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LU-YH-7 Rubber recycling production line (basic model)


Brand
LU-YH-7
Units
15
Name 1. Tire bead seat cutter - 1 unit
2. Tire-to-band cutter 1unit.
3. Band to workpiece cutter 1unit.
4. Main abrasive machine 1 unit
5.Primary purification sieve 1 unit
6. magnetic separator 2 units
7. Air separator - 1unit.
8. conveyors - 3 units
9. Electric board
10.Fine polishing vibration sieve - 1 unit.
11. Tire bead seat extruder 1 unit
12. Fine fraction final attritor 1 unit.
Is not in the set Everything is in the set
Rated power consumption 135 kW.
Actual power consumption 55 kW
Main engine power 43 kW
Water consumption 50 Liters/day (cooling)
raw materials used 3600 kg/shift
Makes workpieces 3600 kg/shift ( 6 delivery truck’s wheels 65 kg/hr)
Crumbs, % 55 (0.5 - 1.0 mm)
Powder, % 45 (0- 0.5 mm)
Textile removes
Metal extracts
Recycles pure rubber Recycles
Tires and bands containing textile Recycles
Tires and bands containing textile and metal Recycles
Tires containing metal Recycles
Tires – diameter up to 4 meters Doesn't recycle
Productivity Depends on rubber content in raw materials
- hour 200-250 kg
-shift (10 hrs) 2000-2500 kg/shift
-22 hrs/day 4000-5000 kg /day
- year 1200-1500 tons/day -22 hrs
-Extracted metal/shift 1000 kg max., depending on raw materials
-Extracted textile/shift 200 kg max/depends on raw materials specifications
Raw materials consumption 3000 tons/year
Diameter of the tires recycled 12 inches
24 inches
Calculation of the operation mode 300 days/year, 22 hrs/day
Personnel/shift 6 persons
Skillful workers 2
Shiftmen 4
The production is divided into sections. There are workers on each section 2 sections
---Attritors’ section 2 persons.
---Tire (up to 24 inches) preparation section 3 persons.
Foreman (engineer) –total production control 1 person.
Weight of the equipment 10250 kg
Certification of the equipment Certified in Pr China, Vietnam, Mongolia, Ukrain, Kazakhstan, Egypt, Turkey, Czech Republic, Israel, Russia
Warranty 1 year
Technical losses, % 0,5% of the raw materials weight
Production area without warehouses 200 m2
Compulsory indoor installation ---preparation section
---attrition section
Outdoor installation No
Mounting time 2 weeks
Fraction are controlled by replacement of sieves 2 fractions simultaneously
Foundation for mounting Is required for the main attritor
Start and adjustment specialists from the factory Desirably but not compulsory
Training of the personnel Desirably but not compulsory
The equipment is made by license USA
Transportation one -40ft.container.
Time of manufacturing 60 days
Shipping time 66 days
Time of delivery 90-120 depending on destination
SPARE PARTS are not included in the set.
Wearing parts  
---Abrasive shafts 2 units Service time -2 year (made in Japan)
---Circular cutters 2 units Service time - 1 year
---Chips breaker service time 1 year
--Tire bead seat cutter’s blades Service time – 4 months
---Drums of tire bead seat extruder Service time – 6 months (but it is possible to extend its service time and/or restore it
---Replaceable sieves Service time – 1 year
Manufacturing scheme 1.Removal of a tire bead seat >> 2.Separation of metal and rubber in tire bead seat >>3. Cutting of tire (without tire bead seat) in spiral bands of width of 3-5 cm >>4. Cutting off the second tire bead seat >> 5. Thinning of band >> 6. Cutting of workpieces >> 7. Production of powder and crumb >> 8. Separation into fractions >> 9. Removal of textile cord >> 10. Shredding of pure rubber (tread strips) and rubber containing textile cord >> Finished product warehouse
The products are used to obtain (further recycling of powder and crumb can yield as follows) - reclaimed raw rubber
-Mats for sport-grounds 500 х 500 mm
-filling seamless coatings
-Foam rubber
-Novotracks
-baseplates for rails and railway hardware
-soles for slippers
- sanitaryware gaskets
- rugs for entrance doors and bathrooms
-additive to asphalt
- roof cladding
-rubber paving blocks
-EPDM granules
-gaskets and sealants for doors and windows
tread strips for restoration of wheels
-mooring dolphins
1.  Destination of the Plant and complete set 
The plant is used for  abrasion of the rubber, besides, it can be applied for production of  the secondary rubber crumb.
Please find below the parts of the whole  LU-YH 7
 
Main Machines
Name
Amount
Размеры (мм)
Main machine (abrasive, mills)
1 unit
3950х1800х1780
Tire bead seat cutter
1 unit
1900х800х1300
 Band Slicer
1 unit
1250х750х1500
Piece slicer
1 set(2 units.)
700х650х1100
Vibration sieve
1 unit.
 
Auxiliary equipment
Name Amount
Rubber conveyor 4 pcs
Electric engine with foundation 1 set
Foundations for equipment 4 units. (2 big  and  2 small ones)
Metal wire net 3 rolls  (large, medium and small))
Conveyor belt’s drum (enlarged a bit) 1 unit
Electric board 1 unit
Small details 3 packs
Magnetic separators
1  set (2 pieces.)

2. Main specifications   

Front and rear  drum diameters  (mm)
400
Operation length of the drum (mm)
600
Linear speed of the front drum (m/min)
17,32
front and rear drum speed ratio 28,4
28,4
Length/diameter ratio of the drums
1:1,38
Main engine power (kwt) 
45
Main engine rpm 
980
Productivity  (3-5)
200-300 kg/hr
Size  (Length * Width * Height)
3950x1800x1780
Weight (kg)
7000

3. Principle of operations and features

Production cycle:
Car tire is loaded into tire bead seat extracting machine and fixed, then the knife pulls down and cuts off the tire bead seat #1, then the knife moves to other direction and cuts off the side wall. It is recommended to cut off the sidewall to put off the weight of the tire and save efforts in further process. Estimate operation time – 15 min. It takes one hour to recycle 4 lorry or wagon tires (65 kg).  For skillful workers the operation on recycling one tire takes 5 minutes, so this machine can either make work-pieces during 5-6 hrs  or fills the whole warehouse and then it can stay idle for 2-3 days. After that the tires are loaded to tire-to-band cutting machine. Average recycling time for 1 tire on this machine is not available,  usually there many cuts on the used tires, these cuts often result in breakages, after it the band has to be loaded again.  Besides, the speed of operation is affected by the band’s width. Standard with is 3 cm however, it is possible to make it 2 cm, as a results, it takes more time. The band width can be also 5 cm, this affords to save time but increases power inputs in abrasion. In practice, the machine operator determines the optimal band width proceeding from its condition and wear. The tire is cut into bands up to the second tire bead seat. The resultant band is loaded manually to work-piece cut machine. The machine operates in automatic mode and depending on the band width and thickness it can recycle 350-400 kg of band/hr. (4-6 wagon tires). In normal organizational management, the productivity of these three machines is twice as much as  that of the abrasive machine, so they can be used 6-7hs/day, whereas the abrasive machine works 22-23 hrs/day. Tire bead seats are manually loaded to metal extruding machine, and the latter recycles them automatically. The tire bead seats are to be loaded one by one. It takes 2-4 minutes for the machine to recycle the tire bead seat, depending on amount of the rubber on it and on skill of the operator of the tire bead seat cutting machine (less rubber –less recycle time). Time of recycling also depends on tire bead seat diameter and  metal structure. If the metal part consists of steel wire as a single rod of 10-15 width, the recycling takes more time. If it is a braid of thin wires it takes less time to separate the tire bead seat from the rubber. Work-pieces from the cutter and rubber from tire bead seat go to the main conveyer of the abrasive machine and drop between the rollers of the abrasive drums via the feed roll. The productivity of one abrasive machine – 2-3 tons/shift (10 hrs). In theory it takes 10-12 min to recycle one tire. No time measurements for one tire recycling have been performed as each operation is individual. As differed from the Italian techniques, fed raw materials are not weighted and/or batched. We can do it by the Customer’s order but it will make the whole line much more expensive. The rubber from the rollers go to the rough vibration screen to be separated into two fractions. Large pieces go to the feeding conveyor to be sent to the secondary treatment. Small fraction is determined by the Customer by installing the sieve of the required diameter. As a rule, standard diameter of the sieve used at a factory doesn’t exceed 8 mm. This fraction is usually fed by conveyor to the fine vibration sieve. This vibration sieve divides the fraction into two parts: 1) Finished products – the size is determined by the Customer by installing the vibration sieve with required diameter of holes.  Air separator removes textile cord from the final fraction. After that the final fraction go via conveyors to magnetic separator with permanent non-electric magnets, removing textile cord. After that the finished product is fed to bag-packing.  Large fraction that did not pass fine sieves goes to the rollers for the secondary treatment. The main abrasive machine, being adjusted properly, removes 99.5% of metal cord.. When the tires recycled passed preliminary treatment, all the textile cord (100%) is removed.  In case when the tires recycled are made in Japan, PR China, “Michelin” tires, or the tires are made in Krasnoyarsk (Russia) where textile cord is alloyed into rubber by hot method, then after abrasive machine there are some strings that can be seen in fine fraction. In this case textile cord containing products go to additional attritor. Its average productivity is 100 kg/hr.  This machine removes the textile cord completely from any type of the rubber.  This very machine can recycle on its own aircraft tires, car tires, hoses and other types of rubber that contains no metal cord. No work-pieces or metal containing materials can be allowed as this will result in quick failure of cast-iron disks (3-4 days). If there’s no problem with textile cord, this very machine can be used for grinding final fraction into powder, this can increase the productivity by 500- 600 kg/shift. Air separator, included in the production line has the power allowing to take the textile cord from vibration sieve and additional attritor simultaneously. 

The machine includes front and rear drums, the drums’ bearings, chassis, bed,  clearance adjustment device, safety washers, brake system, lubrication system, transmission system, heating/cooling system,  electrical equipment system et.c. The above parts form the whole line (see fig.1 –Basic arrangement).
Rolls are the most important part of the machine. During the operation the drums’ surfaces are subjected to high pressure and  strong friction of the  ground rubber, so the drums are maid of solid castings. The drum’s surface has been  polished. The drums possess such features as high internal durability, break strength, structural firmness and stability  of their surface, high  wear resistance..
In order to improve cooling and increase output and quality of the rubber crumb, internal cavities of the drums undergo  mechanic tratment.
 
Transmission system

The engine is muffed with the input shaft of the reducer. The muff transmits rotation from the reducer to the  rear drum. The front drum puts in motion by  eccentric transmission. The gears are located at the butt end of the drum. The drums rotate in different directions with different linear velocities. The drum’s bearing are located on left and right sides of the machine’s chassis. The rear drum’s bearing is rigid. The front drum has clearance adjustment device. The clearance is adjusted by horizontal travel of the front drum along the machine chassis’s guide using worm adjusting gear. The clearance is adjusted within 1-8 mm. The safety washers are located between
frontal end of the worm shaft of the clearance adjustment device and the bearing.
Safety washers secure the machine and an operator  in the case of  the machine’s overrunning during  rubber milling, or  human factor or ingress of metal things between the drums. In the case of  excess of load bearing capacity value (0.7 MN), safety washer breaks and this increases the clearance between the drums. At this a sharp drop in  transverse load on drums  takes place, thus securing drums, chassis and other important parts of  the machine
Safety washers are made of gray foundry iron. We recommend to bay them at the manufacturing plant to  secure their quality.  If customer has good condition to make them himself, it is necessary to do it in accordance with the drawings.

Machine frame

he machine’s frame is a very important part that undergoes  working load. It is tightly adjacent to the upper transverse cross bars, fastened with bolts and form the machine’s framework. The drums’ bearing are fastened to the chassis. There horizontal guides are mounted on the frame as required by operation rules. There is a thrust vertical surface at the rear part of the frame. These parts of the machine serve for tight fastening of the rear drum’s bearings, change of the position of the front drum and  strengthening  the clearance adjustment mechanism.
The frame corresponds to the machine’s operation conditions and it takes the operation loads from the rotating drums.

Drums' bearings

Nylon plain bearings are used for the drums. External detail of the plain bearing is made of casting. Cylinder and bearing bush of the plain bearing are coupled by static pressure during the production process. For  internal surface of  the  plain bearings MC  packed nylon is used.
There are six  nylon lain bearings in the machine, for their greasing calcium based  lubrication oils ZFG3, ZFG4 are used.
There are lubrication holes in the upper part of the body of  the drum’s bearing. The packing glands of  the bearing do let the oil  to drip out. For packing rings either special oil resistant rubber or  felt is used. 

Clearance adjustment device

Clearance adjustment device serve to change the location of drums  to each other as required by specific conditions during the production process. The device’s main parts are hand-wheel of the worm shaft, worm gear, dial, screws, nuts and other details. Adjustment device is fastened o the machine’s frame.  The rotating movement of the handwheel   consecutively transmits to the worm shaft, worm gear, as the result the movements transforms to horizontal movement of the rod (because  the nut is fixed on the machine’s frame)  As a result of  operation of clearance adjustment device the drums makes horizontal movement

Brake systemТормозная система

Brake system is used  for urgent stop of the machine in case of danger for the human or  equipment. To brake the machine disconnect the power supply.  The principle of the operation of the brake system is as follows; if it is necessary to stop the machine urgently, it is necessary to turn safety lever in the upper part of the machine. This  locks the limit switch, stops the power supply to the main electric engine.
At the same time the reverse impulse is given to the engine. For a moment the engine turns backward, thus reducing the rotary inertia and the engine stops.
For security purposes after turning off  the front drum should not turn for more than ? of the circle length (The manual for setting up electric equipment)

System of the support of the temperature conditions of the drums 

 System of the support of the temperature conditions  is of open type.
It has simple design, high efficiency of cooling, convenient temperature control of the coolant (water) , low probability of  plug formation in the coolant system, rare possibility of the  blockage etc.  Principle of operation is as follows; the water is supplied under the pressure  via the adjusting valve into  the spray holed pipes located in inside the drums.The spray pipe has water holes located lengthwise. The holes are drilled under right angle, the water  sprinkles the drum and excessive heat during rubber crumb production  is opportunely  taken away from the operation area. The water  accumulates in the  drum’s cavity and goes into water tank via cone branch pipe and then it is  poured off the machine via soil stack.
.Driving gears of the drums  are equipped with  protective boards improving safery and reducing the risk of industrial injuries. In the case of danger the machine stops by emergency stop lever.
 
 4. Workflow:
 
Car tire is loaded into tire bead seat extracting machine and fixed, then the knife pulls down and cuts off the tire bead seat #1, then the knife moves to other direction and cuts off the side wall.
It is recommended to cut off the sidewall to put off the weight of the tire and save efforts in further process. Estimate operation time – 15 min.

It takes one hour to recycle 4 lorry or wagon tires (65 kg). For skillful workers the operation on recycling one tire takes 5 minutes, so this machine can either make work-pieces during 5-6 hrs or fills the whole warehouse and then it can stay idle for 2 -3 days. After that the tires are loaded to tire-to-band cutting machine.
Average recycling time for 1 tire on this machine is not available, usually there many cuts on the used tires, these cuts often result in breakages, after it the band has to be loaded again. Besides, the speed of operation is affected by the band’s width. Standard with is 3 cm however, it is possible to make it 2 cm, as a results, it takes more time. The band width can be also 5 cm, this affords to save time but increases power inputs in abrasion. In practice, the machine operator determines the optimal band width proceeding from its condition and wear.

The tire is cut into bands up to the second tire bead seat. The resultant band is loaded manually to work-piece cut machine. The machine operates in automatic mode and depending on the band width and thickness it can recycle 350-400 kg of band/hr. (4-6 wagon tires). In normal organizational management, the productivity of these three machines is twice as much as that of the abrasive machine, so they can be used 6-7hs/day, whereas the abrasive machine works 22-23 hrs/day.
Tire bead seats are manually loaded to metal extruding machine, and the latter recycles them automatically. The tire bead seats are to be loaded one by one. It takes 2-4 minutes for the machine to recycle the tire bead seat, depending on amount of the rubber on it and on skill of the operator of the tire bead seat cutting machine (less rubber –less recycle time).
Time of recycling also depends on tire bead seat diameter and metal structure. If the metal part consists of steel wire as a single rod of 10-15 width, the recycling takes more time. If it is a braid of thin wires it takes less time to separate the tire bead seat from the rubber. Work-pieces from the cutter and rubber from tire bead seat go to the main conveyer of the abrasive machine and drop between the rollers of the abrasive drums via the feed roll.
The productivity of one abrasive machine – 2-3 tons/shift (10 hrs). In theory it takes 10-12 min to recycle one tire. No time measurements for one tire recycling have been performed as each operation is individual.

As differed from the Italian technics, fed raw materials are not weighted and/or batched. We can do it by the Customer’s order but it will make the whole line much more expensive. The rubber from the rollers go to the rough vibration screen to be separated into two fractions. Large pieces go to the feeding conveyor to be sent to the secondary treatment.
Small fraction is determined by the Customer by installing the sieve of the required diameter. As a rule, standard diameter of the sieve used at a factory doesn’t exceed 8 mm. This fraction is usually fed by conveyor to the fine vibration sieve. This vibration sieve divides the fraction into two parts: 1) Finished products – the size is determined by the Customer by installing the vibration sieve with required diameter of holes.
Air separator removes textile cord from the final fraction. After that the final fraction go via conveyors to magnetic separator with permanent non-electric magnets, removing textile cord.
After that the finished product is fed to bag-packing. Large fraction that did not pass fine sieves goes to the rollers for the secondary treatment. The main abrasive machine, being adjusted properly, removes 99.5% of metal cord.

When the tires recycled passed preliminary treatment, all the textile cord (100%) is removed. In case when the tires recycled are made in Japan, PR China, “Michelin” tires, or the tires are made in Krasnoyarsk (Russia) where textile cord is alloyed into rubber by hot method, then after abrasive machine there are some strings that can be seen in fine fraction. In this case textile cord containing products go to additional attritor. Its average productivity is 100 kg/hr. This machine removes the textile cord completely from any type of the rubber.
This very machine can recycle on its own aircraft tires, car tires, hoses and other types of rubber that contains no metal cord. No work-pieces or metal containing materials can be allowed as this will result in quick failure of cast-iron disks (3-4 days).
If there’s no problem with textile cord, this very machine can be used for grinding final fraction into powder, this can increase the productivity by 500- 600 kg/shift. Air separator, included in the production line has the power allowing to take the textile cord from vibration sieve and additional attritor simultaneously.
 
5. Mounting, adjusting and alignment

5.1. The specification and durability of the machine depend on the accuracy of its installation, so  it is necessary to mount the equipment properly.
5.2. The fundament is laid at a depth of 0.85 mm (see Fig.2) Foundation laying operations are performed considering the geological conditions at the place of operations. After solidification the surface is to be checked  by level gauge. Accuracy of the  lengthwise plane is 0,2/1000, accuracy in  transverse plane is 0.3/1000. As a rule, the fundament is laid as follows;
5.2.1. The length and width of the breaking ground should exceed those of the bed by 200 mm
In accordance with the drawings when filling in some hollows for filling bolts should be considered.
5.2.2. Then the fundament is filled in. Cement mark not lower than 90 should be used..
During solidification (7-14 days) the fundament must be sprinkled with water every day.
5.2.3. The fastening bolts are to be inserted into the holes. The washers are to be put under the machine, the distance between washers should be no less than 0.5 meter. The washer’s size is 150*150*25 mm.
5.2.4. The axle line should be drawn on the fundament. The divergence of axle lines of the machine an the fundament should not exceed 1 mm.
5.2.5. The bed is to be installed by the plumb line and the level gage. Admissible deviation by axle line is +/-0.02 mm,  the tolerance by meridional plane is +/-0.4mm, the tolerance by height is +/-5 mm/M
5.2.6. After mounting of the bed the equipment is installed on it (See Fig.3) . Guiding rails on two parts of the frame should be placed horizontally, the deviation should not exceed 0.08 mm. (The deviation is easily controlled by clearances between  connectable parts of the machines.). The frame details are closely mated by the instruments and screw up tightly. If the connection is not tight, the details are to be  adjusted. After assembling the frame is screwed up to the machine’s bed once and for all. Then horizontality in A plane and verticality of two part of the frame should be checked. 
5.2.7. The bearings must be mounted prior to the mounting of the drums. The bearings’ bushes should be fair with the drums’ shafts (compatibility of surfaces is to checked by dyeing). Contact area of the bearings’ bushes with the drums’ shafts should be no less then 70%. Wrong mounting will result in wearing of the bearings’ details. Test measurements of the clearances between the bearings’ cyclinders and drums’ shafts for nylon inserts are  0.90-120 mm.Then reducing pinions of the drums are installed (there’s no necessity to do it  if it is done at the manufacturing plant.
5.2.8. The drums are hung and then fasten to the frame. The accuracy of the mounting are controlled by the level gage.  The deviation should’t exceed 0.02 mm.  Then the lids are to be mounted. The clearance between the bearing and the lid of the front drum should be within 0.068-0.378. The clearance between the necks of drums’  shafts and the bearings should be within 2.5-4.5
5.2.9. When mounting the reducer and the engine it is necessary to keep coaxiality of the shafts..
5.2.9.1. Internal teeth of the castle type coupler is threaded to the coupling end shaft of the drums. Then the reducer’s.  outer shaft is threaded to the coupler. The distance between end face surfaces of internal inserts of both shafts drowned into the coupler should be 5 mm           
Then the following metering should be done using  gradiometers.
a) Angle divergence. The gradiometer is pressed to the rear drum’s pinion. The gradiometer’s base surface is pressed to the end of the castle type coupler of the reducer’s output shaft. Then the shafts are turned (the measured pinion is turned by ?  turns, the turns of its coupled pinion are not counted). The measurings are  done using  pitch of ? turn, then total declination of the coupler is calculated. The wobbling should not exceed 0.5% of the coupler’s radius..
b) After determination of the wobbling (that should within 0.5%) the coaxiality of shafts should be checked. The centers of the shafts should be fair. The gradiometer is pressed to the rear drum’s pinion. Base surface of the gradiometer is pressed to the end of the castle type coupler of the reducer’s outer shaft. Then the shafts are turned (the measured pinion is turned by ?  turns, the turns of its coupled pinion are not counted). The readings are checked at a pitch of ? turn. Total deviation should not exceed 0.8 mm (i.e/ error 0.4mm)
c)  On finishing the check the reducer is fastened to the bed and then the measurements are to be done again. The coupler between the reducer and electric engine is to be used..
5.2.9.2. When mounting the coupler between the reducer and electric engine coaxiality of shafts should be kept. The way of measurement like those in pp. 4.2.7.1 and 4.2.7.2. Tolerance – Wobbling should not exceed 0.5% of the coupler radius. Total deviation of the shafts’ centers should not exceed 0.4 mm (error –0.2 mm)..
5.2.10. Then consecutively rubber stock guides are installed, then clearance adjusting devices, urgent braking lever, protective casing of the pinions, rubber tray, lubrication system, temperature regime adjustment system, other details and parts.
5.2.11. When adjusting the clearance between drums it is necessary to secure a low adjusting pitch (0.5-1 mm). There should be even clearance  along the full length of the drums, the indications on the graduation disk should correspond to the real clearance.
5.2.12. After finishing the  mounting make sure that everything is installed properly. Then it is necessary to turn manually the reducer’s high velocity shaft by 3600.  Make sure that there is no hindrance to rotation. After that check control measurements using meter and level gauge and make sure that there are no changes. If the checking revealed no defects then the next stage of concrete filling should be made.
5.2.13  The cement’s grade for second filling should be no less than 150. It is necessary to avoid lacunas  formatiоn and  any foreign layers between two groutings.
5.2.14.  After solidification of the cement it is necessary to check as shown in 4.2.10. Make sure there are no changes and  tighten screw connections. (it is necessary to avoid changes of fixing dimensions)
5.2.15. Following  the user’s guide for electric equipment make the mounting of electric equipment and get the specified technical parameters.
5.2.16. If the equipment has been packed at the factory less then 1 year ago, then there’s no necessity to carry out the operations in pp. 4.2.3., 4.2.4., 4.2.5., 4.2.7., 4.2.8.
 
6. Service and maintenance

On finishing the mounting, assembling and complete checking it is necessary to perform test turning.

6.1.  Preparatory operations prior to turning

6.1.3 To check whether there’s any moisture  in the engine and electric schemes, check whether electric connection are reliable and connected properly. Check the ground connection of casings and electric surfaces.
6.1.4 To check the reliability of fastening of the attached details
6.1.5 To take away the litter, the clearance between drums must be increased by 3-5 mm. (Both ends must be at equal distance.
6.1.6 To check the protective  barriers of the pinions and whether the quantity of  the oil in the lubrication points corresponds to that in the Appendix.
6.1.7 In case if the consistent oil system is used for lubrication of the drums bearings its adjustment and maintenance should be made according to the Appendix “ The pump for centralized multipoint lubrication
6.1.8 Make sure the urgent braking lever has been fixed reliably and moves without  freely. Check proper assemblage of the details of  urgent brake device. Check whether control rods of the urgent brake device are connected properly. Check all joints.
6.1.9 To check temperature regime maintenance device (temperature of water should be about 10o, coolant water should not contain any salt admixtures).
6.1.10 When you finish the checking it is necessary to turn the reducer’s outer shaft manually.
Make sure there is free rotation in both directions, no obstacles, no singularities. Then the oil pump  may be switched on. Wait until the normalization of the oil pressure and  oil gauge glasses show the  presence of oil in the bearings. Turn the engine on, make sure the shaft rotates in proper direction and the drums rotate towards one another. Any alteration of the connection of  electric engine phases  is firbidden.

6.2. Idle running

Check in idling.
Check in idling should be performed on if the preliminary check showed positive results. The time of idle checking is no less then 4 hours
6.2.1. Check the necessary amount of the oil and start the machine
6.2.2. Check the stability of operation whether there are any unusual sounds. vibrations, or any slack in joints. The noise level should not exceed 83 db (А).
6.2.3. Check electric current of the engine (the power should not exceed 20% of the rated power)
6.2.4. Check the urgent brake system by pulling the lever 2-3 times. (Interval between tests is no less than 5 min) Reverse rotation of the front drum should not exceed ? of the drum’s radius.
6.2.5.  The drums’ rotation is good, no jerks or delays
6.2.6  The drums’ bearings should not be heated, their temperature should not exceed 20C..
6.2.7. There should be sufficient amount of oil in the bearings of  drums, reducer, pinion and  other lubrication points.  The bearings’ lids, lubrication points and plugs should be oil tight.

6.3.  Loaded turning

Loaded turning can be performed after idling check on condition that its results was positive.
6.3.1. In the process of loaded turning first minimal load is used, then the load increases. Soft material at the beginning is replaced by solid materials. There are following steps of the checking.
First step: Load is  20-50% of the rated capacity, time of the check is 16 hours.
The second step:  Load is  50-75% of the rated capacity, time of the check is 16 hours.
Third stage: load is 100% of the rated capacity, time of the check is 8 hours.
6.3.2. During the check  controlled are the indices as follows.
6.3.2.1. There should not be sharp increase of temperature in the units, the temp. of the reducer’s bearing and the bearings’ body should exceed those in the table
 

Unit
Temperature (0С)
Max temperature (0С)
Nylon bearings
35
65
Reducer's bearings
40
70
 
6.3.2.2. The load should not exceed rated power of the electric engine (Some excess for a short time is permissible).
6.3.2.3.  Change of indices in pp. 5.2.2. и 5.2.7.  should be within the rate.
6.3.2.4.  In the case of lack of oil in the bearing, on overheat of the bearings, strong vibration appear, the load exceeds the rated load or in case of any other supernumerary situation it is necessary to stop the checking, find out the reason to shoot troubles and re-start the  test.
 
6.4. Memo for an operator

During the test and  running it is necessary to pay attention to the points as follows;.
6.4.1. Before the start it is necessary to adjust the clearance not to damage the drums and rule out carbonization.
6.5. When adjusting the drums it is necessary to secure equal clearance between two opposite ends of the drums. Otherwise pinions and other details can be damaged.
6.6. Before the start it is necessary to check the oil level.
6.7. The rolls are heated and cooled when rotate, this allows to avoid  hogging of the drums caused by temperature. On finishing the operation it is necessary to wait until the drums cool to 500C, only after that the machine may be stopped.
6.8. When the machine is used for rubber crumb production, the rubber should be heated and milled prior to the operation. When rubber pieces of more than 5 kg are fed to the machine, they must be fed from the pinions’ side.
6.9. It is necessary to run the machine  idle for some time. Check the reliability and easiness of operation of the urgent brake. Do not use brake to stop the machine unless it is really necessary.
6.10. When the machine is loaded the engine may not be turned on.
6.11. Prior to the start it is necessary to make sure that all details are fastened tight all the protective boards are in good order. Check oil gage glasses,  lubricators and the reducer’s lubrication points, make sure that water circuit and other devices are in good order.
6.12. It is necessary to regularly check oil  in the drums’ bearings. When consistent oil lubricaton system is used it is necessary to fill up lubrication points in proper time
6.13. After long time running of the machine, the bearings’ plugs can leak the oil because of wear. If the leaking still takes place after tightening of the plugs, it is necessary to take them off and take off  packing rings. Then the lids are to be packed with felt or some other packing material. The ends of the packing band are to be cut at an angle of 45o. The band should be packed into the ring with its ends one under another and squeezed with a plug.
6.14. If safety washer is broken because of  higher loads, it is necessary to stop the engine and replace the washer. The washer’s replacement should be performed as follows;
6.14.4. To unscrew the joined unit and take off  one half of the unit
6.14.5. To turn the handwheel of inter-drum clearance adjusting device,  until the worm rod moves back and take the safety washer off.
6.14.6.  Replace the safety washer. Turn the handwheel clearance adjusting device and secure the balance of the unit with its counterweights. Mount the half of the joint unit and tighten the screws.
6.15. During the adjustment the  the clearances between opposite ends of the drums must be even. When the clearance changes it is necessary to compare real clearance with readings on the graduated disk and correct the error in proper time. Correction of the error is especially necessary after replacement of the safety washer.
6.16. Urgent stop device is to be used only in emergency. To secure reliability of its operation it is necessary to check it regularly. After the handwheel of urgent stop is turned, the front drum makes no more than ? of the turn. If  there are any deviations from the standards it is necessary to operate as required by the User manual for electric equipment of the  machine.
6.17. In the case of any faultiness of the bearing’s insert the machine should not be stopped. It is necessary to unload it and run it idle till the repair mechanic comes.
6.18. It is forbidden to turn on the loaded machine.
6.19. When it is necessary to take of pinions during the repair, the taper key must be taken away. To dismantle the taper key it is necessary to operate as shown in Fig.18. (the other drawing is attached). The taper key is to be replaced in the following way.
6.19.4. To make the remover for the taper key. (metal grove-like profile can be used)
6.19.5. To twist in the screw to the whole near the taper key tail, put the remover on the screw and twist in the nut.
6.19.6. Turn the nut by the wrench until the taper key starts come off, and then take it off by hand.
6.19.7. It is forbidden to hammer pinion and the taper key or used other methods that can damage the details of the machine.
6.20. Under standard conditions it is necessary to perform regular maintenance of the machine. The wear of the accessories and their reliability are estimated, worn out details are reconstructed or replaced. The clearance between the neck of the drums’ shaft and the bearing’s insert is checked, if the clearance is more than 1.2 mm, the bearing’s insert must be replaced.
 
7.  List of lubrication points
 
Main lubrication points The lubrication recommended
Substitute  
Amount of oil Replacement interval
Name Type Name Type
Drums' bearings
Calcium-based oil
ZN-2
Sodium-calcium based oil
ZGN-2
Third ring cut of the oil cup
1 time/shift
The bearing of the reducer’s countershaft.
Calcium-based oil
ZN-2
Sodium-calcium based oil
ZGN-2
Third ring cut of the oil cup
1 time/shift
Reducer
Industrial transmission oil
N150
Engine oil
#11
According to standards
The  oil is replenished  once in the season, annual replacement of oil
Pinions of the rolls gear
Oil for open eccentric drives
68
Industrial transmission oil
N68
To maintain large amount of oil on the pinions  
 
Adjustment unit
Calcium based oil
ZN-2
Sodium-calcium oil
ZGN-2
Sufficient amount
Oil replenishment once a season
  8. Bearings
Bearing name
Type
Size
Amount
Place of installation
d
D
b
1
 Double roll bearing
53520
100
180
46
1
pinions’ drive shaft 
2
Single thrust roll bearings
8106
30
47
11
4
Worm reducer of the adjusting unit

9. Wearing parts
#        
Тип
name
Amount
Material
Note          
1
000103
Elastic rings
40
Rubber
Fig . 5
2
020039
Safety washers
2
НТ150
Fig. 4

10. Main faults and troubleshootings
 
Unit and fault
Reason
Trouble shooting
High vibration and excessive noise of the machine
1. Thread fastening is loose
2. Great clearance between bearings’ cylinders and the machine’s frame.
3. Wearing of the drive pinions of the abrasive drums
1. To tighten the fastening
2. To insert washers
3.To replace pinions
The temperature of the  drums’ bearings is more than 650
1.Wrong clearance between abrasive rolls
2.Poor lubrication
3. Wrong mounting
4. Wearing of the cylinder or the bearing’s insert
5. Insufficient cooling of the rolls
1. To make clearance according to standards 
2. To replenish oil
3.To assembly the details anew.
4. To repair or replace
5. To improve the functioning of the cooling system
Excessive noise of the reducer
1.Wrong engagement of the pinions
2. Backlash of the pinion on the shaft.
3. Wear of the bearings
1. To adjust and align the pinions
2. To repair or replace
3. To replace the bearings
The temperature of the reducer’s bearings is more than 650
1. Poor lubrication
2.Wrong clearances 
3. Wear of the bearings
4. Non convergence of shafts or their misalignment  
1.To improve the lubrication system functioning 
2. To adjust the clearances
3. To replace bearings
4. repair or replacement
Extra time of emergency stop of the drums
Poor operation of the shoes of emergency brake
 To adjust or replace
Safety washers are disabled too often
1. Quality or size of the safety washers do not meet the requirements.
2.Misalignment of the shaft or wrong clearance
1. To replace safety washers
2. To adjust as required 

11.  LU-YH-7.  Blades' diagram

Crusher's blade
Cutter's blade
Tire bead seat cutter's blade

12.  LU-YH-7 layout in a hangar of 12 х 20м
 
1 - Main attritor
2 - Control board
3 - Air separator and final attritor
4 - Metal extruder
5 - Chips cutter
6 - Band cutter
7 - Cutting machine

Main attritor

1. Side view

1 - Drive of primary purification vibration screen
2 - Receiving raw materials gutter
3 - Feeding conveyor
4 - Magnet separator
5 - Air separator fixing frame
6 - Polishing vibration screen
7 - Drive of polishing vibration screen
8 - Fine fraction feeding conveyor
9 - Primary purification vibration screen
10 -Main attritor
11 - Steering wheel of the attritor's fine adjustment

2. Top view

1 - Main attritor
2 - Vibration screen
3 - Small conveyor
4 - Double layer magnet separator
5 - Rubber crumb output
6 - Small vibration screen
7 - Magnet separator
8 - Conveyor

Design shop area - 300 m2 12 m - width, 18 m - length, 5 m -height

Unit #6 requires foundation
The flowchart is recommended. There no strict limitations concerning location of the units relative to each other.
Safety zone is recommended for all the units except for unit 2.
For unit 2 the safety zone is compulsory  

13. Tyre to "endless" band cutter

The machine serves to recycle tires and conveyor belts, containing metal and textile cord by their cutting betwenn two fixed disk blades.
Diameter of the recycled tires - 12-24 inches. 
 
It
1. Upper disk blade ;
2. Upper disk blade;
3. Body with electric engine inside  
 
Application method
The tire without preliminary removed tire bead seat is inserted between disk blades. The machine starts.
During the operation hold the tire suspended or use any pedestal .
The machine can cut the rubber up to 15 cm (the rubber, taken from the isolation of submarines or air planes tires).
Widht of resultant band -2.5-7 cm. It is adjusted by sinchronous shift of both disk blades for the distance required. Required clearance - 3 – 3,5 cm, this is an initial setting of the machine .Estimate time of recycling of  one 24-inch tire - 4-5 minutes. 
Note  1:No foundation is required.
Note 2: The blades' engine life is 1 year. Setting and grinding should be performed once/month, annual complete replacement.

Special safety measures
1. To keep general electric safety rules. The machine must be grounded.
2. As the personell will be in permanent direct contact with the mechanism, it is necessary to avoid  getting  upper extremities and finger bones between disk blades.
3. It is recommended to work in chain armor gloves.
4. In case of the machine's clogging during cutting it can be released by backward movement
5. Avoid readjustment of the machine and  removel  of the limiter of disk blades' rotation speed.
6. The tire is cut into "endless" until there are 4-5 cm to the second tire bead seat
The machine enjoys guarantee service during a year since crossing PR China border.


14. Machine for cutting endless band into workpieces of 3.5-4 cm

The machine serves to recycle "endless" bands to workpieces of 3x3 cm, thickness up to 15 cm (recommended thickness -3-4 cm)

It consists of :
1. Receiving mechanism
2. Cutting element - hexahedral chainwheel
3. Bed with  electric engine.
4. Finished product tray  
 
Application method
"Endless" band is put into receiving mechanism, the machine starts . As the band cutting and workpiece ejection is performed automatically, there is no necessity in constant presence of the personnel.  It is necessary just to feed the band by hand and pack workpieces. After putting the band the machine  pulls it into. It takes 4-5 min to cut the band of one tire
In case of clogging or overloading the machine returns to operation by backward movement
Note 1:No foundation is required.
Note 2: Cutting tool (hexahedral chainwheel) is to be ground once/two months, its service life is 6 months
 
Special safety measures
1. To keep general electric safety rules. The machine must be grounded.
2. As the personell will be in permanent direct contact with the mechanism, it is necessary to avoid  getting  upper extremities and finger bones between disk blades.
3. It is recommended to work in chain armor gloves .
4. Unauthorized adjustment of  operation speed of cutting tool forbidden.
5.Repalcement of hexahedral element by octo or nonohedral elements is forbidden.
6. Replacement of  hexahedral elements by  tetra or pentahedral element is permitted.
The machine enjoys guarantee service during a year since crossing PR CHina border.

15.Machine for horizontal cutting of tire bead seat (circular cutting of tire)
 
 The machine serves to recycle tires (12-24 inches) with metal  and textile cord.

It consists of :
1. Bed;
2. Expandable mechanism to fix the tire
3. Travelling bar for cutting tool;
4. Cutting tool;
5. Electric engine;
6. Control wheel
7. Lock screw 
 
Application method
Control wheel (6) is used to set  required size in the expandable mechanism  (2). A tire is put on and fixed in the machine using the control wheel. Travelling bar (3)with cutting tool (4)  on it is brought to the tire and fixed using lock screw(7). Electric engine (5)turns on . After 20 turns the cutting is over and tire bead seat is removed. The travelling bar returns to initial state.  The expandable mechanism is loosened by the control wheel.  Cut tire without tire bead seat is taken off and sent to further recycling
Note: In case of two-shift operation the cutting tool are to be ground one time/two week. One time/six months the cutting tools must be competely replaced.
 
Special safety measures
1.Do not approach to machine closer than 3 meters during operation, because in the case of break of cutting tools their fragments may  fly arond.
2.Collision of  the cutting element with the cheeks of expandable mechanism can cause its break.
3.Before starting the operation it is necessary to control the fixation of the bar.
4.It is necessary to keep general rules of electric safety .
5.To avoid cutting hands by metal cord fibers it is necessry to work in tarpauline mittens
The machine enjoys guarantee service during a year since crossing PR China border

16. LU-YH 7 devices and gears layout

Fig. 1: Main unit



     

 


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