Laboratory rolling mill for rubber LM-250/500 with the possibility of adjusting the distance between the rolls during rolling. Equipped with two independent aggregates for temperature control of rollers with water and dosing of liquids
LM-250/500 laboratory rolling mills
LM-250/500 laboratory rolling mills for processing rubber and polymer mixtures.
Our rolling mills are designed with the highest occupational safety in mind.
A characteristic feature of our rolling mills is a wide range of operating parameters, enabling the implementation of research on processing processes without restrictions for rubber and polymers
The most important feature of our rolling mills is the ability to simulate industrial rolling processes in laboratory conditions. Safety of operation, ergonomics and short preparation time for the next test are very important.
The LM-250/500 rolling mill can be equipped with two independent motors to drive each roller, with a power of 2 x 11 kW generating 2 x 4200 Nm. torque. The width of the gap between the rolls can be adjusted while the rolling mill is operating under full load of up to 150,000 N [15 tons].
The rolling mill is equipped with doubling mechanisms for regulating the rotational speed of the rollers and friction in the full range of 0 - 100% with high precision. The unique electric gap adjustment mechanism between the rollers automatically controls the distance and parallelism of the rollers during operation. The rolling mill enables quick changes of the setting of the gap between the rolls and its continuous control. Changes can be made during the rolling process, which has a decisive impact on the efficiency of the rolling process and material savings. The driving mechanisms and the mechanisms regulating the distance between the rolls are adapted to transfer high torques and forces during rolling. The rolling mill can be equipped with automatic programmable liquid and granule dispensers. All settings can be saved in the device's memory. All measured parameters can be saved on a medium. The temperature of the rollers is measured by means of 6 precise temperature transducers, arranged in such a way as to enable control along and around the circumference of the roller. The rolling mill is a universal precision automated research tool. It enables testing of rubber and polymer mixtures.
Zamak Mercator manufactures rolling mills in three roll sizes, respectively: LM-150/320 LM-200/400 LM-250/500 and LM-300/600 on special order
Technical data of the device
|Model || || LM - 250 / 500-11 || LM - 250 / 500-15 || LM - 250 / 500-22
|Number of rolls || [pcs.] || 2 || 2 || 2
|Working width of rollers || [mm] || 500 || 500 || 500
|The diameter of the rolls || [mm] || 250 || 250 || 250
|Working distance of rollers || [mm] || 0.2 - 10 || 0.2 - 10 || 0.2 - 10
|Rollers emergency departure distance || [mm] || 50 || 50 || 50
|Accuracy of gap setting between rolls || [mm] || ± 0.1 || ± 0.1 || ± 0.1
|Roller distance adjustment during operation || || Yes || Yes || Yes
|Roller parallelism adjustment and automatic control || || Yes || Yes || Yes
|Regulation of linear speed of rolls || [m / min] || 0.25 - 17 || 0.25 - 17 || 0.25 - 17
|Roller rotational speed adjustment || [rpm] || 0.5 - 22 || 0.5 - 22 || 0.5 - 22
|Regulating friction during work || || Yes || Yes || Yes
|Roller temperature control during operation || || Yes || Yes || Yes
|Temperature measurement of rolls || Multi-zone spatial - 6 measuring points
|Measuring the distance between cylinders || || Yes [0.01mm] || Yes [0.01mm] || Yes [0.01mm]
|Measurement of the operating parameters of each engine || || Yes || Yes || Yes
|UPS battery voltage measurement || || Yes || Yes || Yes
|UPS battery temperature measurement || || Yes || Yes || Yes
|Strain gauge force measurement between cylinders || || Yes || Yes || Yes
|Maximum force between rollers - dynamic || [N] || 149,000 || 149,000 || 149,000
|Maximum force between rolls - static || [N] || 500,000 || 500,000 || 500,000
|Roller torques || [Nm.] || 2 x 2,300 || 2 x 3,000 || 2 x 4,200
|Roller motors power || [kW] || 2 x 5.5 || 2 x 7.5 || 2 x 11
|Friction regulation range || || Any in terms of revolutions
|Roller surface || || Chrome-plated || Chrome-plated || Chrome-plated
|Roller temperature for the water system || [° C] || 20 - 130 || 20 - 130 || 20 - 130
|Roller temperature for the oil system || || 20 - 250 || 20 - 250 || 20 - 250
|Roller temperature control || || Advanced digital PID controller
|Independent heating and cooling units for rolls || || Option || Option || Option
|Heating and cooling capacity || || Depends on the selected system
|Cooling factor || || Depends on the selected system
|Control of all functions || || Touch screen 12 || Touch screen 12 || Touch screen 12
|Control unit || || PLC controller || PLC controller || PLC controller
|Process memory [recipe archiving] || || Yes || Yes || Yes
| || || Optional equipment
|Fluid dispensing system || || Yes || Yes || Yes
|Pyrometric measurement of the temperature of the rolled material || || Yes || Yes || Yes
|Automatic material wrapping [mixing] || || Yes || Yes || Yes
|Independent heating and cooling units for each roller || || Yes - they allow to maintain different roll temperatures
Important performance characteristics
Integration of volumetric dispensers for liquids
- Rollers are moved by means of precise ball screws
- Change and dynamic control of the width and parallelism of the joint under full load
- Stabilization of the gap width in the full operating temperature range
- Gap adjustment range 0.2-10 mm
- Special execution 0.05-5 mm for the LM 150/320 rolling mill
- Two independent roller drives
- High power and torque
- Any friction
Measurement of the force acting between cylinders
The possibility of rolling Rubber, Silicone, Plastic and other materials
The working space can be made of 316 L acid-resistant steel
The roller heating and cooling system ensures accurate and reliable temperature control
The safety system complies with the EN-1417 standard
Emergency braking of rollers < 60o
Rollers emergency separation 50 mm
Time of emergency spread of the rollers < 5s
Mechanical covers with safety sensors
Safety switches - manual buttons 4 pcs.
Safety switches - footswitches 2 pcs.
Digital control and communication system
Multizone electric heating system. Forced air cooling system Temp. max 300oC
One or two-zone oil heating and cooling system. Temp. max 270oC
One or two-zone water heating and cooling system. Temp. max 150oC / 200oC
- Made with high accuracy
- Double chrome plated and ground
- Adapted to work with rubber, plastics and other materials
- The working chamber is made of stainless or acid-resistant steel
Automatic bidirectional mixing system
Professional roller heating and cooling systems
Construction of LM-250/500 rubber and polymer rolling mills.
The working element of the rolling mill are two heated and cooled rollers, covered with a layer of technical chromium, which gives them the required hardness and smoothness of the surface.
The distance between the rolls is infinitely adjustable in the range of 0.2 mm to 10 mm with an accuracy of 0.1 mm.
The width of the gap between the rolls is constantly measured during rolling. The digital control system dynamically controls the parallelism of the rolls relative to each other and corrects any deviations from the set value.
The width of the gap between the rolls during the operation of the rolling mill is constantly corrected as a function of changes in the temperature of the rolls Rollers increase in diameter during heating due to the phenomenon of thermal expansion This phenomenon leads to a change in the width of the gap between the rolls and is noticeable when the gap is set to values below 1 The digital control system corrects these changes, ensuring that the gap has the set value regardless of changes in the temperature of the rolls during heating and cooling.
The main drive of the rolling mill rolls.
The rolling mill is powered by two modern AC motors made in 120 Hz technology. These motors provide power to the rollers. In the case of a rolling mill equipped with rolls with a diameter of 250 mm, the maximum torque per one roller is 4200 Nm. The rolling mill will not stop even when working with extremely demanding materials. Such motors have an increased range rotational speed control, especially in the range of low rotational speeds and ensure a constant maximum torque in the entire speed range In addition, such motors are practically maintenance-free and their operating costs are low An important element of the drive are two cooperating frequency converters [inverters] The inverter allows you to independently control the rotational speed and their torque We use motors and inverters from renowned manufacturers An optional module for measuring the energy consumed and controlling its quality allows you to control the costs and quality of the energy consumed on an ongoing basis, which increases research capabilities of rolling mills.
The main drive of the mechanism for setting the working gap of the rolling mill
The unique electric mechanism for adjusting the gap between the rolls automatically controls the mutual parallelism of the rolls during operation Possibility of quick adjustment of the gap between the rolls and its continuous control during the rolling process determine the efficiency of the process and save material forces during rolling.
The working gap adjustment mechanism is based on precise ball screws
At the heart of the roll gap control system is B&R's [Bernecker and Rainer] ACOPOS P3, a highly efficient and precise dual-axis servo drive that sets new standards in motion control. This servo drive is one of the most powerful servo drives with integrated safety features on the market. sampling time of only 50 µs for the entire controller cascade.The parameters of this drive and the integrated safety system allow you to meet the requirements of the safety standard for rolling mills.
The mechanism for regulating the temperature of the rolls of the LM-250/500 rolling mill.
LM-250/500 rolling mills can be equipped with one of two heating and cooling systems:
Water system enabling operation up to a maximum temperature of 130°C.
Oil system allowing operation up to a maximum temperature of 250°C.
As an option, it is possible to use independent oil or water heating and cooling systems for each roller. This solution allows for independent temperature control of each roller.
Temperature measurement is carried out by means of 6 precise temperature transducers, arranged in such a way as to enable control along and around the perimeter for each of the three heating zones of the roller. The heaters and the heating and cooling systems are simultaneously regulated by a digital PID controller (proportional-integral-derivative) Such a solution allows you to maintain the set temperature with high accuracy and avoid the so-called overshoots, i.e. uncontrolled increases or decreases in temperature A digital temperature controller developed by our automation department supervises the operation of all zones simultaneously, taking into account their mutual influence, thanks to which the temperature is stable and consistent with the set values and the measurement is reliable
In order to ensure high reliability of the temperature measurement system, the sensors are doubled [Redundant system], in practice it means that each roller is equipped with 6 temperature sensors. Additionally, rotating joints transmitting electrical signals to the roller are equipped with spare contacts. Such a system is reliable and reduces costs and time possible repair.
Mechanism of automatic mixing of the rolled mix.
When it is necessary to roll mixtures requiring high temperatures, the operator's work becomes less comfortable, because it requires the use of thick and uncomfortable gloves to protect the hands. To avoid your inconvenience, the rolling mill can be equipped with an automatic mixing machine. in such a way that it wraps the edge of the rolled mix and thus mixes it. The mixer's work cycle is freely programmable from the operator's touch screen. An unused mixer is parked outside the rolling mill's operating area.
Roller safety system
Growing safety requirements for rolling mills and calenders mean that cylinder shifting systems must comply with the applicable standards and ensure high precision and reliability of operation. rolling mill and operator [safety standard EN 1417 and later requires that the speed of emergency opening of the rolls for a minimum distance of 50 mm does not exceed 5 seconds, moreover, the rolls must stop turning by a maximum of 90 degrees. In addition, the force measurement enables constant control of the clamping force of the rolls and protects the machine from overload.
The safety system can be activated by hand, head or knee if necessary. The system complies with and exceeds current requirements.When the rolling mill safety system is activated, the automatic rollers brake practically on the spot and move away from each other within 50 mm in no more than 5 seconds.
To ensure the required work safety, the rolling mill is equipped with two UPS (Uninterruptible Power Supply) systems.
The first and main DC UPS emergency power system is designed for continuous power supply, independent of mains voltage loss, to the internal power bus of the B&R's ACOPOS P3 two-axis servo drive, which is a key element of the rolling mill's safety system, as it ensures safe roll-off of the rolls for a distance of 50 mm in in the event of activation of the security systems, the UPS is equipped with a system for continuous monitoring of battery voltage and temperature. In the event of irregularities in the UPS system, the security system will not allow the device to start or will turn it off in emergency mode. The second UPS is used to power the digital control system of the rolling mill. after a power failure, ensuring reliable operation of safety systems and their control by the operator.
B&R's [Bernecker and Rainer] safety system is integrated with the machine's control system and communicates with it via an extremely fast real-time bus.
Digital rolling mill control system.
The operation of the rolling mill is monitored by a PLC computer system. It is possible to control all parameters of the rolling mill operation with a color touch panel. It is also possible to visualize and save most of the operating parameters and export them to spreadsheet files. Our software allows you to steer, control and manage research processes Continuous control of rolling mill parameters such as: temperature, friction, rotation, torque, force, energy consumption, allow you to have control over the process and the rolling mill Additionally, you can add the ability to save parameters to the database for later use analysis and archiving, on-line display of charts and work in the company network and even global. Thanks to our software, we can conduct research and transmit the process and video image via Ethernet to any place for computers, tablets, etc. Our software can be adapted to the expectations of our customers.The process can be controlled from the touch screen on the device console or over the Ethernet network.
Laboratory extruders have such a durable and reliable construction and a high level of safety that they can be used in industry
Safety system in accordance with the applicable EN-1417 standard - Yes
Emergency braking - Yes < 60 degrees
Roller emergency extension - 50 [mm]
Roller emergency extension time - < 5 [s]
Mechanical shields with safety sensors - Yes
Safety switches - manual buttons - 2 [option 4]
Safety switches - knee buttons - 1 [option 2]
Back-up power supply for safety systems - UPS Yes - maintains the operation of safety systems - enables emergency rolling of the rollers after a power failure
Safety switches for head or hand - Yes
Electronic overload protection - Yes
Short-circuit protection - Yes
Shock protection - Yes
Main switch - Yes
Important usable features:
High performance parameters [torque, force between rolls, precision of operation]
Built-in heating and cooling system adapted to the user's needs.
Precision high temperature spherical roller bearings.
Precise measurement of parameters [torque, force, temperature]
High safety of use even in the event of a power failure
Optional module for measuring consumed energy and parameters of the power supply network
High energy efficiency
High component durability
Adapted to Industry 4.0
We have made every effort to ensure that the information about our products is factually correct. Please treat the technical data of the devices as indicative, because we constantly improve our products, adapting them to changing technologies.
The presented offer is informative and does not constitute an offer within the meaning of the Civil Code