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Low-pressure mixing-and-filling facility for static and statico-dinamic mixing of polymer compounds

Purpose
Universal facility for dosage, mixing and application of polymer systems and filling compounds.
Allows to process the following types of components system:
  • filled polymers
  • polyurethanes
  • polyurethane foams
  • polyesters
  • silicones
  • seals
  • acrylics
  • melts
  • insulators
  • glues
  • epoxy resins
  • lubrication

Application
1. Sealing of electrical items with polymer compounds (production of molded insulation): capacitors, resistors, transformers, electric motors, throttles, electronic components, etc.
2 . Application of polyurethane sealing circuit with sealing ratio of IP54, IP65 on the carcass and covers of small electrical devices, such as wiring, distribution, switch, installation, junction boxes, instrument panels, switches and rotary switches, buttons, starters, lamps, lanterns, worklights, headlights, bodies of electrical control units, boxes, panels, etc.
3 . Production of panel and round automobile filters and filters for industrial vacuum cleaners and of air conditioning and ventilation systems.
4 . Production of items of any type made of two-component polymers.

Characteristics
THE BASE FACILITY INCLUDES:
Mixing device (Variant I - stationary):
  • the carcass with inlet valves
  • a removable static-dynamic (static) amalgamator with an actuator
  • gauging device for components dosage without mixing in separate containers aimed for further weighting for determination of the ratio of mixture
  • set of hoses and stop valves
  • set of spare amalgamators
Amalgamator (Variant II – hand-held mixing unit-gun):
  • the carcass with inlet valves
  • a removable static-dynamic (static) amalgamator with an actuator
  • gauging device for components dosage without mixing in separate containers aimed for further weighting for determination of the ratio of mixture
  • turn-on trigger
  • set of hoses (length up to 10m) and stop valves
  • set of spare amalgamators
Metering unit (Variant I):
  • two special-purpose gear-wheel pumps with motor-drive
  • two manometers in the components-supply lines
  • set of spare amalgamators
Metering unit (Variant II):
  • two special-purpose dosing pneumatic actuators
  • pneumatic gear actuator
  • two manometers in the components-supply lines
  • set of hoses and stop valves
Components-supply line A (Variant I)
The tank of the Component A:
 
volume, l, not less than 40
excessive pressure, МPa, not more than 0,2
the tank is equipped with:  
pneumatic safety valve  
mixing device with an electric drive  
device for components thermostabilization,
heating up to
+500оС accurate within +/- 20оС
minimum level sensor  
maximum level sensor  
visual level meter  
fille  
dump valve  
device for final air purification and dewatering  
filter for the component  

Components-supply line A (Variant II – for high-viscosity liquids)
  • special-purpose booster piston pump with a pneumatic actuator and heated pressure plate (supply of the component A into the dosing pump from a cargo container 20,200 l)
  • special-purpose dosing gear pump with a motor drive
  • rotation speed sensor for axial leaded mixing pump
  • electronic manometer on the component-supply line
  • set of heated high-pressure pipelines (DN=12-15), set of shut-off-and-regulating equipment
Components-supply line B
The tank of the Component B:
volume, l, not less than 40
excessive pressure, МPa, not more than 0,2
the tank is equipped with:  
pneumatic safety valve  
mixing device with an electric drive  
device for components thermostabilization,
heating up to
+500оС accurate within +/- 20оС
minimum level sensor  
maximum level sensor  
visual level meter  
filler  
dump valve  
device for final air purification and dewatering  
filter for the component  
 
System of automatic components supply:
  • boost pump of the component А
  • boost pump of the component B
  • equipment for mixing of the component A in a cargo container
  • level sensors in the components cargo container
  • set of hoses and stop valves
Control board:

Mode selection: «Arrangement»«Application»

Input and imaging of characteristics of the equipment performance:
  • characteristics of the application for 100 programs: the application program number, weight rate of mixture, filling dose (g); waste filling time (0.1 sec)
  • temperature of the components in working containers (ºC)
  • the components weighting coefficients (kg/ dm3)
  • pressure in the components-supply lines, its maximum value (kg/cm2).
  • minimum pressure in the pneumatic actuator system
  • indication of the minimum components level in working and cargo containers
  • automatic maintaining of the temperature of the components in working containers at a given level
  • automatic setting and accurate maintenance of the ratio of the components ratio through the use of frequency converters and the principle of "feedback" in all the modes
In the “Arrangement mode:
  • input of the work settings
  • setting-up procedures
  • functional test of the equipment units
In the “Application mode:
  • selection of an application program with the remote-control console
  • application cycle start-up by pressing the corresponding button on the remote-control console
  • the ability to control weight ratio and production capacity of the components (after fulfillment of the overall application cycle without components mixing, the components are poured out separately for further weighting with the use of a special device)
The following types of malfunctions can be handled:
  • component level in tanks is below the minimum level
  • component temperature in tanks is below the minimum temperature
  • air pressure in the pneumatic system is below the minimum pressure level
  • supply line pressure is above the maximum component
  • deviation of the components ratio
  • any of the thermal relays went off
  • any of the circuit-breakers went off
  • frequency converter failure
The remote-control panel provides light and audible indication in case of the setup parameters differ from the specified values.

The remote-control panel is equipped with LCD display for visualization of the parameters of the equipment performance and membrane keyboard for data input.

The microprocessor control system provides maximum automation and ease of operation over the entire range of functional modes and performance parameters of the equipment, modes setting with the remote-control panel, control of all process parameters and operating modes when setting up and operating, equipment state monitoring with an indication of the corresponding messages on the LCD display, allows to perform automatic tuning and accurate maintenance of specified productivity and ratio the in the process of flowing and management of all equipment units in “Manual and “Automatic modes.

Technical characteristics:


Equipment type low-pressure type with mechanical mixing  
amalgamator type - static
  static-dynamic
  pneumatic drive
amalgamator drive type - electric drive
  servo drive
  fluid drive
number of dosed components 2
the range of regulation of the components ration A:B (depending on the model) from 1:1 to 40:1
automatic components ratio regulation using frequency converters  
productivity by mixture, g/s (depending on the model) from 2 to 125

Application
  • mechanical engineering
  • instrument engineering
  • robotics
Instrument for cooperation: finished products sale