One-time double-sided calendering line

Abstract

This invention discloses a single-pass double-sided adhesive calendering line, belonging to the field of rubber calendering technology. The invention employs two hydraulically adjustable three-roll calenders and a set of linkage devices to achieve a single-pass double-sided adhesive rubbing process for canvas, meeting the requirements of different double-sided adhesive rubbing formulations. By using two hydraulically adjustable three-roll calenders, the process temperature is maintained after the first side adhesive rubbing, and the second side high-adhesion adhesive rubbing is performed before the fabric cools down, improving the adhesive rubbing quality of the canvas and effectively enhancing the wear resistance and adhesion of the belt. A hydraulic tension adjustment device ensures stable canvas tension between the two hydraulically adjustable three-roll calenders, guaranteeing adhesive rubbing quality. This invention can replace the traditional slurry dipping process in the V-belt industry, achieving a single-pass double-sided adhesive rubbing process and meeting different process formulations. It solves the problems of high production cost and flammability / explosiveness safety issues in the production of three-layer adhesive belts, while improving adhesive rubbing quality and production efficiency.

Description

Technical Field

[0001] This invention belongs to the field of rubber calendering technology and relates to a single-stage double-sided rubber rubbing calendering line used in rubber calendering processes. Background Technology

[0002] V-belts are widely used in industries such as manufacturing, agriculture, chemicals, mining, automotive, machinery, and construction. A typical V-belt consists of a fabric layer, a tension layer, a strength layer, and a compression layer. The fabric layer serves as the outer protective layer, integrating the tension, strength, and compression layers. This layer is made of plain-weave rubberized canvas and should possess excellent elasticity and friction resistance to protect the other components from wear and corrosion. Currently, V-belt manufacturers use a slurry-based process for coating the fabric layer. This involves using solvent gasoline to melt the rubber into a slurry, applying it to the fabric, and then drying it with steam. The slurry process involves gasoline evaporation, which can easily cause an explosion when exposed to static electricity. Although steam is used to remove static electricity, safety hazards remain, and gasoline recovery requires a large amount of steam. This process is characterized by high risk, high cost, and low efficiency.

[0003] To address the aforementioned issues and meet market demands, a calendering process is adopted to replace the sizing process. This involves using a calender to apply calendered adhesive to the fabric surface under pressure. Traditionally, a single three-roll calender can only apply adhesive to one side at a time. To apply adhesive to the other side, the wound-up fabric must be hoisted to the guide of the auxiliary machine and re-followed, repeating the process. During the two applications, the first few meters of fabric entering the calender are unusable due to wrinkling and adhesive residue, resulting in material waste. Because of the intermittent application of adhesive to both sides, the process temperature cannot be guaranteed, and the resulting products fail to meet the requirements of clear surface texture, high-strength adhesion, and good abrasion resistance for the outer fabric application process. Furthermore, a single three-roll calender cannot meet the diverse adhesive formulations required by users.

[0004] Based on this, in order to achieve the goals of high efficiency, energy saving, environmental protection, and intelligence, this invention independently developed a single-stage double-sided adhesive coating double three-roll calendering production line, realizing a high-efficiency and high-quality single-stage double-sided adhesive coating process, and adaptable to two formulation processes. This invention significantly reduces production costs, eliminates potential hazards, and improves production efficiency; this production line is the first of its kind in China. Summary of the Invention

[0005] To address the aforementioned problems, this invention provides a single-stage double-sided calendering production line for the calendering and rubbing process in the V-belt industry and even the rubber industry.

[0006] The technical solution of this invention is as follows:

[0007] A single-stage double-sided adhesive calendering line includes, in sequence, a dual-station guide device 1, a drying device 2, a front tension protection device 3, a high tension centering device 4, a spreading device 5, a No. 1 hydraulic adjustable-pitch three-roll calender 6, a receiving conveyor 7, a hydraulic tension adjusting device 8, a No. 2 hydraulic adjustable-pitch three-roll calender 9, a rear tension protection device 10, an adhesive tape cutter device 11, a cooling device 12, a low tension centering device 13, a traction device 14, and a dual-station take-up device 15.

[0008] Among them, the No. 1 hydraulic adjustable three-roll calender 6 and the No. 2 hydraulic adjustable three-roll calender 9 both adopt hydraulic adjustment, use proportional servo valves and high-precision position sensors to detect position, have high position control accuracy, improve the accuracy of calendered products, realize the function of double-sided gluing of canvas in one go and management of different process formulas, and have a high level of automation.

[0009] The hydraulic tension adjustment device 8 includes a cylinder 16, a sprocket transmission system 17, a position sensor 18, a synchronous shaft 19, a floating roller 20, a tension sensor 21, and a guide roller 22. The tension sensor 21 is located on both sides of the fixed guide roller; the position sensor 18 is located at one end of the synchronous shaft 19. The rod end of the cylinder 16 is connected to the sprocket transmission system 17, driving the sprocket transmission system 17 to move the floating roller 20 up and down. The position sensor 18 monitors the position of the floating roller 20 in real time, adjusting the main machine speed through displacement signals. The high-precision tension sensor 21 ensures stable canvas tension between the #1 and #2 hydraulically adjustable three-roll calenders, improving the glue application quality. During the fabric feeding stage, it ensures rapid driving of the floating roller to adapt to the calendering speed and allows the floating roller to stop at any position after completing its movement, facilitating operation.

[0010] The adhesive tape cutting device 11 utilizes the principle of moving and fixed blades for cutting adhesive tape. A disc blade is driven by a motor to rotate at high speed. The width of the blades on both sides is adjusted simultaneously or individually using a shift fork mechanism, ensuring neat trimming, noiseless cutting, no flying debris, and safe and reliable operation. Specifically, the adhesive tape cutting device 11 includes a motor 23, a gear transmission system, a fixed blade 24, a moving blade 25, and a linear guide rail 26. Two sets of adhesive tape cutting devices 11 are arranged opposite each other on the linear guide rail 26. Both are driven by the motor 23 to rotate the fixed blade 24 and the moving blade 25 at high speed via the gear transmission system. The width is adjusted by a handwheel screw. The shift fork mechanism 27 connects the blades of the two sets of adhesive tape cutting devices 11 together, enabling simultaneous adjustment of the width of the blades on both sides or individual adjustment.

[0011] Both the front and rear tension protection devices use high-precision tension sensors in pairs to reduce the influence of the fabric's condition on tension detection. The use of a communication mode improves signal anti-interference capability and accuracy, thereby improving the tension accuracy of the tension section and ensuring that the tension accuracy of the main force section is within ±5%.

[0012] The beneficial effects of this invention are as follows: This invention employs two hydraulically adjustable three-roll calenders and a set of linkage devices to achieve a single-pass double-sided adhesive application process for canvas, meeting the requirements of different double-sided adhesive formulations. By using two hydraulically adjustable three-roll calenders, the process temperature is maintained after the first adhesive application, and the second high-adhesion adhesive application is performed before the fabric cools down, improving the adhesive quality of the canvas and effectively enhancing the wear resistance and adhesion of the belt. The hydraulic tension adjustment device ensures stable canvas tension between the two hydraulically adjustable three-roll calenders, guaranteeing adhesive quality. The hydraulically adjustable three-roll calenders use hydraulic adjustment, resulting in high repeatability and precision of the adjustment position, ensuring high precision of the calendered products. This invention can replace the traditional slurry dipping process in the V-belt industry, achieving a single-pass double-sided adhesive application process and meeting different process formulations. It solves the problems of high production costs and flammability / explosiveness during production of the three-layer tape wrapping, while simultaneously improving adhesive quality and production efficiency. Attached Figure Description

[0013] Figure 1 This is a flowchart of the production process of the present invention.

[0014] Figure 2 This is a schematic diagram of a hydraulic tension regulating device.

[0015] Figure 3 This is a schematic diagram of the adhesive tape cutter device.

[0016] In the diagram: 1-Dual-station guide device; 2-Drying device; 3-Front tension protection device; 4-High tension centering device; 5-Expanding device; 6-1# hydraulic adjustable-pitch three-roll calender; 7-Receiving conveyor; 8-Hydraulic tension adjustment device; 9-2# hydraulic adjustable-pitch three-roll calender; 10-Rear tension protection device; 11-Rubber cloth cutter device; 12-Cooling device; 13-Low tension centering device; 14-Traction device; 15-Dual-station winding device; 16-Hydraulic cylinder; 17-Sprocket drive system; 18-Position sensor; 19-Synchronous shaft; 20-Floating roller; 21-Tension sensor; 22-Guide roller; 23-Motor; 24-Fixed knife; 25-Moving knife; 26-Linear guide rail; 27-Shifting fork mechanism. Detailed Implementation

[0017] The following description, in conjunction with the embodiments and accompanying drawings, further explains the specific implementation of the present invention, but is not intended to limit the present invention.

[0018] like Figure 1The double-sided adhesive calendering line shown employs two hydraulically adjustable three-roll calenders and a calendering linkage device to complete one double-sided adhesive application process (applicable to different adhesive formulations for top and bottom surfaces). The calendering line includes, in sequence, a dual-station guide device 1, a drying device 2, a front tension protection device 3, a high-tension centering device 4, a spreading device 5, a No. 1 hydraulically adjustable three-roll calender 6, a receiving conveyor 7, a hydraulic tension adjusting device 8, a No. 2 hydraulically adjustable three-roll calender 9, a rear tension protection device 10, a tape cutter device 11, a cooling device 12, a low-tension centering device 13, a traction device 14, and a dual-station take-up device 15.

[0019] The production process using the above-mentioned double-sided adhesive calendering line is as follows:

[0020] The canvas is placed on the double-station guide device 1. To ensure continuous operation of the unit, after one roll of canvas is guided, its tail end needs to be overlapped with the beginning of another roll to ensure a continuous supply of fabric. After being guided out under constant tension by the double-station guide device 1, the canvas is dried and dehumidified by the drying device 2, then enters the front tension protection device 3. After being corrected by the high tension centering device 4, it enters the 2nd and 3rd roll gaps of the No. 1 hydraulic adjustable-pitch three-roll calender 6 via the spreading device 5 for top-side adhesive application. The coated fabric then enters the hydraulic tension adjusting device 8 via the receiving conveyor 7, and then enters the 2nd and 3rd roll gaps of the No. 2 hydraulic adjustable-pitch three-roll calender 9 for bottom-side adhesive application. The double-sided coated fabric is fed into the fabric cutting device 11 by the rear tension protection device 10 to remove excess edges, and then passes through the cooling device 12 for shaping, the low tension centering device 13, and the traction device 14 to be conveyed to the double-station winding device 15 for winding, thus completing one double-sided adhesive application process.

[0021] To ensure the quality of adhesive application, tension control in each section of the calendering line is crucial. The entire line is divided into six tension zones of varying sizes, each using a high-precision tension sensor to display tension values ​​and participate in control, ensuring tension stability in each zone. The winding process employs a fundamental frequency boosting method, maintaining stable winding tension even with changes in the user's winding mandrel specifications. A hydraulic tension regulating device 8 controls the tension in the section between the #1 hydraulic adjustable-pitch three-roll calender 6 and the #2 hydraulic adjustable-pitch three-roll calender 9. This device mainly consists of a cylinder 16, a sprocket drive system 17, a hydraulic system, a position sensor 18, a synchronous shaft 19, a floating roller 20, a tension sensor 21, a frame, and guide rollers 22. During the fabric feeding stage, the hydraulic system uses an accumulator to rapidly lift the floating roller, synchronizing it with the speed of the hydraulic adjustable-pitch three-roll calender. This prevents speed mismatch from causing the adhesive fabric to fold and stick, wasting material. Simultaneously, the hydraulic system allows the floating roller to remain in any position, facilitating operation. During the formal operation phase, the position sensor 18 and tension sensor 21 work together to control the speed matching of the No. 1 hydraulic adjustable-gap three-roll calender 6 and the No. 2 hydraulic adjustable-gap three-roll calender 9, ensuring stable tension in this section. For special canvas with rough edges, a tape cutter device 11 is used to cut off the tape on both sides after applying the adhesive. The tape cutter device 11 mainly includes a motor 23, a gear transmission system, a fixed blade 24, a moving blade 25, a linear guide rail 26, and a shift fork mechanism 27. The motor 23 drives the disc blade to rotate at high speed, and the tape is cut using the shearing principle of the moving and fixed blades. The width of the two blades is adjusted simultaneously or individually by the shift fork mechanism 27.

[0022] The aforementioned single-pass double-sided calendering line can achieve a single-pass double-sided calendering process, meeting users' different calendering formulation requirements. The successful development of the single-pass double-sided calendering dual three-roller system not only replaces the V-belt overlay impregnation process, but also breaks through the limitations of single-sided calendering in the rubber industry, achieving a technological leap for V-belts and the rubber industry.

Claims

1. A single-stage double-sided adhesive calendering line, characterized in that, The calendering line includes, in sequence, a dual-station guide device (1), a drying device (2), a front tension protection device (3), a high tension centering device (4), a spreading device (5), a No. 1 hydraulic adjustable-pitch three-roll calender (6), a receiving conveyor (7), a hydraulic tension adjusting device (8), a No. 2 hydraulic adjustable-pitch three-roll calender (9), a rear tension protection device (10), a rubber sheet cutter device (11), a cooling device (12), a low tension centering device (13), a traction device (14), and a dual-station winding device (15). The hydraulic tension adjustment device (8) includes a cylinder (16), a sprocket transmission system (17), a position sensor (18), a synchronous shaft (19), a floating roller (20), a tension sensor (21), and a guide roller (22); wherein, the tension sensor (21) is set on both sides of the guide roller (22); the position sensor (18) is set at one end of the synchronous shaft (19), and the position sensor (18) monitors the position of the floating roller (20) in real time and adjusts the speed of the host machine through the displacement signal; the rod end of the cylinder (16) is connected to the sprocket transmission system (17), and the cylinder (16) drives the sprocket transmission system (17) to drive the floating roller (20) to move up and down; After the canvas is guided out under constant tension by the double-station guide device (1), it is dried and dehumidified by the drying device (2), and then enters the front tension protection device (3). After being corrected by the large tension centering device (4), it enters the 2# and 3# roll gap of the 1# hydraulic adjustable three-roll calender (6) for top glue application. The canvas is then conveyed by the receiving conveyor (7) into the hydraulic tension adjustment device (8), and then enters the 2# and 3# roll gap of the 2# hydraulic adjustable three-roll calender (9) for bottom glue application. The double-sided glued canvas is sent to the cloth cutting device (11) by the rear tension protection device (10) to cut off the excess edges, and then is shaped by the cooling device (12), and conveyed by the small tension centering device (13) and the traction device (14) to the double-station winding device (15) for winding, thus completing one double-sided glue application process.

2. The single-stage double-sided adhesive calendering line according to claim 1, characterized in that, Both the No. 1 hydraulic adjustable three-roll calender (6) and the No. 2 hydraulic adjustable three-roll calender (9) adopt hydraulic adjustment and use proportional servo valves and position sensors to detect the position.

3. The single-stage double-sided adhesive calendering line according to claim 1 or 2, characterized in that, The tape cutter device (11) includes a motor (23), a gear transmission system, a fixed blade (24), a moving blade (25), and a linear guide (26).

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