The operation specifications of the conveyor belt vulcanizing machine cover pre-operation preparation, vulcanization process control and post-operation handling. The following are the specific contents:
Preparations before operation
Understand the specifications, performance of the conveyor belt and the on-site construction operation situation: Have a comprehensive understanding of the specifications, types, single roll lengths of the conveyor belts to be bonded, as well as whether there are any special requirements for belt joints and usage. At the same time, understand the position of the conveyor belt joints, the total length of the conveyor belt, the total length of the frame, the frame slope, the condition of the tensioning device, how many joints need to be made, whether a crane is needed to transport the equipment, and the time arrangement for the machine to be shut down for maintenance, etc. In addition, it is necessary to understand the surrounding environment of the construction, the weather of the day, the dust conditions, the types of dust, etc., and take necessary protective measures.
Prepare tools and materials: Get the vulcanizing machine, rubber compound, clamping plates and other joint tools ready, and ensure that the quality of the tools and materials meets the requirements.
Inspect the equipment:
Electrical inspection: Check that the equipment, electrical appliances and control systems are in good condition, sensitive and reliable, and there are no foreign objects inside the machine before starting it. At the same time, before use, the insulation resistance of the hot plate should be checked. If it is too low, it should be powered on and dried first until the insulation value reaches above 50MΩ before it can be used.
Mechanical inspection: Check whether the heating plate, hydraulic system, mechanical components, etc. of the vulcanizing machine are in good condition to ensure the normal operation of the equipment.
Site preparation: Select the appropriate joint position and fix the conveyor belt with clamping plates. Remove the support and install the vulcanizing machine properly. The bonding site should be cleaned thoroughly to keep it spacious, dry and bright.
Vulcanization process control
Joint treatment:
Stripping: According to the number of layers of the conveyor belt, divide the conveyor belt into several uniformly long steps and strip them layer by layer to ensure that the steps at both ends of the belt joint fit together. Pay attention to the depth of the cut and do not cut the fabric layer.
Grinding: Use tungsten steel grinding discs to grind the surface of the fabric layer and the transition zone into a rough state to remove surface contamination, increase the surface activity and roughness of the adhesive and fabric. Do not damage the fabric layer when grinding.
Cleaning: Use a hair dryer to clean the surface of the joint, and then clean the surface of the joint with a cleaning agent and let it dry.
Gluing and lamination
Gluing: Apply a layer of adhesive slurry on the surface of the belt joint that has been ground and cleaned. When applying the adhesive slurry, do it evenly, without overapplying or missing any areas. Generally, apply the adhesive slurry at least twice or more.
Bonding: When the surface of the belt joint is no longer sticky to the touch, stick the film and add film at the steps to fill the gap. Bond the other side that has undergone the same process of stripping, grinding and applying glue to this head, making sure it is aligned up and down to ensure that both ends of the belt are in a straight line.
Vulcanization operation
Assemble the vulcanizing machine: Assemble all the components of the vulcanizing machine properly and ensure that the heating plate, water pressure plate, pressure transmission plate, etc. are in the correct positions.
Pressurization: Use a water pump to pressurize and maintain the pressure within the specified range (such as 1.2 to 1.6MPa) until the vulcanization joint is completed.
Heating up and constant temperature: Connect the power supply to heat up. When the heating plate has been heated for a certain period of time (such as 15 to 25 minutes), press it tightly once to ensure that the joint is subjected to sufficient pressure. When the temperature reaches the specified value (such as 80℃), it rises to the standard pressure. Continue to heat up to the vulcanization temperature (for example, 145℃ for ordinary conveyor belts and 160℃ for heat-resistant conveyor belts), and then calculate the vulcanization time at a constant temperature.
Vulcanization time control: The vulcanization time should be determined based on factors such as the specifications, thickness of the conveyor belt and the properties of the rubber compound. Generally, the vulcanization time (in minutes) = base time + number of fabric layers × coefficient + (upper cover rubber + lower cover rubber) × coefficient.
Notes:
Temperature control: The vulcanization temperature should be controlled within the specified range to avoid being too high or too low, which may affect the vulcanization quality.
Pressure control: The vulcanization pressure should be uniform and maintained within the specified range to prevent poor vulcanization due to misalignment at the joints or insufficient pressure.
Safe operation: Operators should wear proper labor protection equipment to prevent accidents such as scalding and electric shock.
Post-operation processing
Cooling and mold removal: After the vulcanization time is over, when the temperature naturally cools down to the specified value (such as 80℃), cut off the power supply, remove the power cord, release the water pressure, and then disassemble the vulcanizing machine.
Inspection and repair: Check the overall condition of the joint area to see if there are any phenomena such as bubbling or lack of glue. Trim both sides to make the joint surface flat, smooth and clean.
Record and Maintenance: Keep detailed records of the joint conditions of the conveyor belt, including the joint length, Angle, joint time, location, joint condition and transported materials, etc. Regularly inspect and maintain the joints to ensure the normal operation of the conveyor belt.