The vacuum extruder adopts the principle of single-machine extrusion, single shaft, single mud cylinder, and single spiral coaxial sealing mechanism. The machine body is entirely welded by steel plates. The structural design is reasonable and the extrusion pressure is large. It is suitable for producing hollow bricks of various specifications with raw materials such as shale, high-doped fly ash, coal gangue, clay, etc. The machine has strong practicality, small investment, and quick results. It is an ideal equipment for technological transformation of brick factories.

Introduction

The JKRL series energy-saving vacuum extruder is designed with a single-stage vacuum extrusion principle, reasonable structural design, and high extrusion pressure. It is suitable for producing hollow sintered bricks with low plasticity raw materials such as shale, coal gangue, and fly ash. The machine is highly efficient and energy-saving (one motor), has wide practicality, and low investment. It is an ideal equipment for technological transformation of small and medium-sized brick and tile enterprises.

Performance parameters

Features

The vacuum extruder is a new type of brick-making equipment designed and manufactured by our factory based on my country's actual national conditions, absorbing and digesting the advanced technologies of developed countries such as Germany, Italy, and the United States, and drawing on advanced experience at home and abroad. It has the characteristics of reasonable structure, durability, easy maintenance and strong adaptability. It is an ideal equipment for producing various hollow bricks and solid bricks using various raw materials such as clay, fly ash, coal gangue, shale, river silt, etc.

Maintenance and care

Operation method:

The operator must be familiar with the structural characteristics of the extruder he operates, especially the structural characteristics of the screw, the characteristics of the heating and cooling control instruments, the characteristics of the die and the assembly conditions, so as to correctly master the extrusion process conditions and operate the machine correctly.

The operation methods for extruding different plastic products are different, but they also have similarities. The following briefly introduces the same operating steps and precautions when extruding various products.

1. Preparation before starting

(1) Plastics used for extrusion molding. The raw materials should meet the required drying requirements and need to be further dried if necessary. The raw materials should be sieved to remove lumps, agglomerates and mechanical impurities.

(2) Check whether the water, electricity and gas systems in the equipment are normal, ensure that the water and gas lines are unobstructed and leak-free, whether the electrical system is normal, and whether the heating system, temperature control and various instruments are working reliably; run the auxiliary machine at low speed and observe whether the equipment is operating normally; start the vacuum pump of the shaping table and observe whether it is working normally; lubricate the smooth parts of various equipment. If any fault is found, eliminate it in time.

(3) Install the die and shaping sleeve. Select the die specifications according to the variety and size of the product. Install the die in the following order.

в┘ The die should be assembled together and installed on the extruder as a whole.

в┌ Before assembling the die, wipe off the grease applied during storage, carefully check whether the surface of the cavity is dented, scratched or rusted, perform necessary polishing, and then apply a layer of silicone oil on the flow channel surface.

в█ Assemble the plates of the die in order, apply high-temperature grease to the threads of the bolts, and then tighten the bolts and flanges.

в▄ Place the porous plate between the die flanges to ensure that the porous plate is pressed tightly without overflowing.

в▌ Before tightening the fastening bolts of the die and the extruder flange, the horizontal position of the die should be adjusted. The square die can be adjusted with a level, and the round die can be leveled with the die bottom of the die based on the bottom surface of the molded model rubber.

в▐ Tighten the flange bolts, tighten the die fastening bolts, install the heating ring and thermocouple, and pay attention to the heating ring to be close to the outer surface of the die.

в▀ Install the shaped sleeve and adjust it in place, check whether the center line of the main engine, the shaped sleeve and the traction machine is aligned. After adjustment, tighten the fixing bolts. Connect the water pipes and vacuum pipes of the shaped sleeve.

вр Turn on the heating power supply to evenly heat the die and the cylinder. At the same time, open the cooling water valve of the bottom of the hopper and the gear box and the water inlet valve of the exhaust vacuum pump.

Common Problems

1. Not eating materials (mud cannot go down, "mud returns", mud cylinder heats up)

1. The reamer is seriously worn. The gap between the reamer and the inner wall of the mud cylinder is too large, or the spiral angle of the reamer blade is incorrect: when replacing the reamer, you should pay attention to keeping the gap at 3-5mm, and the reamer blade should be made according to the designed angle.

2. The surface of the reamer blade is too rough, increasing the friction between the mud and the blade: when surfacing the reamer, do not surfacing in groups, and replace them all at once. You should do it step by step and replace them in batches to ensure smooth brick production. If conditions permit, you can slightly grind it smooth.

3. The liner of the mud cylinder wall is seriously worn. The gap between the reamer blade and the mud cylinder wall is too large, resulting in too much rotation of the mud in the mud cylinder, so that the mud cannot come out or go in: At this time, a new mud cylinder bushing should be replaced, or several ribs parallel or inclined to the axial direction should be installed on the inner wall of the bushing to replace the worn-out riveting grooves, so as to prevent the mud from rotating ineffectively and increase its effective extrusion.

4. The gap between the mud pressing knife plate and the reamer is too large to press down the mud: the knife plate should be adjusted or welded, and updated so that the gap between it and the reamer blade is less than 10mm.

2. Mud strip movement bending

1. The mud strip bends to one side: This is because the center lines of the machine mouth, core, mud cylinder and spiral reamer are not aligned.

2. The mud strips are S-shaped: This is because the compression length of the machine neck is not enough, the tops of the main and auxiliary leaves of the first spiral auger are not aligned, or the auxiliary leaves of the first auger are seriously worn and reduced. During operation, only the semicircle of the main leaf pushes out the mud: At this time, the first auger should be replaced and the auxiliary leaves should be welded.

Overload (the load of the motor remains high and the clutch slips. At this time, it is forbidden to force start to avoid damage to related parts, or even cause major accidents such as squeezing the mud cylinder and the machine head)

1. The mud is too dry: The too dry mud should be taken out first. It is best to remove the machine mouth and the machine head, start the machine to drain the dry material in the mud cylinder, and then install and run it, and appropriately increase the molding moisture within the specified range.

2. The remaining material in the mud cylinder becomes dry and hard after being shut down for a long time: This will not only cause serious overload, but sometimes it will fail to start. In order to prevent this from happening, when the machine is shut down for more than 8 hours, do not close the dead machine mouth to use water. For the two-stage vacuum extruder, the mud in the upper mud cylinder should be properly supplied with water to keep it moist. If the machine is shut down for more than 2 days, the mud should be emptied as much as possible before shutting down.

3. Machine "head swing" This is a common problem of screw extruders.

Because the auger shaft is a long cantilever shaft with poor stability, this situation will be aggravated when the bearing is loose, the main shaft is bent, and the auxiliary blade of the first section of the auger is too small. If the mud cylinder is not installed correctly, the gap between the spiral auger blade and the mud cylinder wall is not the same, and the outer edge of the spiral auger blade is seriously out of round, causing the main shaft to be unevenly stressed and swing head, it should be corrected in time, and the anchor bolts and connecting bolts should be tightened frequently to prevent it from swinging head and tail. Spiral lines appear after mud strips are extruded. Because the mud strips are affected by the spiral action of the auger, the mud material advances at different speeds on the mud cylinder section. The mud material near the axis moves faster, and the mud material at the edge moves slower. An interface is formed between the mud flows of different speeds. Water and air are concentrated in the gaps on this surface, resulting in stratification. This is mainly caused by the high plasticity of the mud material, excessive molding moisture, too high spindle speed, and mud return on the inner wall of the mud cylinder.

Handling methods:

1. Raw materials of different properties should be fully mixed and aged as much as possible to allow moisture to fully penetrate into the raw material particles and reduce the moisture on the surface of the original mud.

2. Appropriately reduce the molding moisture to increase the friction between the mud layers.