HZJ-300S Fluoroplastic Torque Rheometer

I. Overview

1.1 Product Features

In the process of shaping rubber and plastic materials, their fluidity is almost always involved. For instance, during extrusion, molding, blowing film, and calendering processes, the material's flow behavior is crucial. The material's fluidity not only affects the processing but also influences the mechanical properties of the final product. For example, molecular orientation significantly impacts the mechanical properties of molded products, films, and fibers. The type and extent of molecular orientation are primarily determined by the characteristics of the flow field during the processing and the material's flow behavior.

A torque rheometer is an ideal device for studying the flow and deformation, plasticization, thermal shear stability, dynamic rheological properties, and plasticizing behavior of polymer materials, presenting the results in graphical forms such as torque vs. time and torque vs. temperature. It is widely used in research and production, serving as a crucial instrument for scientific research and production guidance. Compared to general instruments for measuring material flowability, such as viscometers, this rheometer provides a more dynamic and practical measurement method that closely mimics actual processing conditions. It can continuously and accurately measure the rheological properties of materials under similar processing conditions, including the mixing of multi-component materials, the curing of thermosetting resins, vulcanization of elastomers, material dynamic stability, and the impact of screw speed on system processing performance.

1.2 Scope of Application

The Fluoroplastic Torque Rheometer is used to study the thermal stability, shear stability, flow, and plasticizing behavior of fluoroplastic and thermoplastic materials. Its most distinctive feature is the ability to continuously, accurately, and reliably measure the rheological properties of the system during processing similar to actual operations. It also facilitates the testing of the curing characteristics of thermosetting materials.

1.3 Application Fields

1. Research on UPVC Processing Properties and Material Development

2. Development and processing properties of fluoroplastics and thermoplastic materials

3. Cross-linking and Thermosetting Resin Curing Performance Study

4. Educational and Research Applications

II. Structural Characteristics and Working Principle

1. System Composition

The Fluoroplastic Torque Rheometer is composed of parts such as a compounding torque rheometer, extrusion capillary rheometer, capillary test die, data acquisition and measurement system, electronic computer, and operating software.

Torsional Rheometer for Compounding

The Fluoroplastic Torque Rheometer is mainly composed of imported servo motors, high-precision dynamic torque sensors, gearboxes, kneading chambers, temperature modules, measurement modules, computers, and control software, with its principle illustrated in Figure 2.

Figure 1 Fluoroplastic Torque Rheometer

The enclosed mixer is akin to a small compounding machine, consisting of a removable "∞"-shaped mixing chamber and a pair of rotors that rotate in opposite directions at different speeds. Inside the mixing chamber, the rotors rotate in opposite directions, applying shearing force to the material, forcing it to be mixed within the chamber; the different speeds of the two rotors cause a dispersible mixing in the gap between them.

The unit boasts an overall aesthetic appeal, with the main sheet metal featuring a white and blue color scheme, which can also be customized according to customer requirements. The stainless steel parts are made of SUS304 stainless steel.

Computer software with functions for data collection, storage, calculation, analysis, and output, capable of printing test reports as per user requirements.

System Software

The software suite includes the Mixer – Mixing Test Control Software, Plastic – Extruder Test Control Software, and WinNian – Apparent Viscosity Data Processing Software. The Mixer and Plastic software interfaces are feature-rich, enabling measurement, setting, and control of speed, torque, temperature, and pressure. The curve window can display real-time curves of these data points over time. These data can be processed and graphed by the software. Test control software generates experimental reports and can be printed out by a color printer. Additional features include overlaying multiple curves and smoothing curve processing.

图2 密炼式转矩流变仪                                         图3 各种转子

Figure 4: Panasonic Servo Motor + Panasonic Servo Controller

Figure 5 - Beijing Zhonghang High Precision Torque Sensor

Figure 6: Schematic illustration of a kneading torque rheometer

1 - Rod; 2 - Feed opening; 3 - Compounding chamber; 4 - Material leakage; 5 - Compounding machine; 6 - Emergency stop switch

7 - Manual panel; 8 - Drive and torque sensors; 9 - Switches; 10 - Computer

Figure 7 Test Curve of the High Shear Torque Rheometer

PVC Blending & Heat Stabilization

XLPE Cross-Linked   PVC Blended

III. Main Technical Features and Specifications

Can be used to study the thermal stability, shear stability, flow, and plasticizing behavior of fluoroplastic and thermoplastic materials. Its most distinctive feature is the ability to continuously, accurately, and reliably measure the rheological properties of the system during processing similar to actual production. It can also perform curing characteristic tests for thermosetting materials.

Motor Power: Panasonic 3.0kw Servo Motor

2. Motor Speed: 3000 rpm

Motor Driver 3.0 kW

4. Gearbox: 1:20

5. Power Output Speed: 0 ~ 150 rpm

6. Speed Control Accuracy: 0.05% F.S.

Static measurement accuracy: 0.1°C

8. Temperature Control Accuracy: ±1°C

Torque Measurement Range: 0 ~ 250 Nm

10. Torque Measurement Accuracy: 0.1% F.S.

11. Software: Measurement and Control Software, Polymer Melt Viscosity Data Processing Software, Extruder Data Processing Software, Blender Data Processing Software.

12. Graphical Display: RPM, Torque, Temperature, Pressure

Voltage: AC380V, 7.5kw

The mixer platform can conduct a variety of tests, including thermal fusion tests on multi-component thermoplastic materials, curing property tests on thermosetting materials, thermal stability tests, shear sensitivity tests, and material blending.

Capacity: 60ml

2. Mixing Chamber Material: Alloy Steel (High-temperature and high-pressure resistance, corrosion-resistant)

3. Rotor Type: Roller

4. Rotor Material: Alloy steel (resistant to high temperature and pressure, corrosion-resistant)

5. Rotor Treatment: After high-precision polishing, surface chrome plated

6. Hard Chrome Plating Thickness: 15-20 um

7. Material of Pressure Head: Alloy Steel (resistant to high temperature and pressure, corrosion-resistant)

8. Speed Ratio: 3:2

9. Maximum Torque: 250 Nm

10. Maximum Speed: 200 rpm

Highest Temperature: 450℃

Temperature Sensor: Type K Thermocouple

13. Heating Method: Electric Heating

14. Heater: Heating Tube

15. Total Heating Power: 2000W

16. Heating Zone: 3-way

Single-screw extrusion units are primarily used for filling, blending, modification, reinforcement, chlorinated polypropylene, and desiccation treatment of high absorbent resin; extrusion of biodegradable masterbatch, polyamide condensation, and polyurethane polymerization; granulation of carbon powder and magnetic powder; preparation of insulating materials for cables, sheath materials, low smoke and halogen-free flame-retardant PVC cable materials, and various silane cross-linking materials.

Plastic Single Screw Extruder (Material: HHS Alloy)

1、L:D：     25：1

2. Screw Diameter: φ20mm

3. Screw Compression Ratio: 2.5:1

4. Screw Material: Inconelnel 718

4. Maximum temperature: 450°C

5. Heating Method: Electric Heating

6. Heating Zone: 5 Channels

7. Total Heating Power: 4200W

8. Temperature Sensor: K-Type Thermocouple

9. Machine Dimensions (Length x Width x Height): 1600 x 450 x 1300 (mm)

10. Capillary molds: φ1.27, with core diameters in length ratios of 20:1, 30:1, and 40:1 each.

(φ1, φ2, and other specifications available for selection; prices to be negotiated separately)

Cylinder Die (optional): Inner Diameter: Φ5, Outer Diameter: Φ10

Control and Measurement Host + Mixing Unit Main Configuration

Equipment Installation and Commissioning Plan

Technical staff equipped

Based on the project's engineering scope, construction progress, and complexity, etc., our company has decided to dispatch the following technical personnel for this project after discussion in the engineering department. Each technical personnel must strictly fulfill their duties to ensure the smooth progress of this project.

Pre-installation coordination work

Based on the design drawings, identify the assistance required from the installation party during construction, primarily for equipment that needs to be pre-buried in the early stages. This ensures smooth and accurate installation upon the arrival of the equipment.

2. Equipment in place, installation

1. Basic Re-test: Use on-site measurement tools to have a dedicated person measure the equipment foundation's position and dimensions to ensure they meet design and operational requirements. Detailed record the measurement data to guarantee the accuracy of the equipment's location.

2. Equipment Positioning and Layout: Based on the actual dimensions of the equipment and the re-measurement results of the foundation, rationally arrange the specific location for equipment placement, and conduct positioning and layout. Use this as the final basis for equipment installation.

3. Equipment Arrangement: Upon arrival, equipment positioning tools, forklifts, and cranes will be arranged based on the size and weight of the equipment.

Section 3: Quality Assurance Measures

1. Crafting精品 projects is an ongoing quality pursuit for all our staff. Everyone holds the thought of "a century-long plan," demanding rigorously and striving for perfection, completing the installation and debugging of testing instruments with high standards and quality.

2. Actively accept supervision and guidance from the local quality and technical supervision department and the owner, and strictly comply with all national regulations, standards, and specifications.

3. Installation technical engineers should be familiar with drawings, master construction standards and specifications, and conduct technical handover of equipment to ensure operators perform operations according to process requirements.

4. Adhere to the "Three Inspections and Three Pre-controls" principle, which includes self-inspection, mutual inspection, and specialized inspection. Quality is primarily controlled through pre-controls, with dynamic tracking inspections conducted during the construction process. Upon completion of the previous procedure, a static quality check is performed, followed by transitioning to the next process, where strict pre-controls over quality factors are implemented.

1. Ensure safety organizational measures

1) Installation technicians must strictly comply with the safety and fire prevention regulations of the requesting unit; violators will be penalized.

2) During the debugging and testing period, a fire permit must be obtained from the relevant department of the construction unit before any firework can be conducted. Approval is required before any fire can be ignited.

3) No smoking is permitted in flammable or explosive areas by all personnel involved in debugging and installation.

2. Ensured Safety Measures

1) Electrical Safety Measures

a. Temporary power circuits on-site must be installed using insulated flexible cables and set up according to regulations; they must not be placed or connected haphazardly. Temporary power lines should be suspended at high elevations as much as possible, with protective measures taken at passages and turns. Markings should be set for underground installations. b. In the event of a temporary power outage on-site, all power sources should be immediately disconnected.

c. Various electrical equipment on-site should be operated by designated personnel only.

3. Fire safety measures

To prevent fires, conduct thorough training to ensure staff have basic fire safety knowledge and capabilities, thereby eliminating or reducing the occurrence of fires and effectively controlling the spread of fire.

b. The installation and debugging site should be equipped with appropriate fire extinguishing materials and fire prevention tools.

Section 4: Debugging and Acceptance Plan

1. Equipment commissioning

1.1 Pre-Testing Inspection

Prior to debugging, organize relevant personnel to familiarize themselves with the drawings and complete the technical briefing to ensure safety of both equipment and personnel during the debugging process.

Once wiring between computers and devices is completed, first inspect and verify internal wiring and input/output connections. Before powering on the local control unit, conduct insulation checks on the cabinet and cables. Confirm correctness before powering on for computer static debugging.

1.2 Static Debugging

Through computerized programmed static debugging, the following inspections are conducted:

Is there any short-circuit phenomenon?

b. Are the signal and alarm displays on the simulation screen accurate;

c. Are all output relays operating normally?

d. Are all feedback signals functioning normally?

e. All operation buttons and switch operations are correct;

f. Does the program design comply with the required process control procedures?

g. Are the signal and alarm functions operating normally?

h. Simulation tests of system processes, such as normal operation of simulated failures and shutdown procedures.

i. Is the system's interlock debugging operation normal?

j. Verify the accuracy of each process and preliminarily determine the optimal coordination times for each step.

1.3 Empty and Loaded Testing

The equipment system is automatically controlled for power-on debugging, following the sequence of first debugging the control circuit, then the main circuit, starting with no-load operation and then load operation.

Power-on debugging of the control circuit checks if the wiring of electrical and distribution equipment is correct. During the test, the main circuit is not powered, only the control power supply is connected, and then the corresponding buttons or other main command devices are sequentially connected according to the actual working program. After each operation, check if the respective electrical components have moved according to the prescribed program (such as whether the corresponding signal lights are on, if the contactors are closed or opened, if the action sequence and delay meet the design requirements, and if there are any other abnormal conditions). If necessary, simulate fault signals manually to check, such as pushing the contactor core to verify the effectiveness of the interlock, simulating the action of the limit switch to check the reliability of the protection, pressing the emergency stop button or connecting the power supply to the detaching coil to check the emergency stop and fault interruption functions, etc. After several such power-on tests, all electrical components operate normally, the computer's fault diagnosis function is normal; the local station's fault protection function is reliable; the simulation tests of the system process, such as simulating fault and shutdown procedures, are all normal; this proves that the wiring of the control section is correct and can proceed with the no-load test.

Before energizing the main circuit, reconfirm the correct wiring and conductor selection; during the trial operation, inspect the electrical control and distribution equipment, and note the inspection items; when the system is undergoing联动 load debugging operation, determine the optimal coordination of each step.

2. Online debugging

2.1 Online Testing

The testing requirements for electrical equipment should be carried out and accepted according to the relevant construction and acceptance specifications.

(2) No-load Test: After the installation of all major equipment is completed, conduct a no-load operation test.

(3) Full Load Linkage Commissioning (Test):

(4) Conduct full-load联动 debugging

Before energizing the main circuit, reconfirm the correctness of the main circuit wiring and conductor selection, and check if the short-circuit and overload protective devices meet the requirements. After no-load testing, the computer program can control according to the required process control flow, ensuring all output relays operate normally; all feedback signals are correctly fed back; signal and alarm functions are normal, signal display and alarm display on the simulation screen are accurate; the motor's no-load current is normal, and it can proceed with load test operation.

During the trial operation, an inspection of the electrical control and distribution equipment was conducted. The inspection included checking the data of all indicator instruments, the normal operation of electrical components, whether the contact points of conductors were loose, overheating, and other anomalies. No abnormal phenomena were found upon inspection.

During the linkage load debugging operation of the system, determine the optimal coordination time for each step, further adjust and refine the application software.

5. Equipment Maintenance

Upon receiving a repair call, follow the following requirements for the repair service:

1) Establish a maintenance quality file, with a clear record of each fault and repair issue for easy compilation of system operation status and identification of areas prone to failure. Take necessary measures to prevent common faults in cleaning fixtures.

2) Conduct regular or irregular inspections and follow-ups, actively seek opinions from managers and users, and address issues promptly.

3) Upon receiving a fault report from staff or users, make a record. Generally, a repair person is sent to the site within 24 hours to address the issue, and in urgent situations, personnel are dispatched immediately to handle the matter promptly.

Training Program

I. Training Standards for this Project:

1. Training Content: Equipment installation, precautions before operation, daily maintenance and care, operation and use of equipment, and control of equipment testing procedures.

2. Training for daily operation and usage of instruments, identification of common malfunctions and emergency solutions, as well as safety training, all provided with free system training throughout.

3. Train up to six operators, or customize the training team according to customer requirements.