The working mode of the fabric core conveyor belt vulcanizing machine mainly revolves around the core requirements of the vulcanization process, involving the coordinated control of key parameters such as temperature, pressure, and time to ensure the vulcanization quality of the conveyor belt joints or the entire belt. The following elaborates in detail from four aspects: the basic working principle, the main working mode, the typical working process, and the analysis of mode characteristics:
First, the basic working principle
The fabric core conveyor belt vulcanizing machine achieves a cross-linking reaction between the rubber layer and the fabric layer in the conveyor belt through heating and pressurization, forming a strong chemical bond, thereby enhancing the strength, wear resistance and anti-aging performance of the conveyor belt. Its core working parameters include:
Temperature: It is usually controlled at 140-160℃, depending on the rubber formula and the type of vulcanizing agent.
Pressure: Generally 1.5-2.5MPa, to ensure that the rubber fully penetrates the fabric layer and expels air bubbles.
Time: Depending on the thickness of the conveyor belt and the process requirements, the vulcanization time is usually 15 to 30 minutes.
Second, the main working mode
Manual control mode
Operation mode: The operator manually sets the temperature, pressure and time parameters through the control panel and monitors the vulcanization process in real time.
Applicable scenarios: It is suitable for small-batch production, commissioning stage or vulcanization tasks with special process requirements.
Features: High flexibility, but it relies on the operator’s experience and there may be human errors.
Semi-automatic control mode
Operation mode: The system presets multiple vulcanization process parameters (such as vulcanization curves for conveyor belts of different thicknesses). The operator only needs to select the corresponding process number, and the equipment can automatically execute the vulcanization process.
Applicable scenarios: Suitable for medium-scale production, taking into account both efficiency and consistency.
Features: Reduce human intervention, enhance production efficiency, but still require operators to monitor key parameters.
Fully automatic control mode
Operation mode: Full-process automated control is achieved through PLC (Programmable Logic Controller) and HMI (Human-Machine Interface). The system automatically adjusts temperature, pressure and time according to the preset vulcanization process curve, and records and stores vulcanization data in real time.
Applicable scenarios: It is suitable for large-scale continuous production, especially in situations where the consistency of vulcanization quality is highly demanded.
Features: High precision, high efficiency, and data traceability, but the equipment cost and maintenance requirements are relatively high.
Segmented temperature control mode
Operation mode: The vulcanization process is divided into multiple stages (such as preheating, vulcanization, and cooling), and different temperature and time parameters are set for each stage to adapt to the vulcanization characteristics of different materials.
Applicable scenarios: It is suitable for vulcanization of multi-layer fabric core conveyor belts or special rubber formulations.
Features: Optimize vulcanization effect, reduce the risk of over-vulcanization or under-vulcanization, but the control logic is relatively complex.
Third, typical work processes
Taking the fully automatic control mode as an example, the working process of the fabric core conveyor belt vulcanizing machine usually includes the following steps:
Preparation stage:
Place the conveyor belt joints or the entire belt to be vulcanized on the vulcanizing plate of the vulcanizing machine and ensure they are aligned and fixed.
Shut down the vulcanizing machine, start the hydraulic system and apply the initial pressure to fix the conveyor belt.
Heating stage:
Start the heating system, and the temperature of the vulcanized plate gradually increases to the target temperature according to the preset curve.
The temperature sensor monitors the temperature of the vulcanized plate in real time and feeds the data back to the PLC.
Constant temperature vulcanization stage:
After reaching the target temperature, the system automatically maintains a constant temperature and maintains the set pressure.
During the vulcanization process, the rubber undergoes a cross-linking reaction with the fabric layer, forming a firm bond.
Cooling stage:
After the vulcanization time is over, the system automatically shuts down the heating system and starts the cooling device (such as air-cooled or water-cooled).
The temperature of the vulcanized plate gradually decreases to a safe range, and the vulcanization of the conveyor belt is completed.
Pressure relief and extraction stage:
Release the pressure of the hydraulic system, turn on the vulcanizing machine and remove the conveyor belt that has completed vulcanization.
Check the vulcanization quality, such as joint strength, surface flatness, etc.
Fourth, analysis of the characteristics of different modes
Manual control mode
Advantages: Simple operation, suitable for small batches or special processes.
Disadvantages: Low efficiency, poor quality consistency, and reliance on the operator’s experience.
Semi-automatic control mode
Advantages: It strikes a balance between flexibility and efficiency and is suitable for medium-scale production.
Disadvantages: The adjustment of process parameters still requires manual intervention, and the degree of automation is limited.
Fully automatic control mode
Advantages: High precision, high efficiency, traceable data, suitable for large-scale production.
Disadvantages: High equipment cost, complex maintenance, and high technical requirements for operators.
Segmented temperature control mode
Advantages: Optimized vulcanization effect, adapted to the properties of different materials.
Disadvantages: The control logic is complex and the debugging is difficult.
Fifth, application suggestions
For small-batch production or debugging: Prioritize manual or semi-automatic modes and flexibly adjust process parameters.
Large-scale continuous production: Fully automatic mode is recommended to ensure the consistency of vulcanization quality and production efficiency.
Special materials or processes: A segmented temperature control mode can be adopted to optimize the vulcanization effect.
The working mode of the fabric core conveyor belt vulcanizing machine should be comprehensively selected based on factors such as production scale, process requirements and equipment cost, in order to achieve a balance among vulcanization quality, efficiency and cost.