鄭州巴特熔體泵中英文對照說明書

公司簡介部分CompanyIntroductionBATTE公司自專業(yè)生產高溫容體泵以來，在熔體泵應用技術方面積累了豐富經驗。近年來，根據世界熔體泵應用技術的發(fā)展趨勢，特別是在塑料.橡膠精密擠出領域里，對熔體泵的工作基礎.使用性能.設備結構研制.控制技術等開展了多方面的研究并取得了一定成果。BATTE公司的政策是以一直持續(xù)不斷的研究與開發(fā)為基礎，使巴特公司得以制造出高科技高效率的產品，具有卓越的產品可靠度，這些產品是通過精心挑選原材料與零部件，于整個機械加工過程中，仔細檢查每一個部分，最后再以熟練的經驗來裝配完成。出廠前的調試，是每一個BATTED溫熔體泵離開工廠前最好的品質保證。BATTE公司的目標是以提高客戶的使用價值，通過持續(xù)不斷的努力，提供更好的服務品質，從而獲得客戶的認同，惠于更多的訂單。Battehasaccumulatedabundantexperiencesontheapplicationtechniqueofmeltpumpssincewemanufacturepumpsprofessionally.Recently,accordingtothedevelopmenttrendofmeltpumpsapplicationallovertheworld,especiallyinthefieldofpreciseplasticextrusion,wehavedoneextensiveresearchonthepumpoperationperformance,practicalfunction,equipmentstructureandcontroltechnologyandachievedregularachievements.Batte'spolicyistobebasedoncontinuousresearchesandexploitations.Thatmakesusmanufacturehigh-techandhighefficientproductswhichhaveexcellentreliability.Allrawmaterialsandsparepartsofproductsareselectedcarefullyandassembledwithskilledexperience.Pre-deliverydebuggingofmeltpumpsisthebestqualityassurancebeforetheyareleavingthefactory.產品概述部分概述GeneralInformation熔體泵主要用于高溫高粘度聚合物熔體的輸送、增壓、計量.容體泵將來自擠出機的高溫塑料熔體增壓.穩(wěn)壓后流量穩(wěn)定地送入擠出機頭。其穩(wěn)定熔體壓力、流量的能力優(yōu)于各種類型的擠出機。國外廣泛應用于塑料、樹脂、橡膠制品的擠出成型。如：造粒、薄膜、管材、板材、片材等行業(yè)。隨著機械工業(yè)的日益發(fā)展，熔體泵在國內市場也逐漸地被行業(yè)人士所采納、應用。Meltpumpismainlyusedinhightemperatureandhighviscositypolymermelttransportation,pressurization,metering.Themeltpumppressurizesandstabilizespressureofhotmeltpolymerscomingfromtheextruder,thensendthemintoextruderdies.Thepump'sabilityofstabilizingthepressureandflowisbetterthanallkindsofextruders.Foreigncountrieswidelyapplyinplastic,resin,rubberextrusion,suchaspelletizing,film,pipes,plate,etc.Withtheincreasingdevelopmentofmechanicalindustries,meltpumpisincreasinglyacceptedandappliedbydomestic.雙曲線齒形設計Hyperbolictoothshapedesign壓力脈動率更低Lowerpressurepulsationrate防止剪切熱產生Preventingshearheat非接觸免維護Non-contactFreemaintenance螺旋密封設計Helicalsealingdesign無后顧之憂Freefromanyworries先進的流道設計Advancedflowdesign熔體停留時間短Shortresidencetimeofmeltstream適用熱敏性材料Suitableforheat-sensitivematerial專業(yè)輔助設計軟件Professionalauxiliarysoftwaredesign優(yōu)化軸承潤滑設計Advancedbearlubricationdesign有效延長使用壽命Prolongingtheservicelife使用范圍Application熔體泵屬于容積式齒輪泵，采用一對外齒合的圓柱齒輪(直齒、斜齒、人字齒)相對轉動來運輸送高黏度的流體。所有齒輪和配合面都經過精磨、并嚴格控制裝配間隙來獲得精確的流量。齒輪和泵體根據不同的共況，ZB-B系列采用銘鍥合金鋼、高溫工具鋼材料；ZB-H系列采用進口CPME具鋼或鈦包合金材料，整體淬火，硬度HRC62-68耐磨性好。.ZB-B系列：工作溫度：＜400c(750°F),清洗溫度：＜450c(850°F),出口壓力040Mpa6,000psi),黏度：＜30000Pa.s.ZB-H系列：工作溫度：＜510c(950°F),清洗溫度：＜590c(1100°F),出口壓力070Mpa10,000psi)，最大壓差：50Mpa(7,000psi),黏度：＜20000Pa.s.密封一般采用螺旋密封和填料密封，也可根據客戶要求采用其他機械密封形式。.驅動電機+減速機十萬向聯軸器+泵體，電機采用變頻調速或伺服調速，可以隨意調至所需流量。對于產品看、精度要求高的，建議采用伺服電機調速。.加熱熔體泵采用電加熱棒加熱或熱傳媒加熱，可以精確控制熔體溫度。

Meltpumpbelongstopositivedisplacementgearpump,adoptapairofexternalgearingcylindricalgears(straightgear,helicalgear,herringbonegear)withrelativeturningtodeliverhighviscosityfluid.Allgearsandfittingsurfacesareaccurategrinded,andobtainprecisionflowbycontrollingtheassemblingclearancestrictly.Gearandpumpbodyvariestodifferentmaterials.ZB-Bseriesareproducedbynickel-chromealloysteelsandhightemperaturetoolsteels.ZB-HseriesareproducedbyimportCPMtoolsteelsortitanium-tantalumalloys,therigidityisHRC62-68andtheyarewear-resistant.ZB-Bseries:workingtemperature:0400c(750F),cleaningtemperature:<45(050F),outletpressure:<40Mpa(600sospity:<30000pa.stemperature:<45(050F),outletpressure:<40Mpa(600sospity:<30000pa.sZB-Hseries:workingtemperature:<510c(950F),cleaningtemperature:<65(0100F),outletpressure:R(si),max.Differentialtemperature:<65(0100F),outletpressure:R(si),max.Differentialpressure:50Mpa(7.000psi),visocity:<20.000pa.sSealing:Helicalsealingandpackingsealing.Mechanicalsealcanbeadoptedaccordingtocustomers'needs.Drivemotor+reducer+universalcoupling+pumpbody,youcanusefrequencycontrolordirectcurrentgovernorforthemotorandadjusttheflowtoyourneedoptionally.Wesuggestusingservomotorforspeedgoverningiftheproductsarehighprecision.Heatingmeltpumpadoptselectricheatingorheatmediumheatingandthetemperatureofthemeltcanbecontrolledaccurately.熔體泵的代號及標志CodeandSignofmeltpumpRotationAssembleSealingTemperaturePressurecc/rpmSeriesModel熔體泵的外型尺寸DimensionofmeltpumpZB-BSERIES運用范圍Scopeofapplication將熔體泵與單螺桿或雙螺桿擠出機串聯使用時，能使整條生產線的效益顯著增加，應用熔體泵的主要好處是：1.穩(wěn)定輸出壓力力脈動。能有效的降低擠出機參數引起的物料輸出不穩(wěn)定及壓.提高產品質量將擠出制品的尺寸公差降至最小，減少廢料和降低廢品率。普通擠出機也能生產出高精度產品。.提高擠出產量降底了對螺桿的壓力要求，由原來的螺桿向模頭建壓，改為熔體泵向模頭建壓，螺桿可以高速高效的擠出，且可以調節(jié)擠出機背壓，減少熔體在螺筒內駐留時間，穩(wěn)定塑化過程，降低熔融溫度，提高制品產量和質量。.降低單位能耗有數據表明將擠出與熔體泵組合，具混煉質量和產量比單獨的擠出機大幅提高。加工每公斤物料一般可降低四分之一左右。.延長整機壽命使用熔體泵后擠出機螺筒內壓力降低，能大大降低螺桿和螺筒之間的磨損，減輕齒輪箱推力軸承的負荷，延長擠出機壽命，擠出機在生產工藝中需要排氣的冒料問題也可迎刃而解。Whenmeltpumpandsinglescrewortwinscrewextruderareputintousewithseriesconnection,thebenefitofwholeextrusionlinewillbeimprovedsignificantly.Themainadvantagesofusingmeltpump:Stabilizingtheoutputpressure-reducingtheunstableoutputofmaterialcausingbytheparametersofextruderandpressurepulsations.Improvingtheproductquality-reducingthedimensionaltoleranceofextrusionproductintominimumandreducingtherateofscrapsandrejects.Increasingtheextrusionoutput-reducingthescrewpressure,changingthebuildingpressurestylefrom“screwtodie"to“melttodie”,sothescrewcane】theproductswithhighefficiency,meanwhiletheback-pressureofextrudercanbeadjusted,reducingthemeltresidencetimeinscrewcylinder,stabilizingtheplasticizingprocessandreducingthemeltingtemperature,improvingtheproductqualityandquantity.Reducingtheunitenergyconsumption-somedatesshowthatthecombinationoftheextruderandmeltpump,comparingwiththeextruderalone,canimprovethemillingqualityandquantityremarkably.Energyconsumptionofperkilogrammaterialcanbereducedone-quarter.Prolongingtheservicelife--thepressureofextruderscrewcylindercanbeloweredafterusingthemeltpump.Sothewearandtearbetweenthescrewandscrewcylindercanbereducedconsumedly.六.熔體泵安裝和使用InstallationandUsage1、熔體泵運輸、存放時應輕拿輕放。到貨后如三個月內不安裝，應重新清洗軸封。起吊ZB-100CC以上系列的熔體泵時，應使用吊環(huán)螺釘。.安裝前用測具檢查、調整泵座與電機傳動軸的同心度應確保熔體泵軸在工作時按訂貨時標明的方向旋轉，否則會引起輸入軸斷裂、泵體損壞。熔體泵安裝的底座要平整，并有足夠的強度和剛性。在螺栓均勻緊固的情況下，應保證輸入軸能無卡滯地均勻回轉。萬向聯軸器的安裝誤差應不超過其允許的偏差值，以免引起附加力，縮短軸的壽命。安裝中旋緊螺釘時用力要均勻。.熔體泵在交貨前均經過嚴格的試運轉檢驗，各項指標符號要求，交貨后可以直接投入使用。無論那種規(guī)格的熔體泵啟動使用加載負荷時應低速(5rpm左右)運轉一段時間，待各軸承處充分潤滑后可加載運轉，緩慢的提升工作壓力，當整體運行狀況較為穩(wěn)定后，則可逐步將泵及整個系統調整至正常的工藝速度與壓力。.熔體泵在加載前，應先均勻預熱，溫升不得超過120度每小時。在泵沒有達到工作溫度前不要啟動泵，冷啟動是最容易引起泵損壞的時候。.對于采用填料密封形式的熔體泵，應及時調整密封壓蓋的位置，保證最佳的密封狀態(tài)。對于采用螺旋密封的泵，如果需要使用冷卻水輔助密封，應在螺旋密封組件上安裝1/8或1/4NPT接頭，然后通上水源。對于小排量的泵不要讓冷卻水影響到泵體的加熱。1、Youshouldbecarefuloftransportingandstoringmeltpump.Youshouldcleantheshaftsealwhenyoudon'tinstallitwithin3monthofarrival.UseringsscrewswhenyouliftmeltpumpofZB-100aboveseries.Beforeinstallation,testwithtestingtools,adjustconcentricitybetweenpumpseatandmotorshaft.Ensurethemeltpumpshaftrotatesinorderingindicateddirection,otherwisethatwillcauseinputshaftruptureandthepumpbodydamage.Mountingbaseofmeltpumpshouldbesmoothandhasenoughintensityandrigidity.Undertheholdingdownboltwithistightenedevenly,makesuretheinputshaftsrotateevenlywithoutclampingstagnation.Deviationofuniversalcouplinginstallationshouldnexceedtheallowingdeviationinordertoavoidcausingadditionalforceandshorteningtheshaftlife.Youshouldtightenthescrewsevenlyduringtheinstallation.3、Themeltpumpshavepaststricttest-turninspection,eachindicationsmeettherequirements,youcanputthemintousedirectly.Anykindsofmeltpumpsshouldruninlowspeed(about5rpm)whenyoustartthepumps.Wheneachbearinghassufficientlubricationthepumpcanhaveloadoperationandtheworkingpressurecanbeimprovedslowly.Whenthereisasteadyrunningofthewholeline,youcanadjustthepumpandthewholesystemintonormaloperationspeedandpressure.Beforeloadingthepump,thereshouldbeaevenpreheatingforthepump.Therisingtemperatureshouldn'tex&ed5020)perhour.Don'tstartpumpbeforeitreachestheoperationtemperature,coldstartisthemostlikelytimetodamagethepump.Formeltpumpwithpackingsealform,youshouldadjustthepositionofthesealingglandpromptlytomakesurethebestsealingcondition.Formeltpumpwithpackingsealingform,youshouldadjustthepositionofsealingcovertoensurethebestsealingstate.Formeltpumpwithhelicalsealingform,ifitisnecessarytousecoolingauxiliaryseal,youshouldinstall1/8or1/4NPTjointonthehelicalsealingcomponent,thenconnectingwater.Forthesmalldeliverycapacitypump,don'tletthecoolingwaterinfluencetheheatingofpumpbody.清洗Cleaning.將泵從設備上卸下來，放入真空加熱爐內，緩慢增加溫度至400-450度，升溫過程不得少于兩個小時。要注意溫度的控制，如果過熱，會造成泵體的材料硬度下降，影響尺寸的穩(wěn)定性。.完全炭化物料的時間為3-12小時，這取決于物料本身，泵的大小，加熱溫度及爐子的負荷。泵需要自然冷卻至室溫，不得強制冷卻。.必要時可將泵送回我公司進行徹底修復。Removethepumpfromtheequipment,thenputitintovacuumheater,increasingthetemperaturefrom400-4503(750-850F),theprocessofrisingtemperatureshouldn'tbelessthan2hours.Giveyourattentiontocontroltemperature,ifitistoohot,thatwillreducethehardnessofpumpbodyandinfluencethedimensionstability.Thetimeforcompletecarbonizedmaterialsis3to12hoursthatdependsonthematerialitself,thepumpsize,heatingtemperatureandloadoftheheaters.Coolingthepumptoroomtemperaturenaturally,it'sforbiddentocoolthepumpbyforce.Youcanreturnthepumptousforacompleterepairwhenitisnecessary.拆卸Disassembly如果對泵作定期維護，應通讀并理解本說明，要確保正確的拆卸，應遵守下述要點：.拆卸時要注意所有部件的位置和方向，以保證組裝時正確歸位，存放零件的場地應干凈整潔。2拆卸時要使用軟口臺鉗夾持泵體。進行維護時，要小心拿放部件，避免墜落及碰撞。因為最輕微的劃痕或毛刺都會使裝配困難，并引起對泵的損壞。.小心取出密封組件，注意不要損壞密封溝槽和軸，否則泵工作時，可能會導致物料泄漏。然后檢查冷卻水進出口，確認無堵塞。密封組件是有兩個部件并通過緊固螺釘組合在一起的。如有堵塞，可將其拆開，用機械或化學方法進行清潔。.將端蓋板上所有的螺栓松開一圈，然后全部旋松并取出。取下端蓋板，并將其放在安全的地方，以防損壞。這時要記住每個軸承上的溝槽對應于泵進口的方位。組裝時必須按照原方位裝回，否則，當啟動時泵會被嚴重損壞。.將齒輪軸與軸承從中板中取出，由于泵內留有殘余物料黏度，它們有時很難被取出。因此取出時要特別注意，不要敲打或損壞齒或軸承的邊角，可用塑料或軟銅錘，輕輕敲打，將其取出，不要用鐵錘。.將軸承從齒輪軸上取下，注意不要損壞齒，軸承邊角及軸。如果不易拆開，（由于有殘留物料黏度），可用塑料或軟銅錘敲打軸承使其松動，不可用鐵錘。不要用螺絲刀或其它工具將其撬開，因為這容易將齒損壞。要記住所拆下的軸承來自于哪根軸，然后將其放在一旁安全的地方。.泵被解體以后，所有部件都應仔細檢查，確認是否有磨損，裂紋，毛刺及劃痕等。端蓋板，D型軸承可用600#^紙打磨，如有毛刺，劃痕或其它尖角出現，可用磨石輕輕打磨。計量齒輪，中板及D型軸承之間的關系對保證計量性能是非常重要的，因而打磨時要特別小心，只需將表面拋磨干凈，而不能去除金屬。在任何情況下，都不能對這些部件進行磨削。Ifyouwanttodoregularmaintenanceforthepump,youshouldreadandunderstandtheinstructionandensurethecorrectdisassembly.Observethefollowingpoints:.Noticethepositionanddirectionofallpartsduringdisassembly,soastoreturnthecorrectpositionduringassembly.Placethepartsinacleanandtidyplace..Holdthepumpwithsoftmouthclampduringdisassembly.Takeandputthepartscarefullyduringmaintenance,avoidfallingandcolliding.Theslightestnickorburrwillcausetroubleforassemblyanddamagethepump.Removethesealcomponentscarefully,don'tdamagesealgroovesandaxis,otherwisethatwillcausethematerialleakagewhenthepumpisworking.Checktheinletandoutletofcoolingwater,ensurethereisnojam.Sealcomponentsareassembledbytwopartsthroughtighteningbolts.Ifthereisjam,youcanunpackthemandcleanthembymechanicalorchemicalmethod.Loosenonecircleofallboltsonthecover,thenloosenandremoveallofthem.Removebottomcover;placeitinasafelocation.Remembereachbearingonthegroovecorrespondstotheinletdirectionofthepump.Reinstalltheminoriginallocation;otherwisethepumpwillbedamagedseriouslywhenyoustartit.Removethegearaxisandbearingfrommiddleplate.Itwillbedifficultforyoutoremovethemowingtotheremnantsofviscousmaterials.Don'tknockordamagegearorbearingangel.Youcanremovethembyusingplasticorsoftcopperhammer,butironhammerisnotallowedtobeusedhere.Removethebearingfromgearaxis;takecareofgear,bearingangelandaxis.Ifit'shardtoremove(duelingtotheremnantsofviscousmaterials),youcanloosenthebearingbyusingplasticorsoftcopperhammer,alsoironhammerisforbidden.Donpryitwithscrewdriverorothertools,becausethatwilldamagethebearing.Rememberwhichaxisdothebearingscomefrom,andthenplacetheminasafelocation.Afterbreakingupthepump,checkallpartsandseeifthereisabrasion,crack,burr,andnickornot.ThecoverandDshapedbearingcanbeburnishedby600#sandpaper.Ifthereisburr,nickorothersharpangle,youcanburnishthemwithgrindstone.Therelationshipamongmeteringgear,middleplateandDshapedbearingisimportanttoassurethemeteringperformance,soyoushouldbecarefulwhenburnishingthem.Youshouldonlyburnishthesurfaceclean,don'tremovethemetal.Youcan'tgrithesepartsunderanyconditions組裝Assembly.使用三氯乙烷或氯乙烯熔劑，清洗所有要裝配的零部件。.在組裝過程中，要經常用手轉動齒輪，以確認它們可自由旋轉。組裝過程中，任何時候出現卡死現象，都要在進行下一步前，找出原因，將其解決。任何微小的劃痕、毛刺或外部雜物，都可能引起重要部件的損壞。在裝配過程中，絕不能強力組裝或轉動泵；如果轉配正確，所有部件都會很容易的裝入泵內，軸的轉動也會很靈活。.在裝配時，應使用軟口臺鉗夾持泵體。.安裝螺栓前，用DAG15城相似的耐高溫潤滑脂涂抹螺紋部分，按對角線的方式擰緊端蓋板上的螺栓，首先用所建議扭矩值達到1/4將其擰緊，然后1/2,再然后3/4,最后用全部力矩將其螺栓擰緊。.將密封腔裝到軸上，不要擰緊密封腔上的螺栓，應使其略為松動，這將使密封對中。.將密封蓋板裝到軸上，將蓋板的螺栓孔與密封組件上的螺栓對準，裝上螺栓，以對角線的方式均勻的將其擰緊，封件被平穩(wěn)的壓入密封腔內，當蓋板全面接觸到密封組件上時，將蓋板取下，擰緊密封組件的螺栓，并將其擰緊1、Cleaningallassemblypartswithmethylchloroformorvinylchloridesolvent.2、Turnthegearwithhandsregularlyduringassemblytoensuretheycanrotatefreely.Anyjammedphenomenonshouldbesolvedbeforegoingintothenextstepduringassembly.Anyslightnick,burrorsundrieswillcausetheimportantpartsdamaged.Itisnotallowedtoassembleorturnpumpbypowerfulstrength.Ifyouassembletheminacorrectway,it'seasytoputallpartsintopump.Theaxiswillturnflexibly.3、Youshouldusesoftmouth-griptoholdthepumpbodywhenassemblingit4、Beforeinstallingscrews,daubthescrewthreadwithDAG154orsimilarhightemperatureresistantgrease.Tightenboltsonthecoverbydiagonalway.Firsttightenthemwith1/4torquevalue,then1/2torquevalue,3/4torquevalue;finallytightentheboltswiththefulltorquevalue.5、Putthesealcomponentsontheaxisdon'ttightentheboltsinsealcavity,youshouldloosenthemlittle.Thatwillmakethesealcomponentscentered.6、Installthesealcovertotheaxis,maketheboltholeonthecoverandtheboltonthesealcomponentaligning,installtheboltsandtightenthemevenlybydiagonalway.Thecomponentsarepressedintosealedcavitysmoothly.Whenthecovertouchesthesealcomponentcompletely,tightentheboltsonthesealcomponent.熔體泵控制系統MeltPumpControlSystemS系列控制系統是我公司專為針對熔體泵工作特定，專門開發(fā)的新一代PLC控制系統。行業(yè)標準領導者降低維護要求人機界面友善操作簡易可靠運行成本低SseriescontrolsystemisnewgenerationofPLCcontrolsystemwhichisspeciallydesignedformeltpumps.*IndustryleaderLowermaintenancerequirementsFriendlyhuman-machineinterfaceSimpleandreliableoperationLowcostS60控制系統2-4個壓力閉環(huán)控制壓力上下限報警20-30個獨立的溫度控制區(qū)流量控制自動啟動和停機觸摸屏人機界面過程值的連續(xù)監(jiān)控運行監(jiān)控和故障檢修適合更復雜的擠出或復合系統S60ControlSystem2-4closed-looppressurecont