Exempt from replace wheeled serial paddy hulling rubber roll and production method thereof
Technical field
The present invention relates to the paddy hulling rubber roll in rice milling unit, namely one exempts from replace wheeled serial paddy hulling rubber roll and production method thereof, this rubber roll in use need not replace can single use complete, can be applicable in the existing whole wheeled rubber roll huskers manufactured both at home and abroad.
Background technology
Paddy hulling rubber roll is the core component of hulling machine, is mainly used in paddy husking, easily wears away, and consumption is large.Paddy hulling rubber roll is divided into wheeled series and shell type series two classes by installation way, amounts to tens kinds of specifications and models.Wheeled series is with base core (iron or aluminium) inboard wall flange plane (axis) and Flange Plane endoporus (radial direction) location, and with the paddy hulling rubber roll of the fastening multiple appearance and sizes of nut, as shown in Figures 1 and 2, rubber layer 1 is surrounded by the outside of iron core 2, there are locating hole 5 and plane of orientation 4 in the inside of iron core 2, and the periphery of locating hole 5 has been evenly arranged four fastening bolt holes 3.
Rubber roll is the core work component of hulling machine, is a pair equal diameter and whippy rubber roller, and two roll axis are positioned at same level or slightly difference in height, and with different rotating speeds opposite direction rotating, what linear speed was high is fast roller, and what linear speed was low is slow roller.Paddy feeds between two rollers in rubber roll total length equably with certain flow velocity, after being subject to two roller extruding, producing stranding and tears effect, thus paddy is peeled off as brown rice by two roller linear speed differences.Therefore, linear speed difference between speed roller produces to rub with the hands to tear the prerequisite of effect, directly affect shelling ability and rubber abrasion, is also that (linear speed difference is little for decision paddy flow velocity (flow velocity is greatly that production capacity is large) and roll gap pressure, husking yield decline, can improve roll gap pressure improve) key element.The linear speed difference of hulling machine is according to paddy husking rate and production capacity design, therefore, uses, be conducive to the efficiency and the production capacity that improve paddy husking, reduce glue consumption and equipment failure rate in rational hulling machine linear speed difference scope.
Linear speed, the linear speed difference of rubber roll are introduced: the linear speed of rubber roll means rubber roll peripheral speed operationally, that is:
V=πDN/60(m/s)
In formula: D-top roller diameter (m)
N-rubber roll rotating speed (r/min)
Linear speed difference refers to the difference of the linear speed of fast roller and slow roller, that is:
VA=V1-V2
In formula: the linear speed difference (m/s) of VA-rubber roll
V1-fast roller linear speed (m/s)
V2-slow roller linear speed (m/s)
Domestic and international hulling machine can be divided into three kinds of types by the linear speed difference scope of application: 1, linear speed difference is at 3.4-4m/s, and this is equipment comparatively advanced at present; 2, linear speed difference is at 2.6-3.2m/s, and this is universal equipment; 3, the hulling machine of 2.6-3.2m/s is less than.Existing hulling machine adopts single belt (flat belt, hexagonal belt, Timing Belt) transmission mostly, the rotating speed of two rollers is constant, but because the quality of rubber materials of two rubber rolls is identical, causing the abrasion of speed roller, inconsistent (abrasion of fast roller are large, slow roller abrasion are little), its linear speed along with the abrasion of rubber roll but gradually consistent, tear stranding effect and weaken gradually, cause husking yield obviously to decline.In order to avoid this disadvantage, equipment operating requires that, when two roller footpath difference 5mm, need shut down and be exchanged by speed roller, linear speed is poor to regain comparatively reasonably.As requested, a pair new rubber roll is finished using from installing to, palpus roll change 7-8 time.During roll change, shutdown, loading and unloading clamp about need about 30 minutes used time, and every pair roller barrel calculates, by about 210 minutes consuming time for 7 times by roll change.Separate unit hulling machine is produced also better, if the parallel operation of multiple stage hulling machine works, by 4 hulling machine parallel operation, once, light roll changing time must 120 minutes in per tour roll change.Not only the labour intensity of operative employee is large, and the economic benefit of husk rice enterprise is also greatly affected.Therefore, in actual use, operative employee is in order to save time; reduce roll change number of times; reduce labour intensity, when mostly adopting fast roller to wear away 1/2, just shut down exchange, or simply wait until that changing the new rubber roll of another after fast roller wears away uses with slow roller before simultaneously.There is shortcomings in this violation operation: 1, linear speed difference reduces, and husking yield declines; 2, in order to improve husking yield, operative employee can keep husking yield to improve roll gap pressure (strong tight roller), and this will cause glue consumption, energy consumption and fault rate to increase; 3, linear speed difference is less than paddy flow, and paddy is piled up at roll surfaces, produces local flow uneven, causes glue face to destroy (grooving, local are come unstuck); If 4 only change a new rubber roll, two roller linear speed differences will be made excessive, cause vibration equipment large, rubber roll temperature rise, roll surface destructible, yielding, the invalid wearing and tearing of rubber are many; 4, linear speed difference is too small or cross big city's impact rice huller paddy effect, and cause broken rice rate high, steaming again paddy increases, and also affects the result of use of paddy hulling rubber roll simultaneously.
Summary of the invention
The object of the invention is by raw-materially choosing polyurethane rubber and butadiene hydrocarbon rubbers etc., the setting up and the various combination of rubber compounding of technical indicator, manufacture fast roller and slow roller respectively, reach that the abrasion of speed roller glue face are basically identical and to exempt transposition tired.
Thisly exempt from the wheeled serial paddy hulling rubber roll that replaces, it is characterized in that, comprise a fast roller and a slow roller, the external diameter difference of slow roller and fast roller is 0-5mm, the formula of their surface parcel rubber is different, in work, the performance of abrasion performance is different, but they are isopyknic abrasion in the work of different revolution, and the linear speed of fast roller and slow roller difference is remained in an optimum scope.
The abrasion of rubber are the process of a mechanical damage in essence.Its is main with the molecular structure of main gel, various physical and mechanical properties of vulcanizate, mainly relevant with breaking strength, elongation at break, hardness factor, while also, paddy seed-grain as poor in temperature, linear speed with the service condition of rubber because have substantial connection.Its influence factor is a lot, and according to rubber abrasion mechanism in the past, the abrasion of rubber are mainly divided into two kinds of forms: 1, abrasion wear, 2, tired abrasion; As follows with regard to these two kinds of forms application note in the present invention below:
One, paddy hulling rubber roll rubber layer because of hardness high, Shao Er hardness 90A-95A, intensity is large, relative deformation is little, constantly cut by sharp-pointed, coarse grain, swipe under duty, pull apart into small particle, therefore, the abrasion of rubber are auxiliary process based on the abrasion of the fatigue of the shearing behavior of abrasion wear, relaxed stress; So utilize Akron abrasion value and rubber volume rate of wear to weigh, determine paddy hulling rubber roll rubber abrasion advantageously:
The result of Akron abrasion experiment, can be expressed as the wear volume in the mileage of 1.61km, that is:
U=(g2-g1)/P(formula 1)
In formula: U-wear volume (cm3)
P-sample density (g/cm3)
G1, g2-be respectively the quality testing front and back sample
Two, the result of volume worn rate is expressed as contact one timing, and the rubber volume rate of wear of unit distance is directly proportional to the long-pending inverse of the hardness of sample, breaking strength, elongation at break three, namely
A=K/HQ ε (formula 2)
In formula: A-volume worn rate,
K-constant, generally gets 1
H-sample hardness
Q-sample breaking strength
ε-sample elongation at break
Rubber abrasion volume ratio under fast, the slow roll working state of existing paddy hulling rubber roll, through repeatedly on-the-spot test, result is:
During linear speed difference 2.6-3.2m/s, fast roll body amasss (B is fast): long-pending (B the is slow)=100:60 of slow roll body;
During linear speed difference 3.4-4m/s, fast roll body amasss (B is fast): long-pending (B the is slow)=94:60 of slow roll body;
Three, the relation between U, A, B three: wherein A is empirical value during we work, reflects the relation between volume worn rate A and rubber physical mechanical property, and A value is less, and wearability is better; According to the test data provided in GB GB/T1689-1998, Akron abrasion value U can be used to the wearability weighing main gel, can check, verify the reliability of volume worn rate A, slowly, the wear volume of fast roller must solve the synchronous wearing and tearing of paddy hulling rubber roll by volume worn rate A and Akron abrasion value U than B, meet following formula, fast roller wear volume=slow roller wear volume can be solved:
U is fast: U is slow=A is fast: and A is slow=and B is slow: B fast (formula 3)
In formula: U is fast, U is slow---the Akron abrasion value of fast, slow roller;
A is fast, A is slow---the volume worn rate of fast, slow roller;
B is slow/and B is fast---the wear volume ratio of slow, fast roller.
Rubber roll outside dimension can be adjusted change within the scope of 0-5mm, the abrasion difference caused with the hulling machine reducing various different linear speed difference scope.
Advantage of the present invention
1, optimize linear speed difference scope, be conducive to improving production capacity, give full play to the service efficiency of rubber roll;
2, the invalid abrasion of rubber reduce, and can extend the service life of rubber roll;
3, the high and low all kinds of negative effects caused of linear speed difference are avoided;
4, save roll changing time, reduce labor strength;
5, be conducive to multiple stage hulling machine parallel operation operation, adapt to large-scale continuous production.
Accompanying drawing explanation
Fig. 1 is the profilograph of paddy hulling rubber roll
Fig. 2 is the left view of paddy hulling rubber roll
Fig. 3 is the production technology figure of 1#, 2# pouring polyurethane rubber paddy hulling rubber roll
Fig. 4 is the production technology figure of 3#, 4# butadiene hydrocarbon rubbers paddy hulling rubber roll
In figure 1 and Fig. 2 in: 1, rubber layer, 2, iron core, 3, fastening bolt holes, 4, plane of orientation, 5, locating hole.
Detailed description of the invention
Use three embodiments below, containing 4 kinds of paddy hulling rubber rolls, the production stage of this wheeled serial paddy hulling rubber roll of exempting to replace be described in detail as follows:
One, raw material are prepared:
A, be chosen at the pouring polyurethane rubber PUR in rubber type of material with best wearability, its breaking strength 28-60MPa, elongation at break 400-800%, there is hardness number widely, but such rubber heat resistance is poor, only adapt to use at-20 DEG C of-80 DEG C of temperature, main raw material(s) comprises: polyester-diol, vulcabond DTI, 33 '-dichloro-4 4 '-diaminodiphenyl-methane MOCA; NBR, styrene butadiene rubber sbr, butadiene rubber BR, three kinds of rubber with alone or and by mode, through reinforcement and resistance to heat treatment, can at 100 DEG C of temperature the long period use; Main raw material(s) comprises: butadiene hydrocarbon rubbers, white carbon, zinc oxide ZnO, stearic acid SA, age resistor, accelerant CZ, vulcanizing agent, plasticizer, Hardening agent, bulking agent;
Two, the key technical indexes of four kinds of rubber, formula and Akron abrasion value is produced:
This technical indicator is slow with linear speed difference 2.6-3.2, B: B is as the criterion soon=0.6, by the A value of the 1# that fills a prescription, utilizes formula A=K/HQ ε, obtains the performance indications of 2#, 3#, 4# formula;
Three, formula Design, the i.e. parts by weight of component:
1#, 2# polyurethane rubber is filled a prescription: polyester-diol 100, vulcabond 18-22, MOCA14-16, other 2.0-10;
3#, 4# fill a prescription: alkadiene rubber 100, white carbon 60-90, ZnO5-10, SA1-3, Cz0.5-2.5, age resistor 1-3, plasticizer 5-15, bulking agent 5, Hardening agent 10-30;
Akron abrasion pH-value determination pH, according to GB/T1689-1998
Formula number |
1# |
2# |
3# |
4# |
Akron abrasion (cm3) |
0.02 |
0.033 |
0.055 |
0.092 |
Four, manufacturing process
1#, 2# press the production technology of Grain Roller of Polyurethane-pouring Type as Fig. 3:
Polyester-diol is added in reactor, dehydration 1.5h is stirred under the condition of temperature 100 ° of C ~ 110 ° C and vacuum 0.1MPA, the vulcabond measured is added drop-wise in glycol, heating is stopped after 85 ° of about C add thermal agitation 2h, reactant sealing is passed into nitrogen and preserves 24 hours, measure the content of its isocyano, the performed polymer of the end group-NCO namely made.
Reactor is heated to 80 ° of C by performed polymer, add the MOCA of melting and stir, then material being poured into one is preheated in the mould of 100 ° of C, sulfuration 4 ~ 6h in the sulfuration cabinet of 100 ° of C ~ 115 ° C, when mold temperature is down to room temperature condition naturally, open mould after sulfuration completes take out goods, vulcanized article is parked a Zhou Houzai at ambient temperature and is sized on lathe, then test package warehouse-in.
3#, 4# press the production technology of general butadiene hydrocarbon rubbers paddy hulling rubber roll, that is:
Plasticate butadiene hydrocarbon rubbers input banbury 4min, add Hardening agent, the mixing 3min of bulking agent again, then ZnO, SA is added, after finally adding white carbon, the mixing 5min of plasticizer, the lower sizing material of row, be cooled to 80 ° of C, add vulcanizing agent, cz on a mill until, through mixing evenly after bottom sheet park 24h;
Bottom sheet sizing material through freshening heating after on coiling machine, elastomeric compound is coated on scribble adhesive iron core on or on aluminium core, the then die-filling sulfuration kettle cure 160min at 150 ° of C; After sulfuration completes, mould is opened in cooling, then through paint, machined, test package is put in storage;
Five, products obtained therefrom
Embodiment 1,1# fill a prescription fast roller, and 2# fills a prescription slow roller
Embodiment 2,2# fill a prescription fast roller, and 3# fills a prescription slow roller
Embodiment 3,3# fill a prescription fast roller, and 4# fills a prescription slow roller
Carry out the collocation of speed roller by above-mentioned three kinds of schemes, form product.
The pluses and minuses of three kinds of schemes are as follows:
Embodiment 1: the wearability of rubber roll is fabulous, and service life is the longest; Shortcoming uses under the operating temperature of only adaptation-20 DEG C-80 DEG C, and long-grained nonglutinous rice processing broken rice rate is high, and vibration equipment is large.
Embodiment 2: wearability and service life are better, broken rice rate and equipment seismism excellent compared with scheme 1, but still there is the inadequate shortcoming of fast roller heat resistance.
Embodiment 3: wearability and service life poorer than scheme 1, scheme 2, but good heat resistance, operating temperature can reach 110 DEG C-120 DEG C, and broken rice rate is low, and equipment fault is few, and combination property is best.
Foregoing invention is set about from the wear characteristic of rubber, utilizes multiple technologies means fundamentally to solve the synchronous abrasion of speed roller.But paddy hulling rubber roll is under actual working state, also can be subject to paddy seed-grain (husk thickness, soft or hard), environment temperature (Summer and winter and different regions) and the abrasion difference of different linear speed difference caused by hulling machine, be in particular in following three aspects:
For the hulling machine of linear speed difference 3.4-4m/s, speed roller wear volume compares 94:60, because linear speed difference is large, frictional heat, rubber roll temperature is slightly high, fast roller rubber abrasion is bigger, therefore increases fast roller outside dimension 0-5mm(and is equivalent to improve rubber abrasion volume 0-13%) be conducive to improving the operating efficiency of paddy hulling rubber roll, increase the service life.
Linear speed difference is less than to the hulling machine of 2.6-3.2m/s, reduces fast roller 0-5mm, can ensure that paddy hulling rubber roll synchronously wears away, and linear speed difference scope all-the-time stable.
When paddy hulling rubber roll is thick in rice hulls, hard and summer, height is when thermally district uses, is reasonable to reduce slow roller 0-5mm.
In sum, adjustment rubber roll outside dimension changes within the scope of 0-5mm, pointed, is of the present invention supplementary and perfect.