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Laboratory rolling mills LM-150/320
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Laboratory rolling mill for rubber LM-150/320 with the possibility of adjusting the distance between the rolls during rolling. Designed for plastics and rubber, electrically heated with an automatic mixing machine for rolled plastic

Laboratory rolling mill for rubber LM-150/320 with the possibility of adjusting the distance between the rolls during rolling. Designed for plastics and rubber, electrically heated with an automatic mixing machine for rolled plastic

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Laboratory rolling mill for rubber LM-150/320 with the possibility of adjusting the distance between the rolls during rolling. Designed for plastics and rubber, electrically heated with an automatic mixing machine for rolled plastic
Laboratory rolling mill for rubber LM-150/320 with the possibility of adjusting the distance between the rolls during rolling. Designed for plastics and rubber, electrically heated, air-cooled, with an automatic mixing machine for rolled plastic
Laboratory rubber rolling mill LM-250/500 Equipped with two independent units for thermostating the rolls with water
Laboratory rolling mill for plastics and rubber heated with thermal oil
Laboratory rolling mill for plastics and rubber heated with thermal oil
Laboratory rolling mill for plastics and rubber heated with thermal oil
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Laboratory rolling mills LM-150/320

LM-150/320 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.

Research opportunities.

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 - 150 / 320-6  LM - 150 / 320-8  LM - 150 / 320-11 
Number of rolls  [pcs.] 
Rolls working width  [mm]  320  320  320 
Roll diameter  [mm]  150  150  150 
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 
Adjusting the distance of the rollers during operation  Yes [from touch screen] 
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 - 36  0.5 - 36  0.5 - 36 
Regulating friction during work  Yes  Yes  Yes 
Roller temperature control during operation  Yes  Yes  Yes 
Roller temperature measurement  Multi-zone spatial - 6 measuring points 
Measure 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 
Temperature measurement of UPS batteries  Yes  Yes  Yes 
Strain gauge force measurement between cylinders  Yes  Yes  Yes 
Maximum force between rollers - dynamic  [N]  56 600  56 600  56 600 
Maximum force between rolls - static  [N]  254 400  254 400  254 400 
Roller torques  [Nm.]  2 x 750  2 x 1,000  2 x 1,250 
Roller motors power  [kW]  2 x 3.0  2 x 4.0  2 x 5.5 
The range of friction regulation  Any in terms of revolutions 
Roller surface  Chrome-plated  Chrome-plated  Chrome-plated 
Roller temperature for electrical system  20 - 300  20 - 300  20 - 300 
Roller temperature control  Advanced digital PID controller 
Number of cylinder heating zones  3 zones  3 zones  3 zones 
Refrigerant  Air  Air  Air 
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:
  • 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
Ważne cechy użytkowe
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
Rollers:
  • 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
Ważne cechy użytkowe
Technical description

Construction of LM-150/320 rubber and polymer rolling mills.

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. The rolling mill will not stop even when working with extremely demanding materials. In addition, such motors are practically maintenance-free and the costs of their use are lowAn important element of the drive are two cooperating frequency converters [inverters]The inverter allows you to independently control the rotational speed of the rollers and their torqueWe use motors and inverters from reputable manufacturersOptional module for measuring the energy consumed and controlling its quality, allows you to control the costs and quality of energy consumed on an ongoing basis, which increases the 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&amp;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 rollers of the LM-150/320 rolling mill.

The LM-150/320 rolling machine is equipped with an electric heating and air cooling system that enables operation up to a maximum temperature of 300°C.

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 meets and exceeds current requirements When the rolling mill safety system is activated, the automatic rollers brake practically on the spot and travel within 50 mm of each other 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&amp;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 case of activation of the safety systems.The UPS is equipped with a system of 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. 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 the 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, displaying graphs on-line 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

Security system:

  1. Safety system in accordance with the applicable EN-1417 standard - Yes

  2. Emergency braking - Yes < 60 degrees

  3. Roller emergency extension - 50 [mm]

  4. Roller emergency extension time - < 5 [s]

  5. Mechanical shields with safety sensors - Yes

  6. Safety switches - manual buttons - 2 [option 4]

  7. Safety switches - knee buttons - 1 [option 2]

  8. 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

  9. Safety switches for head or hand - Yes

  10. Electronic overload protection - Yes

  11. Short-circuit protection - Yes

  12. Shock protection - Yes

  13. Main switch - Yes

Important features:

  1. High performance parameters [torque, force between rolls, precision of operation]

  2. Built-in heating and cooling system adapted to the user's needs.

  3. Precision high temperature spherical roller bearings.

  4. Precise measurement of parameters [torque, force, temperature]

  5. High safety of use even in the event of a power failure

  6. Optional module for measuring consumed energy and parameters of the power supply network

  7. High energy efficiency

  8. High component durability

  9. Ethernet integration

  10. Adapted to Industry 4.0

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Other products in this category   >

LM-200/400 laboratory rolling mills

LM-250/500 laboratory rolling mills

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

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