I Description of static mixer vacuum resin casting machine
This static mixer vacuum resin casting machine is special for epoxy resin casting dry type transformers, reactors, bushings, current transformers, potential transformers, HV switch insulators, arc-distinguish coils and other electric apparatus.
This machine adopts STATIC-MIXING technology, developed by ourselves with Patent technologies, similar to HEYDRICH Germany and HUEBERS Germany, suitable for viscosity less than 4000mPa.s mixing. Because of its high intelligent degree, strong continuity and mixing-for-immediate-casting features, casted coil invasion is super high!
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II Full sketch of static-mixer vacuum resin casting machine plant:
III Technology plan achievement
- This plan is a FULL-AUTOMATIC STATIC-MIXING vacuum epoxy resin casting machine, compact structure, high reliability, strong continuity. - Full automatic means auto drying, degassing, mixing, feeding, counting, vacuuming, heating and casting, controlled by computer.
- This plan can satisfy all requirements of prevailing dry-type transformer casting, both resin with stuffing or pure resin. - This plan is suitable for stuffing feeding from separate warehouse 30m away, very clean casting environment. (Suitable vertical transmitting height 5m; Pre-condition is that hourly transmitting weight is not less than 1000kg) - This plan can satisfy requirements by continuous production: Two material storing & degassing tanks feed qualified materials to two counting tanks; Counting tanks feed materials to static mixer; Storing & degassing tanks absorb materials again and degas materials. - Storing & degassing tanks adopt umbrella-film-degassing method, perfect degassing result; Because of special design, there will be no sedimentation even material stored for long time. - All the related parts & components such as counting pumps, filters, valves and static mixers have been anti-wear treated, avoiding external & internal leakage because of long-time wearing by material. - There are cleanable filters between counting pumps and static mixers, avoiding jam inside mixers and casting valves. If filters are jammed, the control system will alarm and prompt settlement way. - All counting pumps, static mixers, filters and material transmitting pipelines adopt mesotron-transfer heating method, heating temperature precision is within +/-1ºC! Thus avoids material transmitting failures and proportion error because of material crystallization.
- Heating elements are evenly put on tank inner surface, quick heating, accurate temperature control, maintenance free.
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IV Main technical data of one typical static mixer vacuum resin casting machine:
No.
Item
Data
1
Casting tank size
Ф2400 x 3000mm
2
Mixing & degassing tank volume
300L
3
Counting tank volume
300L
4
Stuffing tank volume
600L
5
Counting pump piston cylinder diameter
100mm
6
Counting pump max. feeding amount
1L/R
7
Static-mixer cross-mixing stages
15
8
Static-mixer temperature exchange
15-90ºC
9
Vacuum system pumping speed
300L/S
10
Casting tank working temperature
70-85ºC
11
Mixing tank degassing vacuity
1mbar
12
Mixing tank vacuum leakage rate
0.05mbar.L/s
13
Casting tank working vacuity
0.5-1.5mbar
14
Casting tank vacuum leakage rate
0.05mbar.L/s
15
Casting tank casting nozzles
12
16
Compressed air pressure
0.5-0.8MPa
17
One batch duration (300L full consumed)
60~90min
|static mixer vacuum resin casting machine| static mixer vacuum resin casting machine| static mixer vacuum resin casting machine|
V Main buildup and configuration list:
VI Technical data and illustration
5.1 Stuffing bag (1000kg) opening system
- For opening stuffing bags in max. 1000kg weight under sealing condition, avoiding pollution.
- System includes frame, lifter, beam, collecting hopper, vibrator, gas-ballasting valve, connectors & plastic flexible pipes, etc.
- Transmitting under sealing condition, vacuum absorbing; open/closing angle of gas-ballasting valve and gas-ballasting time can be adjusted according to season and humidity.
- System design is capable for transmitting 1000kg~1500kg per hour.
5.2 Stuffing drying and transmitting system
- For transmitting stuffing from hopper to drying tank by vacuum pressure difference. System includes vacuum transmitter, vacuum pump, filter, vacuum drying tank, releasing valve, heater, etc.
- Vacuum drying tank has heating system, heat up to 125ºC; Inside tank there is horizontal stirring mixer.
- Dried stuffing will be fed into two storing & degassing tanks via screw transmitter mounted on the bottom of this vacuum drying tank.
- Stuffing feeding quantity to two degassing tanks are weighed and controlled by two electronic scales with digital displaying on both scale and industrial computer; Feeding quantity data can be saved and has power-off memory function.
5.3 300L resin mixing & degassing tank system
- This tank can mix, degas and store resin & stuffing, ready for being counted into accounting tank; Adopting film-degassing method.
- Tank effective volume 300L; Heat induction oil heating, share one 9kW electric heater with another counting tank, working temperature 60~80ºC.
- Adopting stainless steel anchor mixing method; Mixer is driven by a reducer on tope tank.
- Liquid material is added by high-viscosity diaphragm pump; Adding quantity is controlled by electronic scale self-equipped; Automatically finish material adding by preset parameter; Every proportion can be supervised and recorded; Material counting precision +/-1%.
- Ultimate vacuity under idle condition is ≤0.02mbar; vacuum leakage rate under idle condition (including pipeline) ≤0.05mbar. L∕S; Data is measured by imported vacuum transmitter.
- Tank mouth seal is made by material from Dupont America; Door open/close transmission section is our special design, life can be compared with any other competitors in the world.
- Tank door has one lighting-observing window.
5.4 300L hardener mixing & degassing tank system
- For mixing liquid type hardener and stuffing, then degassing and storing.
- Configurations are exactly same as above Item 4.3 for resin.
5.5 300L resin counting tank system
- This tank can mix and store materials fed into it and keep ready for timely casting. Counting pump is installed on side wall of tank. Optimized design makes no residual material.
- Effective volume 300L; Heat induction oil heating, share one 9kW electric heater with another counting tank, working temperature 60~80ºC.
- Adopting stainless steel anchor mixing method; Mixer is driven by a reducer on tope tank.
- Material feeding to this tank from mixing & degassing tank is by vacuum absorbing; Quantity is controlled by material leveler inside the tank. When material level reaches the top limit, stop absorbing; When material level reaches the bottom level, system alarm and start absorbing. The process is full automatic.
- Ultimate vacuity under idle condition is ≤0.02mbar; vacuum leakage rate under idle condition (including pipeline) ≤0.05mbar. L∕S; Data is measured by imported vacuum transmitter.
- Tank mouth seal is made by material from Dupont America; Door open/close transmission section is our special design, life can be compared with any other competitors in the world.
- Tank door has one lighting-observing window.
5.6 300L hardener counting tank system: same configuration as that for Item 4.5.
5.7 High precision carborundum counting pump system, two sets
- For counting & feeding resin and hardener separately; Pumps are mounted on the side wall of counting tanks. Each counting pump is comprised of ball screw, servo motor, servo driver, etc. Torque of servo motor can satisfy for pumping viscosity max. 8000mPa.s.
- Counting pump body is made by high quality carborundum from Germany, life more than million times feeding.
- Feeding speed 5-10kg per minute, counting precision +/-0.5%; Various casting proportion can be achieved and displayed on displayer for convenient adjustment.
- Quantification feeding, preset and controlled by PLC; All main valves are interlocked for safety.
- When the whole machine stops, counting pump will timely cycle materials for cleaning pipeline and mixing material.
5.8 Static mixer system, one
- Static mixer and casting system are mounted on top of casting tank. Static mixer is comprised of 15 pieces cross mixing blocks. After obtaining pressure from counting pump, material inside this mixer will have cross mixing for more than 100 million times. Flow speed matches the counting pump.
- Static mixer has quick temperature rising and quick cooling functions. When start working, mixer temperature can be raised to max. 90ºC very quickly; After casting finished, mixer can cool down to 15-25ºC very quickly thus delaying curing speed of two components.
- When changing casting material without stuffing, only change few parameters, very simple and convenient.
- Our design can avoid any small leakage because of wearing. There is real-time supervision function to assure reliable and stable running.
5.9 Vacuum casting tank
- Inner dimension: Φ2400mm (diameter) × 3000mm (length)
- Round structure, horizontal laying
- Door side opening, hanged on one side of tank; manual lock
- Ultimate vacuity: less than 10Pa (idle, cool)
- Leakage rate: less than 50Pa.L/s (idle)
- Working vacuity: 100-300Pa
- Pumping speed: not more than 15 minutes from atmosphere to working vacuity
- Heating method: state-of-the-art electric heating plate method, heating plate from Germany;
- Heating temperature: ambient temperature to 120ºC (automatic adjustable, constant temperature, over-temperature alarming), temperature evenness ±2ºC
- Tank body is rockwool insulated and stainless steel armored, outer surface temperature rise is not more than 10ºC plus ambient temperature.
- There are 12 sets pneumatic valves and injecting nozzles for casting. Injecting amount of every nozzle can be preset. The whole injection can be PLC control automatic or manual; Pneumatic valves are anti-wear treated, avoiding interior leakage. After whole casting finished, the static mixer and whole system can be cleaned by one single component.
5.10 Heating system, four sets
- Casting tank is heated by Germany heating plates, total power 48kW
- Each mixing & degassing tank and counting tank are heated by electric heater and transferred by mesotron, each 9kW;
- Static mixer and material transmitting pipeline share one electric heater, power 9kW
- Stuffing drying tank is heated by Germany heating plates, total power 18kW
- Each heating system adopts power-control module assuring temperature even and stable. Electric consumption in temperature-keeping stage is about 35% of total power, save energy.
5.11 Vacuum system, three sets
- Vacuum pump system for casting tank: extracting speed 300L/S, Germany RA0302 rotary vane pump + Sunshine ZJY300 Roots pump
- Vacuum pump system for mixing & degassing tanks: extracting speed 300L/S, Germany RA0302 rotary vane pump + Sunshine ZJY300 Roots pump
- Stuffing drying tank is vacuumed by a special vacuum pump with optimized filtering system.
- Each system is equipped with Germany digital vacuometer and special filters.
5.12 Compressed air system, one
- Air compressor is to be provided by Buyer, 3m3/min, 0.6~0.8MPa
- Other pneumatic parts and accessories are included.
5.13 Water cooling system, one
- Equipped with industrial water chiller for cooling vacuum condensing filters and heat exchangers.
5.14 Control & measuring system, one
- Integrated control cabinet, 19” LCD displayer, industrial computer, OMRON PLC, with air conditioner, both Auto and Manual operation methods.
- Displayer displaying technological process mimetic sketch, human-machine dialogue parameter table, every unit working conditions
- Displaying temperature, vacuity, pressure and prompting reference range
- Controlling & supervising every motor for mixing; Controlling & supervising every pneumatic valves and electromagnetic valves
- Achieving interlocks among every pump and valve
- Achieving alarm of pneumatic pressure, temperature and timing and providing analysis report.
- Displaying material flow amount and pressure
- Present technological parameters can be printed out and saved
5.15 Steel frame & structure, one set
- Includes frame, stairs, rails, casting platform, etc.
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