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The word random may come to mind when thinking about the details in the process of rubber mixing, but it is far from the truth. Meeting a specific quality threshold on a rubber mixing project requires precision and reliability, and this is ultimately determined by the equipment used. Advanced rubber mixer technology is game changing. Modern rubber mixers incorporate intelligent control systems to eliminate error and uncertainty. The technology focus is on improving precision control while the human focus is on efficiently operating the rubber processor. A competitive advantage is gained by switching to precision control and the correct equipment.
The Control System Does All the Work
Using older mixers requires a lot of attention from operators. They need to consistently monitor the temperature gauge, listen to the mixer for tiny changes, and when the time seems right, adjust the rotor speed. A single mistake could ruin the batch. An intelligent control system on a rubber mixer changes that scenario. The control system utilizes many sensors to track the mixer current, to monitor temperature, and to monitor pressure. Then, it makes the system changes to keep variables in the set range. Because of this, the operator lacks the need to stand by and question themselves. Some control systems can adapt and create 20 different mixing steps and keep 20 saved recipe spaces. This automation makes product changeovers easy. All you need to do is pull up the control recipe, and the control system will know the rest.
The Challenge of Ideal Temperature Control
The main challenge of mixing rubber is temperature control. Pick too hot of a temperature, and you prematurely cure the material. Pick too low of a temperature, and the physical characteristics of the material are suboptimal. Control systems can utilize the function of a tight PID temperature control system within the rubber mixing. It is expected by control systems to have a temperature control of plus or minus 1 degree Celsius. The smart technology of control systems can manage many more complex and challenging control systems. Control systems can be set to constantly control the circulation of the mixing, and the control system can still be set to control the cooling and the heating. The systems are very beneficial for rubber mixing, and for other materials with similar characteristics. During the mixing of materials, control systems can also be used as a smart technology to manage the control and balance of the systems.
Managing Recipes Without the Headaches
Using old mixers came with the frustration of trying to recreate a successful batch, and for a while, old mixers seemed to offer no solution to that problem. Getting a recipe just right might yield a good batch, but replicating that result took a lot of effort and skill. With the intelligent control system, that problem has been eliminated. Recipes can be saved with the system, including every specification of the mixing process. Parameters for mixing time, temperature, mixing speed etc. When a new batch of the same material needs to be mixed, the recipe is selected on the touchscreen and the process is started. The mixer is then programmed to follow the same steps every time. The ability to store recipes is invaluable to factories that use the same production line for many products. Switching from a tire tread compound to a hose formulation can be done in a matter of minutes, wasting no raw material and eliminating guesswork.
Real Time Monitoring Keeps You Informed
You need to monitor the mixing process to the extent possible without having to do something like open the mixing chamber, which would let heat escape from the chamber. Intelligent control systems let you access the information you need with a fully customizable display that shows you where a mixing process is at any point with the mixing chamber's temperature, the machine's power consumption, the time elapsed, and the position of the ram. Some systems can even display the instantaneous power curve for the entire mixing process and give you an idea of the mixing material's characteristics at every point in the process. You can immediately see incorrect mixing process inputs and take the necessary corrective action for preventing a mixing process from failing to meet batch requirements. You can also identify the source of the failing batch. Defects occurred due to elevated mixing temperature. The mixing time limit was exceeded. The system was configured incorrectly. The data reconciles defects.
Better Oversight through the Factory Network
Connectivity is becoming more critical to modern manufacturing, and there is good evidence that a high quality rubber mixer fits that definition. These systems tend to include an intelligent control system with an Ethernet communication port, which allows connecting the system to the factory network, or, in some cases, a cloud based monitoring system. The impacts of this are very positive. Data from production can be retrieved from a number of systems. Recipes can be changed without having to go to the control panel of each mixer. Production status can be checked from any location. Changes can also be made to the applications to suit the users. For data driven operations, the value of these tools cannot be overstated. Connectivity moves the factory from reactive to true measurement based proactive process improvement. All of this is a huge improvement.
More Precision Means Less Waste and Increased Profitability
More precision means that there will be less waste. Each batch that comes out of the rubber mixer done right the first time will be less batches that will need to be done again and tossed out. This will lower the cost of wasting final material, the cost of the energy, and the cost of the labor to do the work. An intelligent control system will help you meet your targets , meaning that you will have a consistently lower scrap rate. This allows you to increase the good batches going through the system. Since you will now increase the good batches in each shift, you will increase your profit. This is a good argument for production managers. The intelligent control system will help you operate your system in an doing it efficiently not to do it in an efficiently fit system.