Wet Masterbatch Line for Precise Water Vaporization Control
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Solution Overview
Problem
Existing rubber production processes struggle to accurately control the water vaporization amount in rubber materials during extrusion-dehydration-expansion-drying, affecting the final processing results due to variations in internal pressure, stirring speed, and shearing speed.
Innovation Solution
A wet masterbatch production line utilizing a high-speed impinging stream reaction system, which includes a mixing unit, dehydration unit, conveying and refining unit, cooling treatment unit, and a control unit, with integrated devices for precise control of internal pressure, stirring speed, and shearing speed to achieve controlled water vaporization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional extrusion-dehydration-expansion-drying integrated machine is used, then rubber material can be processed, but water volatilization amount cannot be accurately controlled
Solution Approach 1:
The patent applies preliminary action by pre-setting multiple working condition matrices (A1-A4) with specific internal pressure, stirring speed, and shearing speed parameters before processing. The control unit selects appropriate matrices based on real-time weight detection, preventing water content deviation before it occurs rather than correcting it afterward.
Solution Approach 2:
The patent implements feedback control through real-time weight detection during the extrusion-dehydration-expansion-drying process. The control unit continuously monitors weight changes and adjusts working conditions by selecting different pre-set matrices, creating a closed-loop control system that accurately manages water volatilization.
2Manufacturing precision
If multiple working parameters (internal pressure, stirring speed, shearing speed) are adjusted, then water volatilization can be controlled, but control difficulty increases
Solution Approach 1:
The patent merges multiple working parameters (internal pressure, stirring speed, shearing speed) into integrated working condition matrices. Each matrix (A1-A4) combines specific values of all three parameters, allowing the control system to manage water volatilization through unified matrix selection rather than independent parameter adjustment, significantly simplifying operation.
Solution Approach 2:
The patent applies parameter changes by establishing four distinct working condition matrices with progressively different internal pressure, stirring speed, and shearing speed values. The control unit selects appropriate matrices based on real-time weight detection, dynamically adjusting parameters to maintain precise water content control throughout the processing stages.
3Reliability
If real-time monitoring and automatic control are implemented, then processing quality improves, but device complexity increases
Solution Approach 1:
The patent applies self-service principle by enabling the control unit to automatically select working condition matrices based on real-time weight detection without manual intervention. The system monitors its own processing state and self-adjusts working parameters through pre-programmed matrix selection, ensuring consistent processing quality while reducing operational complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system ensures that the rubber material achieves the required water vaporization levels by generating heat at specific pressures and speeds, allowing for efficient dehydration and meeting qualified index requirements.
Implementation Method 1
the rubber material generates heat at a certain internal pressure, a certain stirring rotating speed and a certain shearing speed
Implementation Method 2
the rubber material generates heat at a certain internal pressure
Implementation Method 3
the rubber material is extruded by the screw of the extrusion-dehydration-expansion-drying integrated machine and the water in the rubber material is extruded out
Implementation Method 4
when the rubber material is discharged indoors, the water volatilization amount in the rubber material reaches the qualified index requirements due to the sudden drop of pressure and temperature
Data Source
AI summary
The wet masterbatch production line based on high-speed impinging stream reaction is provided, and includes: the mixing unit, configured for mixing and standing carbon black and latex to obtain granular rubber material; the dehydration unit, configured for performing dehydrating treatment on granular rubber material after standing to obtain flocculent rubber material; the conveying and refining unit, configured for conveying and refining dehydrated flocculent rubber material to obtain sheet rubber material; the cooling treatment unit, configured for cooling, and folding and stacking refined sheet rubber material; and the control unit, configured for automatically controlling the mixing unit, the dehydration unit, the conveying and refining unit and the cooling treatment unit. The working state of the extrusion-dehydration-expansion-drying integrated machine is accurately controlled, so that the rubber material generates heat at a certain internal pressure, a certain stirring rotating speed and a certain shearing speed.