Elastomer Casting Machine

1.   Introduction

EMM090 series elastomer casting machine, a new kind of machine, develop on the base of EMM087 series, has reached to the world level. EMM090 series elastomer casting machine suits pours precisely two component PU systems.

2.  Applicable Viscosity:

A (Prepolymer ): ~4000mpa.s (45℃-100℃)

B (Moca or chain extender alcohols): ~500mpa.s (130℃)

3.  Pouring output:

Output: 2-10L/min

The pouring output will be different as result of raw materials’ density and mixing proportion.

As the same time, the standard two-component casting machine could to increase the third injection head, according to the product needs to add color, add catalyst (customers can choose according to their own needs). The casting machine by intelligent computer control.

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4.     Performace index: 

4.1        Material Tanks (A、B tank)

Material: stainless steel AISI 304

The max. capacity: A 200L, B 30L

The safe capacity: A 160L, B 25L

The heating system: hot oil circulation heating

Temperature measurement system: PT100

The max. temperature: 130℃

Temperature error: control +/- 1.5°C

Stirrer: stainless steel impeller anchored to maximize the tank close to the wall.

Stirring speed: adjustable speed, scope to set in accordance with the nature of raw materials.

Windows: through a glass eyepiece observation tank.

Electronic sensors level of raw materials: min. liquid level control.

Auxiliary system: Vacuum system

               Nitrogen filling system

               Vacuum meter

               Artificial additives material system

               Vacuum system to draw raw materials

               Unloading systems

Each material cans are installed in a separate incubator, hot air circulation heat, can ensure the tank temperature prior + / - 1.5℃. Impeller anchor type design can ensure material fully mixing. This design can avoid some of the raw material such as: excessive heating effect.

4.2       Pipeline  

Material:  PTFE strengthen stainless steel wire mesh 

The heating system: oil heating

The max. pressure: 20 bar

The max. Temperature: 130℃

Temperature error: control +/- 1°C

These high flexibility insulation pipe can ensure the consistency of temperature in the whole pipeline.

4.3       Metering system (A、B component)

Metering pump: gear pump import from Germany Barmag

Filter screen: nets type filter, stainless steel AISI 304 

Motor: converter in accordance with tachometer and motor to control the flow speed.

The measurement system and filter in ovens, insulation material below. This design method can be pressurized tank in the wrong circumstances, to maintain sustained and steady output of raw materials; and keeping the consistency of the temperature. Computer will be set to control output of the wheel pump. This control system can ensure that the output of raw materials in the setting value of + / - 0.3% .

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4.4        Mixing head

    Material: high strength alloy

Speed: 0~6500 rpm/min

The heating system: independent electrical heating

Mixing system: dynamic mixed-head match with the motor

Temperature measurement system:  PT100 thermal sensor

Temperature error: control +/- 1°C

Motor: electric motors, controlled by a frequency converter

EMM uniquely mixing head design has the following features:  it can guarantee the accuracy of speed, and at a very low speed of the mixed quality of raw materials; so that the prepolymer does not cause pressure damage to properties. Made of special alloy mechanical seal system made the mixing head also could work in the high anti-pressure, while ensuring the reliability of mixed system. Unique design of the mixing chamber can be cleaned to ensure easy-to-use and thoroughness.

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4.4.1  Injection head

     Material: high strength alloy

      Injection system: injection pressure independent of each other

      The heating system: independent electrical heating

Temperature measurement system:  PT100 thermal sensor

Temperature error: control +/- 1°C

      Each injection pressure control is independent of each other, can be adjust alone pressure casting and recycling pressure. The loop injection pressure will be tested by the head of sensor, and with pressure adjusting device. This control method can avoid every time before pouring out some materials must be mixed and the uneven.

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5.   Auxiliary measurement and injection system: colourants, catalyst, additive, etc.  (choose parts)

Pump: gear pump

Gear pump volume: 0.15cc

Range of flow: 0.006-~0.06L/min

Pressure control: by a pressure sensor to monitor

Material can’s volume:  0.6L/2L

Motor system: electric motors, controlled by a frequency converter

Injection head: each material has a single injection head, and it can adjust discharging pressure independent.

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6.   Cleaning system

Cleaning can: 20L steel barrel

Liquid level control: visual level

Injection head: directly injected into the mixed head

Cleaning, air, mixed head of speed and cycle are independent control system, this can make the maximum cleaning effect. In order to the maximize reduce consumption of cleaning, settings of each component can be pre-cleaning procedures. The casting machine Settings when suddenly loses power in the artificial emergency cleaning device. Cleaning solution should use non-flammable solvents, such as:DBE\MC.

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7.   Electronic display screen and software system

Electronic display design according to the EC criteria.

Software: The software system can control the machine to work and in the standby machine control.

Data in the user interface through the following procedures:

􀂃 Working state real

After all the machine on real-time parameters can be displayed on the interface, such as temperature, pressure, pumping and mixing speed, security levels, alarm conditions and other procedures set by the parameters must be displayed.

􀂃 Calibration interface

This interface is mainly used to automatically correct out of three different charge, by a balancer to determine quality.

The software also include some other systems, such as casting machine maintenance control, work time, data statistics and alarm records. Computer software must pass a set of passwords or keys in order to start, this can guarantee the authorized person is different for different levels of machine control.

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8.   Machine standard size:

   Height:          2,200mm

     Length:          3,420mm

     Width:           2,100mm

     Pouring arm length: 1,300mm

     Total weight:      about 2,500kg

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9.   Installation conditions

Compressed air:         dry air 5/7 bars

Compressed air flow:     >5Nm3/hour

Connections:           220V/380V-50Hz(3P+N+T)

Power:                32KW

Super voltage protection:  required

Installation environment:  do not install in the explosion of the workshop

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10.      Explanation

EMM according to client's requirement will, in standard machine machine, for customised machine with their requirements.