1、 Equipment Safety and Operating Standards

1. personal protection
   • Operators must wear protective equipment, including helmets, goggles, earplugs, anti slip gloves, and protective shoes, to prevent high temperatures, mechanical injuries, or noise damage.
   • Prohibit wearing loose items such as necklaces and watches to avoid getting caught up in equipment.
2. Equipment status check
   • Before starting, it is necessary to check whether the roller surface is flat and free of cracks, and whether the roller spacing meets the process requirements.
   • Confirm that the cooling system, lubrication system, and safety interlock devices (such as emergency stop buttons) are working properly.
   • Regularly calibrate the parallelism of the rollers and pressure sensors to ensure accuracy.
3. Safe operating procedures
   • Prohibit overloading operation and strictly operate according to process parameters (temperature, pressure, speed).
   • When adjusting the roller distance or cleaning the roller surface, the machine must be stopped and the power must be cut off, and special tools must be used.
   • When abnormal vibration, noise, or odor is detected, immediately shut down the machine and notify maintenance personnel.

2、 Process parameter control

1. temperature management
   • Set the roller temperature according to the material characteristics (such as preheating rubber to 80-120 ℃) to avoid local overheating and material degradation.
   • The temperature difference of the roller should be controlled within ± 5 ℃ to prevent uneven material thickness.
2. Speed matching
   • The speed of the front roller is slightly higher than that of the rear roller, forming shear force, but a large speed difference can easily cause material tearing.
   • The initial speed should start from low speed and gradually increase to meet the process requirements.
3. Material Pretreatment
   • The material should be dried to a moisture content of ≤ 1% to avoid bubbles or burning.
   • Anti sticking agents or lubricants need to be added to the formula to prevent the material from sticking to the rollers.

3、 Production environment and maintenance

1. Environmental Requirements
   • The workshop temperature should be controlled at 20-30 ℃, with humidity ≤ 60%, to prevent material moisture absorption or static electricity accumulation.
   • Keep the area around the equipment clean to prevent debris from getting caught up in the rollers.
2. routine maintenance
   • Clean the surface of the roller daily to prevent residue from affecting subsequent production.
   • Check the oil level and lubrication points of the gearbox every week, and replace the hydraulic oil every six months.
   • Regularly calibrate the thickness gauge and tension control system.
3. Long term shutdown management
   • When stopping, the roller should be cooled to below 50 ℃ to prevent thermal deformation.
   • Long term disuse requires covering with a dust cover and starting the equipment to idle for 30 minutes every quarter.

4、 Emergency response and personnel training

1. Emergency Response Plan
   • Equipped with fire extinguishers and first aid kits, operators need to be familiar with emergency handling procedures for burns, mechanical injuries, etc.
   • In the event of a pinch accident, it is strictly prohibited to forcefully pull or tug, and the emergency stop button should be immediately pressed.
2. personnel training
   • Operators need to undergo professional training to master equipment principles, process parameter adjustments, and safety regulations.
   • Regularly conduct safety drills to strengthen risk awareness.

5、 Common problems and preventive measures

1. Uneven material thickness
   • Reason: Uneven roller temperature and pressure fluctuations.
   • Measure: Calibrate the parallelism of the rollers and check the temperature control system.
2. Bubble or burnt
   • Reason: The material has a high moisture content and the roller temperature is too high.
   • Measures: Strengthen material pretreatment and reduce roller temperature.
3. Roller scratch
   • Reason: Hard impurities mixed into the material.
   • Measure: Install magnetic filters and clean metal particles from the material.

6、 Compliance and Records

• The operation records need to be fully saved, including parameters such as temperature, pressure, speed, and equipment maintenance.
• Regularly undergo third-party security audits to ensure compliance with international standards such as ISO and OSHA.

By strictly adhering to the above precautions, the operational risks of the three roll rolling mill can be significantly reduced, and production efficiency and product quality can be improved.