Gangda enhanced synchronous belt patent design train of thought
摘要：2014年以來(lái)，江蘇港達(dá)帶業(yè)有限公司，轉(zhuǎn)型升級(jí)，生產(chǎn)高端港達(dá)工業(yè)同步帶，gangda同步帶，加強(qiáng)型同步帶，改善同步帶動(dòng)態(tài)性能試驗(yàn)首先在同步帶骨架材料采用粘合和模量性能優(yōu)異的進(jìn)口線繩；在同步帶膠料配方設(shè)計(jì)上主體材料采用進(jìn)口氯丁橡膠和國(guó)產(chǎn)氯丁橡膠并用；在配方中的硫化體系中添加助硫化體系，提高膠料硫化程度和抗硫化還原能力；改善膠料配方中的粘合體系；改善膠料配方設(shè)計(jì)中的補(bǔ)強(qiáng)體系和添加抗屈撓疲勞體系；添加粘磨劑降低同步帶傳動(dòng)過(guò)程中的生熱，增強(qiáng)其耐磨性能。在膠料混煉工藝采用二段混煉，成型工藝增加停放時(shí)間。采用以上措施很好地提升了同步帶的動(dòng)態(tài)性能。
Abstract: since 2014, jiangsu port with industry co., LTD., the transformation and upgrading, the production of high-end port industrial synchronous belt, gangda synchronous belt, enhanced synchronous belt, improve the dynamic performance of synchronous belt test first in the synchronous belt skeleton materials with excellent adhesion and modulus of import cord; On synchronous belt rubber formulation design main body material imported neoprene and domestic neoprene with; Help the vulcanization system is added in the formulation of curing system, increase the degree of rubber vulcanization and reversion resistance; The adhesive system of rubber formulation was improved; Improve the recipe design of rubber reinforcing system and add the yield torsion fatigue system; Add glue grinding agent reduce heat generating in the process of synchronous belt transmission, enhance its wear resistance. In rubber mixing process adopts the binary mixing, molding process increase parking time. Adopt these measures is to improve the dynamic performance of synchronous belt.
關(guān)鍵詞：橡膠并用、助硫化體系、抗屈撓疲勞體系、動(dòng)態(tài)粘合性能、膠料二段混煉、成型停放時(shí)間、江蘇港達(dá)帶業(yè)有限公司、生產(chǎn)高端港達(dá)工業(yè)同步帶、gangda同步帶、加強(qiáng)型同步帶。
Keywords: rubber and, vulcanization system, flexible fatigue resistance system, dynamic adhesive performance, 2 of rubber mixing, molding, port, jiangsu parking time of tape industry co., LTD., the production of high-end port of industrial synchronous belt, gangda synchronous belt and enhanced synchronous belt.
隨著我國(guó)工業(yè)化技術(shù)水平的不斷提高，作為傳動(dòng)帶的同步帶質(zhì)量水平要求越來(lái)越高。江蘇港達(dá)帶業(yè)有限公司為了提升同步帶的質(zhì)量水平，采取了新技術(shù)和新材料及新工藝等措施。通過(guò)青島橡膠研究所、南京機(jī)電職業(yè)技術(shù)學(xué)校等單位技術(shù)合作，針對(duì)同步帶在使用過(guò)程中出現(xiàn)的問(wèn)題，在同步帶骨架材料、膠料配方、膠料混煉工藝、成型工藝上進(jìn)行改善，試驗(yàn)效果顯示，提升了同步帶動(dòng)態(tài)性能，延長(zhǎng)了同步帶的試驗(yàn)壽命，也在實(shí)際使用中取得了比較好的效果。
With the continuous improvement of technical level of industrialization in China, as a synchronous belt of the belt are increasingly demanding quality levels. Jiangsu port of tape industry co., LTD. In order to improve the quality of synchronous belt, adopted new technology and new materials and new technology. By Qingdao rubber research institute, nanjing electromechanical vocational and technical schools and other units and technical cooperation, in view of the synchronous belt the problem in use process, and the synchronous belt skeleton materials, rubber, rubber formula to improve on the mixing process, molding process and test results show that improve the dynamic performance of synchronous belt and prolong the life of the synchronous belt test, and achieved good effect in actual use.
一、同步帶膠料主體材料并用JPN電氣化學(xué)公司產(chǎn)品PW40。
A synchronous belt rubber, the main body of material and JPN PW40 electrical chemical company products.
原來(lái)同步帶膠料配方中主體材料氯丁橡膠全部采用國(guó)產(chǎn)CR322,由于國(guó)產(chǎn)膠在工藝性和質(zhì)量穩(wěn)定性上與進(jìn)口橡膠有一定的差距,工藝上的差距會(huì)造成混煉膠料性能不均勻,質(zhì)量不穩(wěn)定會(huì)造成產(chǎn)品質(zhì)量的波動(dòng)。為了改善產(chǎn)品質(zhì)量不穩(wěn)定這樣的情況，采用進(jìn)口橡膠同國(guó)產(chǎn)橡膠并用的方法，來(lái)提高國(guó)產(chǎn)橡膠在工藝性和質(zhì)量穩(wěn)定性上的不足。
Original synchronous belt neoprene rubber formulation main body material all adopt domestic CR322, because the domestic rubber on the manufacturability and quality stability and import rubber has a certain gap, mixing rubber technology gap will cause uneven performance, the quality is not stable will cause fluctuations in product quality. In order to improve the product quality unstable situation, using the method of import rubber with domestic rubber and to improve the quality of domestic rubber in the manufacturability and the lack of stability.
二、改善同步帶骨架材料。
Second, improve the synchronous belt skeleton material.
加強(qiáng)型同步帶的骨架材料是衡量同步帶動(dòng)態(tài)性能和質(zhì)量水平的指標(biāo)，一般同步帶生產(chǎn)廠家都采用玻璃纖維線繩，國(guó)產(chǎn)的玻璃纖維線繩產(chǎn)品質(zhì)量較國(guó)外同類產(chǎn)品質(zhì)量有一定差距：動(dòng)態(tài)粘合性能低、強(qiáng)力較小(約為進(jìn)口產(chǎn)品的1／2)、斷裂伸長(zhǎng)率較大、表面粗糙(有明顯的粒狀膠疙瘩)且直徑公差較大。目前，英國(guó)NGF公司、德國(guó)米勒公司、JPNporcher公司生產(chǎn)的同步帶用玻璃纖維線繩質(zhì)量上乘，根據(jù)性價(jià)比港達(dá)帶業(yè)采用上述公司生產(chǎn)的玻璃纖維線繩代替國(guó)產(chǎn)玻璃纖維線繩，改善gangda同步帶動(dòng)態(tài)性能。
Reinforced skeleton of synchronous belt material is measured by synchronous belt dynamic performance and quality indicators, generally synchronous belt manufacturers are using glass fiber cord, made of glass fibre cord product quality than similar foreign products quality has a certain gap: dynamic low adhesive performance, powerful smaller (about 1/2 of imported products), large elongation at break, surface roughness (has obvious granular gel bumps) and the larger diameter tolerance. At present, the British model NGF company, Germany miller, JPNporcher production of synchronous belt with glass fiber cord are superior in quality, according to the ratio of the port to take use of the company production of glass fiber cord instead of domestic glass fibre cord, improve the dynamic performance gangda synchronous belt.
三、在同步帶膠料配方中添加助硫化體系
Three, is added in the synchronous belt rubber formula helps the vulcanization system
在膠料配方中原來(lái)硫化體系用金屬氧化物加DM(1份)和NA-22(0.5份)，這樣的硫化體系對(duì)同步帶膠料性能技術(shù)要求來(lái)說(shuō),硫化程度不夠，抗老化性能不高。有時(shí)硫化程度不穩(wěn)定時(shí)會(huì)降低膠料的老化性能，生產(chǎn)出的同步帶產(chǎn)品在實(shí)際使用過(guò)程中常常會(huì)出現(xiàn)產(chǎn)品出現(xiàn)帶齒磨損，膠料斷裂等使用壽命降低的現(xiàn)象。為了解決這個(gè)問(wèn)題,港達(dá)帶業(yè)在原來(lái)的配方基礎(chǔ)上增加助硫化體系，添加抗硫化還原劑提高膠料硫化程度和抗硫化還原性能，這樣提升了gangda同步帶動(dòng)態(tài)性能及穩(wěn)定性。
Originally in the rubber formula using metal oxide vulcanization system with DM (1) and NA - 22 (0.5), the vulcanization system of technical requirements for the performance of synchronous belt material, degree of cure is not enough, anti-aging performance is not high. Sometimes the degree of cure instability will reduce the aging properties of rubber, produce product of synchronous belt in actual use process products often occur with tooth wear and fracture reduce the service life of phenomenon such as rubber. In order to solve this problem, the port to take industry on the basis of the original formula to increase help vulcanization system, adding sulfide reducing agent resistance increase the degree of rubber vulcanization and reversion resistance, this improved gangda synchronous belt dynamic performance and stability.
四、改善同步帶膠料動(dòng)態(tài)粘合性能。
Fourth, improve the synchronous belt dynamic rubber adhesive performance.
原來(lái)同步帶產(chǎn)品在實(shí)際使用過(guò)程中會(huì)出現(xiàn)帆布和線繩脫層現(xiàn)象，為了加強(qiáng)芯線繩的動(dòng)態(tài)粘合性能,把動(dòng)態(tài)粘合性能不好的古馬隆樹(shù)脂去掉，添加粘合附膠性能和動(dòng)態(tài)粘合性能比較好的粘合樹(shù)脂。這樣保證了橡膠膠料與線繩和帆布的粘合性能,又能提高膠料的動(dòng)態(tài)粘合能力。
Original synchronous belt products will appear in the process of actual use of canvas and cord delaminating phenomenon, in order to strengthen the dynamic adhesion performance of wire rope, remove the bad dynamic adhesive performance of coumarone resin, adding glue with adhesive performance and the dynamic and good adhesive resin adhesive performance. This ensures the rubber adhesive performance of rubber and cord and canvas, and can improve the dynamic rubber adhesive ability.
五、改善同步帶的抗屈撓疲勞體系。
Five, the improvement of synchronous belt system of flexible fatigue resistance.
原來(lái)同步帶產(chǎn)品的實(shí)際使用過(guò)程中出現(xiàn)過(guò)膠料斷裂的現(xiàn)象，其屈撓疲勞性能不理想,為了加強(qiáng)膠料和產(chǎn)品的抗屈撓疲勞性能,首先就生熱高的炭黑N330換成疲勞性能好，生熱低的N550。添加能提高屈撓疲勞性能的橡膠助劑HG-90，加入能提高膠料屈撓疲勞的動(dòng)態(tài)性能較好的防老劑H-71(1份），同時(shí)加入產(chǎn)品JC-069纖維狀鋁硅納米材料,這種材料不僅能提高橡膠的模量,而且生熱低，抗撕裂好，耐屈撓疲勞性能顯著，用量可以達(dá)到5份。
Synchronous belt products appeared in the process of the actual use of original rubber fracture phenomenon, its flexible fatigue performance is not ideal, in order to strengthen the rubber and product flexible fatigue resistance, high heat production in the first place of carbon black N330 into fatigue performance is good, low heat generating N550. Added can improve the fatigue properties of flexible rubber additives HG - 90, to join can improve flexible rubber fatigue stabilizer with better dynamic properties of H - 71 (1), at the same time to join JC - 069 fibrous aluminum silicon nanometer materials, the material can not only improve the modulus of rubber, and gave birth to low heat, tearing resistance, resistance to flexion bending fatigue performance significantly, dosage can achieve five copies.
六、在同步帶配方中添加耐磨劑。
Six, wear-resisting agent is added in the synchronous belt formula.
耐磨劑JTH-315是通用型聚四氟乙烯(PTFE)超微粉經(jīng)特殊工藝加工而成的低分子量微粉。為了提高同步帶的耐磨性能，在膠料配方中增加耐磨體系，添加耐磨劑JTH-315和抗撕裂樹(shù)脂HR-801.這兩種助劑相互配合，即提高了膠料的耐磨性能，又改善了膠料的工藝性能。
Wear-resisting agent JTH - 315 is a universal polytetrafluoroethylene (PTFE) superfine powder by the special process of low molecular weight micro powder. In order to improve wear resistance of synchronous belt, increase the wear resistant system in the rubber formula, add wear-resisting agent JTH HR - 801-315 and tensile resin. These two kinds of additives to cooperate with each other, namely to improve the wear resistance of the rubber, and improved the processing properties of the rubber.
七、優(yōu)化混煉膠和同步帶成型工藝。
Seven, optimization of mixing rubber and synchronous belt molding process.
同步帶膠料混煉膠工藝原來(lái)采用一段混煉，氯丁橡膠極易粘輥和焦燒，會(huì)造成膠料性能不均勻，導(dǎo)致同步帶產(chǎn)品性能不穩(wěn)定，出現(xiàn)產(chǎn)品在使用過(guò)程中的齒跟斷裂等現(xiàn)象。采用膠料二段混煉工藝，膠料性能和工藝得到提升，產(chǎn)品質(zhì)量水平和穩(wěn)定性得到提高。
Synchronous belt rubber mixing rubber process using a mixed, neoprene glue roller and charred extremely easily, cause rubber performance is uneven, lead to synchronous belt product performance is not stable, a product in the process of using the phenomenon such as teeth with fracture. 2 of rubber mixing process, sizing performance and technology promotion, product quality and stability was improved.
同步帶成型工藝原來(lái)沒(méi)有停放時(shí)間，成型好的帶坯直接放入硫化罐硫化。這樣成型過(guò)程中所使用的溶劑沒(méi)有完全揮發(fā)，膠料由于成型過(guò)程中運(yùn)動(dòng)沒(méi)有恢復(fù)過(guò)程的時(shí)間，會(huì)導(dǎo)致同步帶產(chǎn)品質(zhì)量水平的不穩(wěn)定性。
Synchronous belt molding process was no parking time, forming a good strip directly into vulcanizing pot sulfide. So that the solvent used in the process of forming not volatilize, rubber because of the movement in the process of forming no recovery time, will lead to the instability of synchronous belt product quality level.
八、增加張力調(diào)整同步帶節(jié)線長(zhǎng)度
Eight, increase tension adjustment of synchronous belt pitch line length
由于加強(qiáng)型同步帶，港達(dá)帶業(yè)采用了進(jìn)口玻璃纖維線，拉力強(qiáng)度從400牛頓左右提高到800牛頓以上，所以在成型過(guò)程中將成型機(jī)張力加大了20%左右，這樣能夠保證港達(dá)同步帶節(jié)線長(zhǎng)度控制在國(guó)標(biāo)以內(nèi)更小范圍。
Due to enhanced synchronous belt, the port to take industry adopted imported glass fiber yarn, the tensile strength increased from about 400 Newton to more than 800 Newton, so in molding process, molding machine tension increased by about 20%, it can ensure the port of synchronous belt pitch line length control in the national standard within a small range.
結(jié)束語(yǔ)：在同步帶骨架材料采用進(jìn)口玻璃纖維線繩，提升同步帶的動(dòng)態(tài)性能和質(zhì)量水平；膠料設(shè)計(jì)配方中優(yōu)化主體材料，通過(guò)采用進(jìn)口氯丁橡膠和國(guó)產(chǎn)氯丁橡膠并用，提升了同步帶膠料主體材料使用的穩(wěn)定性能和質(zhì)量水平；通過(guò)在同步帶膠料配方硫化體系中添加助硫化體系，提高膠料硫化程度和抗硫化還原性能；通過(guò)改善膠料配方中的粘合體系，加強(qiáng)同步帶帆布和強(qiáng)力材料線繩的附膠程度和動(dòng)態(tài)粘合性能；通過(guò)改善膠料配方設(shè)計(jì)中的補(bǔ)強(qiáng)體系和添加抗屈撓疲勞體系，提升膠料在同步帶傳動(dòng)運(yùn)轉(zhuǎn)過(guò)程中的耐屈撓疲勞能力；添加耐磨劑降低同步帶傳動(dòng)過(guò)程中的生熱，增強(qiáng)其耐磨性能；優(yōu)化膠料混煉工藝和同步帶成型工藝，提升產(chǎn)品質(zhì)量水平的穩(wěn)定性能，增加張力調(diào)整同步帶節(jié)線長(zhǎng)度。采用以上措施很好的提升了同步帶的使用壽命，取得了非常好的使用效果。
Conclusion: in the synchronous belt skeleton materials imported glass fiber cord, enhance the level of quality and dynamic performance of synchronous belt; Rubber design formula optimization subject material, by using imported neoprene and domestic neoprene with, improve the stability of the synchronous belt rubber using the main performance and quality levels; Compounds through the synchronous belt vulcanizing system add to vulcanization system and improve the sizing degree of cure and reversion resistance; Compounds by improving the bonding system, strengthen synchronous belt canvas and powerful cord attached to the glue material and dynamic adhesive performance; By improving the formula design of rubber reinforcing system and adding flexible fatigue resistance system, in the process of ascension in rubber synchronous belt drive running flexible fatigue resistance ability; Add wear-resisting agent to reduce the heat generating in the process of synchronous belt transmission, enhance its wear resistance; Optimization of rubber mixing process and synchronous belt forming process, improve the level of product quality stability, increase the tension adjustment of synchronous belt pitch line length. Using the above measures good promoted the service life of the synchronous belt, has obtained the very good use effect.
朱彤（1971-）：機(jī)電一體化專業(yè)、工程師職稱，江蘇港達(dá)帶業(yè)有限公司董事長(zhǎng)、總經(jīng)理，從事工業(yè)同步帶，生產(chǎn)管理、配方研究、工藝設(shè)計(jì)、質(zhì)量管理等。
Zhu tong (1971 -) : mechanical and electrical integration of professional titles, engineers, jiangsu port of tape industry co., LTD., chairman of the board of directors, general manager, engaged in industrial synchronous belt, the production management, formulation research, process design, quality management, etc.
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