Batch Mixer Inspection for Optimal Performance

September 2015

Bob McNabbHF Mixing Group

Sales Manager, North America

HF MIXING GROUP

2

HF MIXING GROUP

MIXING GROUPFreudenberg, Germany

GROUP Harburg-Freudenberger Maschinenbau GmbH

TireTech GROUPHamburg, Germany

Press+LipidTechHamburg, Germany

• Batch Mixing Equipment

• Continuous Mixing Equipment

Harburg-Freudenberger Maschinenbau

GmbH

Freudenberg, Germany

Rubber Machinery, IncTopeka, KS, US

Farrel

Rochdale, UK

Pomini

Rescaldina, Italy

Farrel Pomini

Ansonia, US

HF NaJUS, a.s.

Dubnica n. Vahom , Slovakia

• Extrusion Manchinery

• Tire Building Machines

• CuringPresses

Harburg-Freudenberger Maschinenbau

GmbHHamburg, Germany

Belišće d.o.o.Belišće, Croatia

Rubber Machinery, Inc.Akron, OH, US

3

Mixer Inspection and Maintenance Service

EFS INSPECTION CAPABILITIES

Inspections of Traditional Mixers in the NAFTA region:

•HFRM Manufactured

•Harburg Freudenberg Intermesh

•Farrel LTD Tangential

•Pomini Manufacture

•Kobelco Manufacture

•Others.

•All makes, sizes

•Yearly Inspection Maintenance Contracts

Inspection and condition assessment included in a preventive

maintenance program together with knowledge of component life and

machine history can be used to establish a wear trend to form the

foundation for a mechanical maintenance program to ensure peak mixer

performance.

So how do we get there?

Know your mixer condition.

Knowledge of the Individual mixer by regular INSPECTIONS

History of the mixer needs to be established and updated

at regular yearly intervals

•Document the mixer specifications

•Document the compounds mixed

•Confirm fill factors

•Note the shifts per day

•Note pounds of rubber produced

•Update component parts life

expectancy

•Reference past machine history

•Detail the current condition

of the mixer

Low Impact FailuresComponents that do not have an impact on other

components.

Repair them when needed.

No collateral impacts and it is not broken, don’t fix it.

Spare Parts in stock or readily available.

High Impact FailuresComponents failures that impact operations and possibly

cause damage to other components.

Two groups

•Predict with reasonable accuracy based on information

provided by inspections .Take preventive action knowing that

we are not being overly conservative in our decision to

repair before failure.

•Cannot predict failure with reasonable accuracy.

•Run to failure and accept the impacts that

unscheduled failures and unreliable machines have

on operations

•Bring the machine down for repair, and accept the cost of

shortening component lives by taking early preventive

action.

Why? To avoid:

• Mixer Inspection To Determine:

– Process control remains accurate

– Lubrication program is adequate

– Machine adjustments are indicated

– Wear component replacement is warranted

– Planning for future Capital Expenditures.

E.L.C.I.

Equipment Life Cycle Indicator

E.L.C.I. is a data warehouse system which is able to give a forecast of the

remaining main components life-time of the internal mixer on the basis of

client-specific and tech-nological basis information and the process experience

of our engineers as well as based on information taken from inspections of

the internal mixer.

With the help of the results coming from this system future repairs or

replacements of main components can be planned accurately timed and

unplanned breakdowns/shut-downs of the internal mixer including all negative

consequences can be avoided.

Rotor Tip to Chamber Bore

Measure always from rotor top/wing!

This means, you have to turn the rotor.

13

Mixing Chamber

E.L.C.I. Description

14

Wing

15

Rotor End to End Plate

e

f

g

h

drive side

16

Endplates

Point m (from endplate to endplate)

m

Point l

l

Mixing Chamber Throat (A) and also Feeding

Device (B)

w - y

u - v

s - x t - v

st - uv

Mixing Chamber Throat (A) and also Feeding Device (B)

Shaft (measurement in the area of the corner

ledges)

w

s

Shaft (measurement in the area of the corner ledges)

x

u

Rotors: medium wear

23

Mixing Chamber: very heavy wear

24

GK 320 E Comparison of Endplates Between Mixers

wear

in m

m

running time in years

25

GK 320 E Comparison of Rotor Front Side Left

wear

in m

m

running time in years

26

GK 320 E Comparison of Rotor Wings Between Mixers

wear

in m

m

running time in years

27

Rotor axial floatMeasures the axial play of rotors to

detect bearing problems which could

lead to internal damage of components.

PSurfaceFlow Direction

Compound Ingredients

Oil Disposal

Take temperature readings

Check lubrication flow

Observe waste oil flow

Measure wear gaps

Dust Rings Observation

Electronic device to determine the gap measurements. There are up to three ports available.

INTRODUCING ELECTRONIC GAP CONTROL TECHNOLOGY

Angle sensor for determining the rotor position

Measuring method with new sensor

The sensor is fixed on the rotor with a magnet and adhesive tape

min. gap: 5 mmmax. gap: 14 mm

Measuring grid

measuring points radial: 19

measuring points axial: 9

measuring points total: 171

Controller Software to automate the measuring process

Evaluationof the measurement result

gaps depicted in colours

Result

the new measuring method provides exhaustive precise and replicable values.

nearly automated measuring method with fast and error-free sequences

Knowledge:

a visual inspection is still needed

the mixing chamber must be cleaned very carefully

the manual rotation of the rotors need to be facilitated

38

Predictive Maintenance with Online Condition Monitoring

Dust Seals

Mixing Chambers

Gear Box

Motor

Condition Monitoring indentifies deviations from a nominal condition, by using

special sensors, to predict the wear condition of a component, before the

machine breaks down.

Online-Chamber Side thickness measurement system

Ultrasonic

Sensor

area of “gun-drilled”

cooling channels

On Line Dust Stop measuring system

Ring gap measurement Ring temperature measurement

Dust Stop without sufficient pressure or out of adjustment

41

42

System Solution, from Sensor to Maintenance Plan

Information

Planning

Supervision

Visualization

Conversion

Calculation

Signal

captureSensor

43

Machine Data Acquisition and Condition Monitoring

Elapsed hour and event counters for all motors,

valves and sensors are displayed as trend and as

table. All information are stored in the ADVISE

database.

SUPPORT AND AUXILIARY EQUIPMENT

Dust ring lubrication

Operation of pump

Leakage of lines

Flow rates

Motor/Gear/Coupling

Grease lubrication

Operation of pump

Canister Level

Leakage of lines

Flow rates

Hydraulic System

Pressure, system

Leakage

Pump

Temperatures

Functions

Timing of

Ram

Latch

Door

Piping Tightness

Zone Flows

Temperatures

Inflow

Outflow

Mixer Drive Checks

Motor

Noise or vibration

Gearbox

Lubricator Function

Oil level

Oil contamination

Bearing

temperatures

Alignments

HS Motor to

Gearbox

LS Gearbox to mixer

Couplings

Customer

Location

Customer‘s specific machines‘ name

Mixer Type

Machine No.

Start-up

Inspection Date, Inspector‘s name

Inspection Report

Summary of the Inspection

• Rotors ZZ-2

- medium wear

• Endplates

- medium wear, deformed

• Dust Sealing

- medium to heavy wear

- lubrication not running

• Mixing Chamber

- very heavy wear

• Drop Door

- medium wear

• Interlocking Latch + Interlocking Plate

- heavy wear

• Feeding Hopper

- very heavy wear

- chromium-plating broken out

• Feeding Door

- material leakage

Maintenance

• Maintenance should be improved.

HF recommendations:

• Replace the feeding hopper and ram, including all guiding and sealing

elements.

• Replace the mixing chamber

• Replace the dust sealing.

• Replace the interlocking latch and the interlocking plate.

• Clean and check all elements of the lubrication pumps.

• Replace safety valves at distributor mixing block.

• Check the cooling system (rotors are very hot).

• Gearbox should be checked by manufacter.

• INSTALL ORIGINAL FEEDING DOOR SAFETY PIN !!! MORTAL DANGER !!!

Next inspection due...........

MAITENANCE INSPECTION SUMMARY

It is vital to implement the best tools and techniques available for

inspection and condition assessment of all internal mixers. Inspection

technicians are the CUSTOMERS eyes and ears. They must posses

the training and tools needed to inspect and report, so good business

decisions may be made.

This is what has driven the

HF Mixing Group to develop

and release these new

inspection technologies.

bob.mcnabb@us.hf-group.com

QUESTIONS?