, thickness is 15 mm. (8) Mold closing guide device There re four pairs of gap adjustable mold closing guide device at both sides of platen press, the displacement tolerance of heating platen is no more than 0.5 mm. (9) On both side of curing press, there are supporting roll (steel tube) frames for thin belt transfer. 7. Belt pulling device It consists of F&B supporting rollers, traction roller, frame, clamping device and gearing device etc. Six small cylinders clamp the conveyor belt and then stretch the steel cord with tension station. The roll has knurling on working surface to increase roll traction on belt. This device has clamping, stretching and pulling function on belt to meet the steel cord clamping and belt traction. 8. Belt repairing machine Fixed structure, stream heating, manually control. It is steel structure, and there is temperature display device on the heating platen side. The plunger is made of chilled cast iron. Heating platens are Tel: sheldon@doublestar.cc 13/29

The control system adopts PLC control to realize auto cutting. 10.

15 made of 35# steel plate which is treated by normalizing. 9. Hydraulic belt cutting device It adopts horizontal moving cutting method which can cut any kind and size of conveyor belts. The control system adopts PLC control to realize auto cutting. 10. Double ground roller type wind-up and packing device This device is double ground roller type with edge guide device. It has centering device. Digital display counter can show accurate numbers. Tel: /29

(note: picture is just for indicate the type and structure) 12.

16 11. Shaft type wind-up and packing device(picture is just for indicate the type and structure) This device is driving and shaft type with edge guide device.it has centering device.digital display counter can show accurate numbers.(note: picture is just for indicate the type and structure) 12. Hydraulic system The hydraulic system is designed according to the technological process and action requirement. The main hydraulic parts are Yuken brand or Beijing Huade brand to guarantee the quality and Tel: /29

The temperature and pressure are set by manual and automatic display. There should be Ethernet module.

17 reliability of operating 13. Electrical system The perfect control system uses Mitsubishi Q series PLC. Other normal parts are mainly Schneider brand. The assist machine use electro connecting pressure gauges. The temperature and pressure are set by manual and automatic display. There should be Ethernet module. Each part of the curing press line can operated manually, automatically or whole line link operation. Tel: sheldon@doublestar.cc 16/29

18 Ⅳ.Technical parameter 1. Equipment manufacturing standards Standards:GB/T9002-ISO ,GB/T Steel cord conveyor belts for general use, GB/T Conveyor belts Specification for rubber or plastic covered conveyor belts of textile construction for general use, HG/T daylight press, HG/T Testing and measuring methods for daylight press, and some Computer-aided design standards. 2. Technical parameter 2.1 Creel (1)spindle Qty. 196PCS (2)Initial tension (3)Acting method of initial tension in creel (4)Steel wire diameter (5)Spindle arrangement 80~400N/one steel wire Torque motor φ2.5~φ13mm 3 layers, 3 lines (6)Steel spindles loaded & unloaded (7)Direction-finding equipment (8)Max. spindle size 2.2 Tension station with clamping holder (1)Steel wire Qty. (2)Dia. Of steel wire (3)Tension of each steel wire (4)Clamping force of clamping device (5)Arc clamping plate width (6)Clamping cylinder dia. (7)Clamping cylinder stroke (8)Clamping cylinder Qty. (9)Clamping cylinder pressure (10)Small tension cylinder dia. (11)Small tension cylinder stroke 3 sets electrical cranes (load capacity: 1000kg) Abrasion resistant ceramic φ760mm 390mm; 192pcs φ2.5~φ13mm 0.8~4KN 1200KN 500mm Φ200mm 150mm 2pcs 19.6Mpa φ25mm 150mm (12)Small tension cylinder Max. working pressure 16.3Mpa Tel: sheldon@doublestar.cc 17/29

19 (13)Pull-back cylinder diameter φ63mm (14)Pull-back cylinder stroke (15)Pull-back cylinder Qty. (16)Constant tension cylinder diameter (17)Constant tension cylinder Qty. (18)Constant tension cylinder stroke 2.3 Sewing comb device (1)Height from pin bottom to floor (2)Slots Qty. 160mm 2pcs φ200mm 2pcs 350mm 1260mm 192pcs (3)Structure type Swing type 2.4 Building machine with rubber edge cutter(trimming knives) (1)Diameter and Qty. of cutting knives(trimming knives) 2pcs (2)Cool pressure plate size (3)Max. pressure of cool pressure (4)Cool pressure cylinder (5)Cool pressure cylinder stroke (6)Max. working pressure of hydraulic system (7)Building machine moving speed (8)Max. diameter of upper cover rubber material roll (9)Max. diameter of lower cover rubber material roll (10)Max. width of cover rubber material roll (11)Square shaft size of rubber roll let-off (12)Max. diameter of liner winding-up (13)Max. width of liner winding-up (14)Square shaft size of liner winding-up (15)Lateral moving speed of let-off device (16)Prevent belt sticking 2.5 Supporting roller (1)Supporting roller height (2)Diameter of supporting roller (3)Diameter of centering roller mm 4Mpa 2 φ600mm 280mm 20Mpa 6m/min,positioning accuracy<10mm 1500mm 1200mm 2600mm 80 80mm 600mm 2600mm 45 45mm 6m/min Covered with PTFE 1260mm φ120mm φ110mm Tel: sheldon@doublestar.cc 18/29

20 2.6 Curing press (1)Structure type Frame type hydraulic up stroke (2)Size of platen (3)Curing width (4)Thickness of curing (5)Mold closing force (6)Unit pressure (7)Max. stroke of ram (8)Dia. of ram (9)Qty. of ram (10)Max. working pressure of hydraulic system (11)High and low pressure switch pressure value (12)Rising speed of platen (13)Platen dropping mm mm 6~40mm MN 4.5MPa 350mm φ650mm 16pcs 23 Mpa 1.5MPa 360mm/min rely on it s own weight (14)Max. working temperature of platen 170 (15)The heating platen surface roughness Ra 1.6μm (16)Cold ends of platen (17)Steam pressure 300mm (Two ends can be used for cooling and stream heating) 0.8Mpa (18)The height from lower surface of upper platen to floor 2.7 Belt pull device (1)Max. belt width (2)Max. belt thickness (3)Max. diameter of belt pulling roll (4)Max. traction force 1300mm 2400mm 40mm φ750mm 150KN (5)Linear velocity of pull belt (6)Max. clamping force (7)Qty. of clamping cylinder (8)Dia. of clamping cylinder (9)Max. working pressure of clamping cylinder 2.8 Repairing press (1)Size of platen Steel cord belt linear velocity 8m/min 1200KN 6pcs Φ125 mm 16.3Mpa mm Tel: sheldon@doublestar.cc 19/29

21 (2)Unit pressure 3.0Mpa (3)Mold closing force (4)Dia. of ram (5)Qty. of cylinder (6)Max. working pressure of hydraulic system (7)Stroke of culinder (8)Control 7.8MN φ500mm 2pcs 20 Mpa 150mm Manually operation (9)Heating Steam heating (10) Cold ends of platen 80mm (Two ends can be used for cooling and stream heating) 2.9 Hydraulic belt cutting device (1)Max. cutting width 2600mm (2)Max. cutting thickness (3)Belt cutting mechanism moving speed (4)Max. working pressure of hydraulic system 40mm 2.75m/min 14MPa 2.10 Wind-up and packaging device(double ground rollers type) (1)Max. width of rolling belt (2)Max. dia. range of rolling belt (3)Max. weight of rolling belt (4)Linear speed of rolling belt (5)Type 2400mm φ3500mm 30T 12m/min Double ground rollers 2.11 Wind-up and packaging device(shaft type) (1)Max. width of rolling belt (2)Max. dia. range of rolling belt (3)Max. weight of rolling belt (4)Linear speed of rolling belt (5)Driving Type 2500mm φ4000mm 50T 12m/min Torque motor Tel: /29

22 Ⅴ. Manufacturing process 1. All produces are designed with SolidWorks and have finite-element analysis to ensure the quality. Frame static displacement analysis Stress analysis Beam static displacement analysis 2. All welding materials such as steel plates, merchant steel are cleaning and surface de-rusting before welding Tel: /29

23 3. Large welding parts are weld with submerged-arc welding and have weld inspection test. Tel: /29

24 4. After welding, welding parts have stress relieving treatment Tel: /29

25 5. CNC (computerized numerical control) plasma cutting device are used to cut the steel plate to reduce the deformation Tel: /29

26 6. Assembly workshop Tel: /29

27 1800x16000x1 steel cord conveyor belt curing press 7. Customer s workshop 1800x16000x1 Tel: sheldon@doublestar.cc 26/29

28 Zhejiang Hanbang Zhejiang Tiantie Tel: /29

29 Kaifeng Tieta Dongying Zhongyi Tel: /29

30 8. Main customers Qingdao Rubber Six Group Co., Ltd Zhejiang Tiantie Industry Co., Ltd Zhejiang Sanwei Rubber Item Co., Ltd Shandong Han Bang Rubber Belt Co., Ltd Qingdao Juhang Tape Co., Ltd. Hebei Yichuan Conveyor Belt Group Kaifeng Iron Tower Rubber Co., Ltd Chongqing Zhongnan Rubber Co., Ltd Dongying Zhongying Rubber Co.,Ltd Anhui Pandeng Heavy Industry Co., Ltd. Jiangxi Wanri Rubber Co., Ltd Guizhou Guihang conveyor Belt Co., Ltd Ohji Rubber & Chemicals Co., Ltd Australia Goodyear Thailand Union Belt Thailand MUI Rubber Tel: /29

SP / LP SERIES. Ultra Performance Bridge Type Vertical Machining Center AWEA MECHANTRONIC CO., LTD. ISO 9001 ISO 14001

SP / LP SERIES. Ultra Performance Bridge Type Vertical Machining Center AWEA MECHANTRONIC CO., LTD. ISO 9001 ISO 14001 SP / LP SERIES Ultra Performance Bridge Type Vertical Machining Center AWEA MECHANTRONIC CO., LTD. HEADQUARTERS 629, Suezhetou Section, Kwanpu Rd., Wenshan Li, Hsinpu, Hsinchu 5, Taiwan TEL : +886-3-588-5191