1、 Preparation before installation

1. venue selection
   • Basic requirementsChoose a flat and solid concrete foundation with a bearing capacity that is 3-5 times the weight of the equipment (including adhesive). The basic surface levelness error is ≤ 2mm/m.
   • spatial layoutEnsure sufficient operating space around the equipment (≥ 1.5m in front and back, ≥ 1m on both sides) for easy maintenance, loading, and unloading.
   • environmental conditionsKeep away from vibration sources, corrosive gases, and high temperature environments, and avoid direct sunlight or rainwater erosion.
2. Equipment inspection
   • Open box inspectionVerify that the equipment model and specifications are consistent with the contract, and check if the components are complete and undamaged (such as rollers, bearings, reducers, etc.).
   • Pre assembly testingConduct no-load test runs on key components such as motors and reducers to confirm that there are no abnormal noises or vibrations.
3. Preparation of tools and materials
   • Tools: spirit level, jack, wrench, torque wrench, welding machine (if required), lifting equipment, etc.
   • Materials: foundation bolts, shims, shock pads, lubricating oil, sealant, etc.

2、 Installation steps

1. Equipment positioning and rough adjustment

• Lifting and positioningSlowly lift the main body of the rubber mixing machine onto the foundation using a crane or forklift, and preliminarily align the installation holes through a guiding device (such as a positioning pin).
• Horizontal adjustment：
  • Place level gauges in the axial and radial directions of the roller, and adjust the height of the shim to ensure a levelness error of ≤ 0.05mm/m.
  • Before fixing the anchor bolts, recheck the levelness to avoid deviation caused by tightening.

2. Anchor bolt fixation

• primary grouting：
  • Inject non shrink cement mortar (with a height of 2/3 of the hole depth) into the foundation hole, insert anchor bolts, and preliminarily fix them.
  • After the initial setting of the mortar, use a torque wrench to tighten the bolts according to the equipment instructions (usually gradually increasing the force in 2-3 times).
• grouting：
  • Pour mortar into the gap between the equipment base and the foundation, filling the surface of the base to ensure a tight connection between the equipment and the foundation.
  • Keep moist and cured for 7 days after grouting to prevent cracking.

3. Installation of transmission system

• Alignment of reducer and motor：
  • Use a dial gauge to check the coaxiality between the output shaft of the reducer and the roller shaft, with an error of ≤ 0.05mm.
  • Adjust the position of the motor to ensure even clearance between the pulley or coupling (usually 1-3mm) and meet the required tension.
• Belt/Coupling Installation：
  • Avoid twisting the belt during installation, and adjust the tension by pressing the middle of the belt to reduce the amount of depression (about 10-15mm).
  • The installation of the coupling requires the application of lubricating grease and the use of a dial gauge to detect radial and axial runout (≤ 0.1mm).

4. Installation of rollers and bearings

• Roller cleaningUse diesel or specialized cleaning agent to remove the rust proof oil on the surface of the roller, and check that there are no scratches or cracks on the surface.
• Bearing assembly：
  • Heat the bearing to 80-100 ℃ (oil bath or induction heating), quickly insert it into the roller journal to avoid jamming after cooling.
  • When installing the bearing end cover, apply sealant to prevent oil leakage.
• Roller distance adjustment：
  • Adjust the parallelism of the two rollers manually or through hydraulic devices, and use a feeler gauge to detect the gap between the rollers with an error of ≤ 0.05mm.
  • Lock and adjust the nut to prevent loosening during operation.

5. Installation of lubrication system

• Oil circuit connection：
  • Clean the fuel tank and oil pipes to ensure there are no impurities.
  • Connect components such as oil pumps, filters, and coolers, and avoid sharp bends or compression in the pipeline direction.
• Refueling and Exhaust：
  • Inject the specified grade of lubricating oil (such as N46 mechanical oil), and raise the oil level to the centerline of the oil mark.
  • Start the oil pump, check the oil outlet of each lubrication point, and eliminate the air in the pipeline.

6. Electrical system installation

• Wiring of distribution cabinet：
  • Connect the main circuit, control circuit, and grounding wire according to the electrical schematic diagram to ensure correct phase sequence.
  • Cable conduit protection to avoid mechanical damage.
• Debugging of safety devices：
  • Test emergency stop button, safety rope, roller temperature protection and other devices to ensure sensitive and reliable operation.
  • Adjust the height of the safety fence (usually ≥ 1.2m) to prevent personnel from coming into contact with rotating parts.

7. Trial operation and acceptance

• No load test：
  • Run for 2-4 hours and check for any abnormal noise, vibration, or oil leakage in the equipment.
  • Monitor motor current, bearing temperature (≤ 70 ℃), and roller surface temperature (≤ 80 ℃).
• Load test：
  • Gradually add the rubber material and observe the mixing effect (such as dispersibility and temperature uniformity).
  • Adjust the roller spacing and speed to ensure that the production parameters meet the process requirements.
• Final Acceptance：
  • Submit installation records, trial operation reports, and equipment qualification certificates, which shall be jointly signed and confirmed by the user, installation party, and supervisor.

3、 Installation precautions

1. Safety first：
   • Wear a safety helmet and protective gloves during installation to avoid falling objects or mechanical injuries.
   • Electrical wiring or mechanical maintenance can only be carried out after cutting off the power supply.
2. precision control：
   • Parameters such as levelness and coaxiality need to be strictly adjusted according to standards, otherwise it may lead to increased equipment wear or product defects.
3. Cleaning and rust prevention：
   • Before installation, rust and rust prevention treatment should be carried out on all contact surfaces to avoid jamming caused by rust during operation.
4. Document Management：
   • Save equipment manuals, drawings, certificates of conformity, and other materials for later maintenance and spare parts procurement.

4、 Common problems and solutions

• Problem 1: The roller runs unevenly
  • reasonBearing damage, roller parallelism exceeding tolerance, or poor alignment of the transmission system.
  • solveReplace bearings, readjust roller spacing, or realign transmission components.
• Problem 2: Lubricating oil leakage
  • reasonSeal aging, loose oil pipe joints, or high oil level.
  • solveReplace the sealing ring, tighten the joint, or adjust the oil level.
• Question 3: Electrical malfunction (such as motor not starting)
  • reasonPower phase loss, control circuit break, or protective device action.
  • solveCheck the power supply, repair the circuit, or reset the protective device.