An open-type rubber mixing machine

An open-type rubber mixing machine

【Basic Principle】

An open mixing mill, commonly used in rubber factories for plasticizing rubber, mixing rubber compounds, or performing thermal refining and shaping. The primary working components are two hollow or perforated rollers that rotate in opposite directions. The raw rubber or compound is fed between the rollers, where it is subjected to intense shearing forces, achieving the goal of plasticizing or mixing.

【Change in Startup Method】

Before using a frequency conversion system, the open mixing mill utilized a rotor resistance starter, which caused significant current surges (100–150A) when switching from the rotor resistance phase to normal operation, resulting in noticeable equipment vibrations and noise, negatively impacting the lifespan of the machinery. After adopting a frequency converter, the current can increase smoothly to operational levels, reducing the impact of current surges caused by the switching of the rotor resistance starter.

【Change in Speed Control】

With the frequency conversion system, the mixing mill initially operated at a constant speed with no speed adjustment capability. After modification, the mixing speed can be adjusted according to production requirements, allowing better synchronization with the process and improving the quality of the rubber compound.

【Energy Efficiency Evaluation】

When using a frequency converter, the motor consumes current based on actual load conditions, unlike direct start-up where an AC motor operates at full power constantly. During alternating operations, the current during unloaded conditions can be controlled between 60% to 80% of the full motor output. Preliminary estimates suggest energy savings of about 30%.

Based on the data measured during current operations:

Before using the energy-saving system, the load at 50Hz resulted in a power consumption of 78,979W. After adopting the energy-saving system, the power consumption during operation was 50,020W.

This indicates an improvement of 37% in energy efficiency.