Content
1. Range of application of the equipment
2. Basic technical parameters
3. Principles of operation and structural features
4. Machinery mounting
5. Control turning of gears
6. Operator's memo
7. Operation and maintenenance
8. Attachments 
 
1. Application range of the equipment
This machine is basic equipment for rubber processing. it is mainly used for rubber powder production. 
 
2.Main technical parameters

 

 

3.1. Operation (in brief
.The operation principle of this machine is based on different speed of two working parts which are hollow drums rotating in opposite directions The rubber is brought to the drums and then drawn in the clearance between the drums by simultaneous effect of the drums' pressure and sticking friction to the drums' rolls The rubber rolls into wedge-shaped strips then the drums crash, crumb and mill it. Simultaneously, the repeated mixing causes chemical effect. The whole process yields finished rubber powder
3.2. Structural features
The machine consists of front and rear drums, drum bearings, frame, stand, clearance control device, safety washer, brake system, greasing system, transmission system, heating and cooling system, electric equipment system, et.c The above parts form the unit (see picture 1. Primary device).
3.2.1. Transmission system
The connecting sleeve couples the engine to the shaft. The sleeve transmits the reducer's rotation to the rear drum. The front drum starts by the eccentric drive. The gear wheels are installed on the drums' butt ends. The drums rotates in opposite directions with various linear speed. The drums' bearings are installed on left and right sides of the machine's frame. Rear drum has a rigid bearing. The clearance between drums is controlled by horizontal movement of the front drum along the rails on the machine's frame using control device.(see picture 2. Transmission) This machine has a NGW transmission reducer. The advantages of this reducer is its good service life, load resistance, high efficiency, low noise, compactness, low weight et.c The transmission is ready to install and to operate
3.2.2. Drums
Drums are the most important part of the machine. As the drums during the operation are subjected by high pressure on their surface, they are made of solid castings. They have polished surfaces. Their advantages are good internal resistance, breaking strenght, surfacial resistance and durability. Mechanical treatment of internal cavities of the drums allows to improve the cooling effect, to increase production and to improve its quality
3.2.3. Machine frame
Machine frame is the most important part subjected to operation loads. It lays on upper transversal cross-piece and bolted to form the framework Both the drums' bearings and the horizontal rails are fastened to the frame as required There's a vertical base surface at the rear frame section. These parts serve to fasten the rear drum's bearings, changing the front drum's position and fixing the clearance control device. The frame is firm and rough enough to conform to the machine operation conditions and to bear the drums' operational load.
3.2.4. The drums' bearings
Both rolling bearing and plain bearing can be used for the drum While placing an order it is neccessary to stipulate the type of the bearings and the details of construction.
External parts of all the plain bearing used for drums are made of casting Internal and external parts of plain bearings are connected by static pressure. Internal surface of plain bearings consists of packed nylon (see fig.3 The bearing's nylon cylinder)
The oil port is located in upper part of the drum's bearing body The packing devices are located sidewise both in fronal and rear part (See Fig 4. Packing devices of the bearings of frontal and rear drums). Packing devices prevents the oil leakage. For seal ring a special low resistance rubber or felt is to be used.
In case of rolling bearings used for the drums, the low melting point grease is to be used.
3.2.5.Clearance control device
.Clearance control device serves to change the drums' position depending on rubber crumb production conditions The basic parts are a flywheel, (motor) worm shaft, worm pinion, drum/indexing plate , male and female screws and other details. The worm shaft is attached to the frontal drum using involutive side with protections washers The control device is fastened in the aperture of the machine's frame. In this way rhe rotating movement goes from the flywheel to the worm shaft, worm pinion, resulting to horizontal rod movement (as the female screw is toughly fastened to the machine's frame So, the clearance control operation results in horizintal shift of the frontal drum.
3.2.6.Safety washers
Safety washers are installed between the frontal end of the worm shafe of the clearance control device and the bearing. Safety washer serve to ensure the machine safety in case of overloads during rubber-milling operations, or operator's mistake, or occurence of metal part between the drums. In the case of exceeding projected bearing capacity of the safety washer, the safety washer goes out of order thus increasing the clearance between the drums. This causes sharp decrease of transverse load on the drums thus saving the drums frame and other important parts of the machine The safety washers are made of grey foundry iron. The safety washers should be bought at the manufacturing plant. If the customer has conditions for independent work, it is necessary for him to be guided by the drawings to avoid any problems and troubles.
3.2.7. Brake system
.Brake system serves for emergency stop of the machine in case of danger for personnel or equipment. To stop the machine it is necessary to change the mode of electicity supply. The operation principle of the brake device In case of the necessity of the emergency stop, it is necessary to turn safety lever in the upper part of the machine's frame, thus stopping the limit switch and energy supply to the main electric motor. Simultaneouslu, the reverse impulse sets out for the motor. For a moment the motor goes to opposite direction thus allowing to slow the rotary inertia and the motor stops To provide safety the front drums should not turn more that 1/4 of the circle length after turning off. (Electric equipment setting up Manual).
3.2.8. Greasing system
Grease system serves to grease four bearings of the drum For this purpose manual feeding pump for low melting point grease or liquid grease cirulation automatic system can be used. Low melting point grease of liquid grease is fed separately for each bearing If the machine is completed with liquid greasing system, it is additinally supplied by oil feeding meter glasses, so the grease feeding to each bearing can be controlled using the oil meter glass..
3.2.9. Drum temprature mode control system
This machine applies open type drum's temperature control system. It is notable for its simple design, high cooling efficiency, good water temperature control, etc. The operation principle. The water is fed through control valve to the spraying holed tubes, located inside the drums. Spraying tubes have water holes along its full length. The holes are drilled by the right angle, and excess heat caused by rubber crumb production operation is taken away from the operation zone. The water is accumulated in the drum's cavity and flows into water tank through cone branch pipe, and then pourse out through the soil stack. 
 

4. Mounting of the machine
The machine's service time and functioning depends on its proper installation. In this connection it is necessary to provide proper mounting
4.1. Fundament
The fundament is prepared according to the drawings. The works on fundament are performed considering the geological conditions Usually, the works are perfomed as follows
4.1.1. The fundament's depth - no less than 1 meter. The length and depth should be more than those of the machine's bed by 20 cm
4.1.2. In accodrance with the drawings the holes in the fundment are drilled. The holes serves for the machine's screws
4.1.3. The filling of the fundament is performed. The cement's mark should be no less than 90.
4.1.4. During the solidification the fundament is daily sprayed with water during 7-14 days
4.2. Mounting of the equipment
4.2.1.The fastening screws insert into the holes. The washers are put under the machines, the distance between them is no less than 0.5meters. The washers' size is 150X150X25 mm.
4.2.2. The axial line is drawn on the fundament. The deviation of the machine's and fundament's axial lines cannot exceed 1mm.
4.2.3. The bed is installed using plummet and level gauge. The admissible deviation on axial line is +/-0.02mm/M, meridianal plane tolerance is +/-0.04 mm/M, altitude tolerance is +/-5mm/M
4.2.4. The bed is mounted two parts of the machine's frame are put on it. Guiding on two parts of the frame should be placed horizontally, the deviation should not exceed 0.08 mm. Vertical bearing surface on the rear part of the machine is fixed at the same level the deviation can not exceed 0.08 mm. (the deviation can be easily controlled by clearances between connectable parts of the machine. The frame's details are connected using the tools and screwed together. In case of non-compact connections the details are adjusted, no washers are used After assemblage the frame is screwed to the machine's bed. Then the horizontality and vericality of two part of the frame are checked.
4.2.5. .The bearings are installed prior to the drums' mounting The bearings' bushes should level with the drums' shafts (the surfaces compatibility is checked by dyeing). The bearings' bushes and the drum's shaft contact area should be no less than 70% Wrong installation will lower durability of the bearings' details. Control measurement of the clearances between the bearings' cylinders and the drums' shafts. The bearing's copper bush - 0.35-0.65 mm b.Nylon bush of the bearing is 0,90-1,20 mm Then reduction pinions of the drums will be installed (excluding the case, when they were installed at the plant).
4.2.6. The drums are fastened to the frame. The accuracy of the installation are controlled by the level gauge The deviation can not exceed 0.02 mm/ M. The istallation of covers follows. The clearance between the bearing and the frontal drum's cover should be between 0.068-0.378 mm. The clearance between the shafts' necks and bearings should vary from 2.5 to 4.5 mm
4.2.7. In installation of reducer and the motor the axe coaxility should be observed.
4.2.7.1.The splined coupler's internal teeth are inserted into connecting shaft of the drums. Then the reducer's output shaft is inserted into the couples There should be a distance of 5 mm between end faces of internal bushes of both shafts inserted in the couple, and the external edges of the couple
Then it is necessary to use gradiometer to control the meterings as follows;
a. Corner divergence. The gradiometer is pressed to the rear drum's pinion. The gradiometer's bearing surface is pressed to the end face of the coupler of the reducer's output shaft. Then the shafts are turned through (the pinion used for metering is turned though by 3/4 rotation, the rotation of the pinion coupled to it is not taken into consideration WIth a pitch of 1/4 rotation the metering is performed, the total inclination of the coupler is calculated. The wobbling should not exceed 0.5% of the coupler's radius
b. After wobble metering the cooxiality of shafts is checked. The shafts centers should be on the same level The gradiometer is pressed to the rear drum's pinion. The gradiometer's bearing surface is pressed to the end face of spline couple of the reducer's output shaft. Then the shafs are turned through (the pinion used for metering is turned through by 3/4 rotation, the rotation of its coupled pinion is not taken into consideration) With a pitch of 1/4 the metering is performed. Total deviation should bot exceed 0.8 mm (so the error is 0.4 mm
4.2.7.2. The checking is over, the reducer is fastened to the bed followed by the second metering. Then the coupler is fastened between the reducer and electric motor.
4.2.7.3. While installing the coupler between reducer and electric motor is is necessary to maintain the shafts coaxiality. The metering methods are the same like those in 4.2.7.1 and 4.2.7.2 . Tolerance: The wobbling should not exceed 0.5% of the couple's radius Total deviation of the shafts' center should not exceed 0.4. mm (error 0.2 mm).
4.2.8.Then the the series installatin of rubber stock guides, emergency stop lever, protective casings for covering, the tray for the rubber, greasing system, temperature regulation control other parts and
4.2.9. While adjusting the clearance between the drums it is necessary to adjust the control pitch of 0.5 -1mm. The clearance should be equal all along the drums' length, the indications on the calibrated disc should be in conformity with real clearance
4.2.10. The mounting is over make sure that everything is properly installed. Then it is neccessary to manually turn the reducer's high-speed shaft by 360o. Make sure, nothing impedes the rotation. Use level gauge and meter measure ruler to check the control meterings to make sure that there are no changes. If the checking shows good results, then you can start the next stage of the concrete filling.
4.2.11. In the second filling, is necessary to use cement 150 or more. It is neccessary to avoid gap formation and foreign layers between two fillings.
4.2.12. After the cement solidification it is necessary to repeat the checking as shown in p.4.2.10. Then, having made sure that no changes occured it is necessay to tighen screwed joints.(Changes in fixing dimensions should be avoided)
4.2.13. Make installation of the electic equipment and get to the specified technical properties as said in electric equipment user manual.
4.2.14. If the equipment was packed at the factory 1 year ago or later, the operations specified in pp. 4.2.3., 4.2.4., 4.2.5., 4.2.7., 4.2.8. may be omitted. 
 

5. Control turning of the mechanisms
Control turning should be performed after finishing the mounting, assemblage and complete testing.
5.1. Preparatory operations prior to turning
5.1.1. .To check motor and electric motor for moisture To check electric joints for reliability and proper connection. To check the ground connection of casings of electric devices
5.1.2. To check reliability of fastening of the associate details
5.1.3. .To remove litter, to increase the clearance between drums to 3-5 mm
5.1.4. To check the pinions protective enclosures, reducers, make sure that quantity of grease in greasing points corresponds to that in the Attachment
5.1.5. If the drums bearings are greased by low melting point oil, then the services and control are performed as said in the supplement (Multiple lubcricating pump.
5.1.6. Make sure that emergency stop lever is secured and moves smoothly To check proper assemblage of the details of the emergency stop device. To check reliability of connection of the control rods of the stop devices. To check all the hinges.
5.1.7. To test the operation of temperature mode maintenance device. (Temperature of water should be about 100o o, cooling water should not contain any salt.
5.1.8. The checking is over, the reducer's out put shaft should be turned by hand To make sure that it affords free rotations in both directions without any oddities. Then the oil pump may be turned on. Wait till the oil pressure will normalize and oil-metering glasses will show oil in the bearings Turn on the motor ,make sure that the shaft rotates properly and drums rotates to each other directions. Any changes in connections of the phases of electric motor are forbidden.
5.2. Check up at idle stroke
.Check up at idle stroke is to be performed after preliminary check up, on condition that the latter yielded positive results The time of idle stroke check up is not less than 4 hours.
5.2.1. .Add the oil to the standard level and start the machine
5.2.2. To check up for steadiness of operations, unusual noises, vibrations and the slacks in connections. The noise should not exceed 83 DB ().
5.2.3. To check up electric current of the motor (The power should not exceed 20% of the nominal one)
5.2.4. To check up the emergency by pulling the level two or three times Intercheck interval should be no less than 5 minutes The drum's reverse rotation should be no more than 1/4 of the drum's radius.
5.2.5. Standard rotations of the drums without jerks and delays.
5.2.6. The drums' bearings should not heat up, their temperature should not exceed 200o.^o.
5.2.7. .The bearings in drums, reducer, pinions of other points of lubrication should contain sufficient quantity of oiu The bearings' casings, connections, lubricating points and end caps should be oil-tight.
5.3. Turning through with the load.
Turning through with load is to be performed after finishing the check on the idle step on conditions that the latter yielded positive results
5.3.1. The first stage of the loaded check up requires minimal load, at the next stages the load should be increased First soft material is used, followed by tough material. The Check up stages
First stage: Load is 25-50% of the standard one, the time of the check up is 16 hours The second stage. The load is 50-75% of the standard one the time of the check up is 16 hours Third stage The load is 100% of the standard one, the check up time is 8 hours.
5.3.2. .During the check up the following specification should be controlled
5.3.2.1. The units't temperature should not be too high, the temperature of the reducer's bearings and the bearings' body should not exceed the value pointed below 
 

5.3.2.2. The load should not exceed standard power of the electric motor (Short-time excess is permissible).
5.3.2.3. .Metering indices on pp 5.2.2. and 5.2.7 should not exceed the standard
5.3.2.4. In case of oil lack in the bearings during the test or in case of their warm-up, vibratiion, exceed of load, or other supernumenary situation occurs, it is necessary to cancel the testings, find our the cause of the problems solve and problem and re-start the testings again. 
 

6.1. .Before starting up it is necessary to adjust clearance to avoid any damage to drums and to avoid carbonization
6.2. While adjusting the drums it is necessary to secure eveness of the clearance between to butt-ends of the drums. Otherwise the pinion or other details will be ruined
6.3. Before the start it is necessary to check the oil level.
6.4. The drums' cooling and warm up should be performed while in rotation to avoid hogging caused by change of temperature. After finishing the operation the machine can be stopped only after cooling the drums to 50 ^oC.
6.5. Prior to production of rubber crumbs the rubber shoud be heated and crumbled. When loading rubber pieces of more than 5 kg the loading must be made from the pinions side.
6.6. For a definite time it is necessary to use idle step. To test reliability and easiness of operation of the emergency stop Emergency stop should be used only in case of extreme necessity.
6.7. When the machine is loaded, the motor's turning on is forbidden. 
 

7. Operation and maintenance
7.1. Prior to start it is necessary to make sure that all the details are safely fastened and in good order. To check up oil-meter glasses, lubricators and the reducer's lubrication points
to make sure in proper operation of water circuit and other devices.
7.2. It is necessary to regularly check the lubrication in the bearings' drums When grease oil system is used, it is necessary in to fill up lubrication points in proper time
7.3. After long period of the equipment operation, the bearings' caps may allow oil leakage. In this case it is necessary to tighten the caps, and if the leakage still takes place, the caps should be taken off and sealings rings should be removed. Then caps should be tightened by felt or other stuffing material. The ends of the stuffing strip should be cut by the angle of 45-45^oC. The band is packed in the ring with one end on another and pressed by the cap
7.4. If safety washer is broken because of overload, it is necessary tp stop the motor and replace the washer in the following way;
7.4.1. Unscrew the unit, remove half of it
7.4.2. Turn interdrum clearance control device, to make worm rod to go backward and remove the safety washer
7.4.3. To replace the safety washer. To turn safety control device to gain the balance and screw
7.5. During the adjustment the clearance between opposite drums' ends should be equal While metering the clearance it is necessary to compare real clearance and the indication on the calibration disc to recover from error. Recovery from the error is especially necessary after replacement of the safety washer.
7.6. The emergency stop device should be used only in extremity To secure its smooth operation it is necessary to make regular check ups. After turning the lever of emergency stop the front drum makes no more than 1/4 mechanical rotation. In case of any deviations it is necessary
.to make adjustment according to the manual for the machine's electrical equipment
7.7. In case of any faultiness of the bearing's insert, the machine should not be stopped. It is necessary to unload it and operate on idle step until an engineer comes
7.8. .It is forbidden to turn on the loaded machine.
7.9. If the machine's repair demands removal of pinions, it is necessary to remove the tapered key, by performing operations as follows
7.9.1.To make a remover for the key (Metallic groove-like profile can be used).
7.9.2. To screw in a whole near the rear part of the tapered key, to put remover on the screw and screw a nut tight.
7.9.3. To turn the nut by a wrench until the tapered key begins to fall off and then put it off manually.
7.9.4.. It is forbidden to hammer the pinion and the tapered key or use other methods which can damage the machine's details 7.10. .Under standard conditions it is necessary to make regular maintenance of the machine, to estimate the wear of accessories and their reliability, the aged datails should be recovered or replaced. The clearance between the drums' shaft neck and the bearing's insert is to be checked if the clearance exceeds 1,2 mm the bearing's insert should be replaced

8. Attachemnt