Process optimization of vulcanizing machines in rubber products factories
Optimize the three elements of vulcanization
Vulcanization temperature: Select an appropriate vulcanization temperature range based on the type of rubber. Increasing the vulcanization temperature can accelerate the reaction, but it is necessary to avoid excessively high temperatures that may cause molecular chain cleavage or vulcanization regression.
Vulcanization time: By measuring the vulcanization curve with a vulcanizing instrument, and in combination with the characteristics of the rubber material and product requirements, the optimal vulcanization time is determined to avoid under-vulcanization or over-vulcanization.
Vulcanization pressure: Adjust the pressure according to the thickness of the product. For thin products, a lower pressure can be used, while for thick products, the pressure needs to be increased to ensure density and mechanical properties.
Improve the vulcanization process parameters
Preheating treatment: Fully preheat the rubber compound to eliminate internal bubbles and prevent hole defects in the finished product.
Pressurization method: Adopt a reasonable pressurization method to ensure that the rubber compound fully fills the mold, reducing bubbles and defects.
Cooling and shaping: Optimize the cooling process, utilize the residual heat of steam to cool and shape the rubber compound, reduce manual intervention, and enhance production efficiency.
Optimize mold design
Exhaust system: Reasonably arrange exhaust holes and exhaust grooves in the mold to ensure smooth gas discharge and reduce surface bubbles and internal voids of the product.
Surface finish: Enhance the surface finish of the mold, reduce gas retention and the flow resistance of the rubber compound, and improve the appearance quality of the product.
Cavity structure: Simplify the cavity structure, avoid overly complex designs, and reduce the possibility of gas retention.
Introduce intelligent and automated technologies
Real-time monitoring and control: By introducing PLC (Programmable Logic Controller) and sensor technology, parameters such as temperature, pressure and time during the vulcanization process are monitored in real time to achieve automatic control and optimization.
Data recording and analysis: Establish a complete process data recording system to conduct real-time monitoring and recording of various parameters during the vulcanization process, so as to quickly locate the source of problems and take corresponding measures.
Intelligent optimization and predictive maintenance: By leveraging big data and artificial intelligence technologies, intelligent optimization and predictive maintenance of the vulcanization process are achieved, enhancing production efficiency and equipment reliability.
Energy conservation and environmental protection measures
High-efficiency heating system: It adopts high-efficiency heating methods such as electric heating or magnetic heating to replace traditional steam or oil heating, reducing energy consumption.
Waste heat recovery and utilization: Recycle and utilize the waste heat generated during the vulcanization process for preheating rubber compounds or other production processes to reduce energy consumption.
Application of environmental protection materials: Use sulfur-free vulcanizing agents, bio-based vulcanizing agents and other environmental protection materials to reduce the emission of harmful substances during the vulcanization process and achieve green production.
Optimization of rubber compound formula
Selection of vulcanization system: According to the usage requirements of rubber products, choose the appropriate vulcanization system and dosage of vulcanizing agent, and optimize the vulcanization speed and effect.
Accelerators and additives: Adding an appropriate amount of vulcanization accelerators and additives can lower the vulcanization temperature, shorten the vulcanization time, and enhance the physical and mechanical properties of rubber.
Fluidity improvement: Optimize the rubber compound formula, reduce the viscosity of the rubber compound, improve fluidity, shorten the residence time of the rubber compound in the mold, and enhance production efficiency.