1. Rotors – These are the main mixing elements of the mixer. Between the rotors,
the raw material gets mixed. The rotors are shaped in the form of wings (two –
wing, four – wing and six – wing); sometimes the wings are also called helical
blades.
The shape of these wings is important to get a smooth and predictable
flow of mix in the mixing chamber. The way the material gets mixed also
determines the temperature rise in the mixing chamber. Optimal rotor length – to
– diameter ratio aids mixing. Another factor which influences the mixing is the
rotor speed. Sometimes for certain mixing stages, even the alignment of the rotors can be adjusted
the raw material gets mixed. The rotors are shaped in the form of wings (two –
wing, four – wing and six – wing); sometimes the wings are also called helical
blades.
The shape of these wings is important to get a smooth and predictable
flow of mix in the mixing chamber. The way the material gets mixed also
determines the temperature rise in the mixing chamber. Optimal rotor length – to
– diameter ratio aids mixing. Another factor which influences the mixing is the
rotor speed. Sometimes for certain mixing stages, even the alignment of the rotors can be adjusted
The rotors are provided with extensive cooling systems (in the form of
complicated geometric pathways inside the rotor) as the temperature during the time
of mixing may well reach about 150 – 170 degrees centigrade. The cooling at the tips
of the wing is especially important, as here the temperature rise is more than the other
regions.
The rotors are manufactured from high tensile steel castings, and are shrunk into
place around a forged steel shaft. The unique feature of this two-piece construction is
prevention of rotor and shaft deflection. The rotors have to work in the harshest
conditions possible, so they are coated with a hard material on the working surfaces
to improve wear resistance. On the other hand, a one piece steel rotor construction is
stronger and more durable than a blade welded rotor, eliminating leak lines between
shaft and wing.
Innovative rotor designs can adjust the clearance between the rotors thus getting
advantages of both the rolling mill mixer and the internal mixer.
complicated geometric pathways inside the rotor) as the temperature during the time
of mixing may well reach about 150 – 170 degrees centigrade. The cooling at the tips
of the wing is especially important, as here the temperature rise is more than the other
regions.
The rotors are manufactured from high tensile steel castings, and are shrunk into
place around a forged steel shaft. The unique feature of this two-piece construction is
prevention of rotor and shaft deflection. The rotors have to work in the harshest
conditions possible, so they are coated with a hard material on the working surfaces
to improve wear resistance. On the other hand, a one piece steel rotor construction is
stronger and more durable than a blade welded rotor, eliminating leak lines between
shaft and wing.
Innovative rotor designs can adjust the clearance between the rotors thus getting
advantages of both the rolling mill mixer and the internal mixer.
2. Sides – The sides of the Banbury mixer chamber are provided with
cooling/heating channels so that whatever area comes in contact with the hot
compound dissipates heat to reduce compound degradation or ”scorching”
3. Bed plate – Have holes for mixer anchorage and leveling.
4. Drop door – The wide door tops are rigidly fitted on its support and has
cooling/heating channels. Usually operated by a linear hydraulic actuator. The
drop door is mounted flexibly against the mixing chamber end plates with
adjustable wear strips, ensuring minimal material leakage and contamination.
cooling/heating channels so that whatever area comes in contact with the hot
compound dissipates heat to reduce compound degradation or ”scorching”
3. Bed plate – Have holes for mixer anchorage and leveling.
4. Drop door – The wide door tops are rigidly fitted on its support and has
cooling/heating channels. Usually operated by a linear hydraulic actuator. The
drop door is mounted flexibly against the mixing chamber end plates with
adjustable wear strips, ensuring minimal material leakage and contamination.
5. Dust stops – These dust stops eliminate batch contamination. They are
hydraulically operated.
1. Feeding hopper – The doors are hydraulically operated.
7. Ram group – The ram is usually hydraulically or pneumatically operated. The
ram is cooled and sensors indicate the position of the ram.
The ram can generate pressures in excess of 100 bar.
A hydraulic ram offers some advantages over the pneumatic top cylinder.
In a hydraulic ram, the pressure rise to the desired pressure level is more or less
instantaneous, and more importantly the hydraulic’s working pressure is
unaffected by variable load as in the case of air – compression systems.
Gear reducer – Reduces the motor speed (~ 800 rpm) to rotor speed (~ 70 rpm).
hydraulically operated.
1. Feeding hopper – The doors are hydraulically operated.
7. Ram group – The ram is usually hydraulically or pneumatically operated. The
ram is cooled and sensors indicate the position of the ram.
The ram can generate pressures in excess of 100 bar.
A hydraulic ram offers some advantages over the pneumatic top cylinder.
In a hydraulic ram, the pressure rise to the desired pressure level is more or less
instantaneous, and more importantly the hydraulic’s working pressure is
unaffected by variable load as in the case of air – compression systems.
Gear reducer – Reduces the motor speed (~ 800 rpm) to rotor speed (~ 70 rpm).
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