Installation, commissioning and application of the TSAP-2000AS mixer from South Korea

The TSAP-2000AS asphalt concrete mixer from South Korea has now occupied a considerable proportion in China's highway engineering construction machinery due to its low price and reliable performance, and has played a significant role in the construction of the Bolai Expressway. This mixer is of intermittent type. The main control system is controlled by a PLC programmable controller, with a measurement accuracy of 0.2%. The designed maximum output is 160 tons per hour. It is equipped with a two-stage dust removal system of a one-stage cyclone dust collector and a two-stage bag dust collector, which complies with the standards set by the national environmental protection department. The production process is:

The Highway Bureau of Tai 'an City has completed the installation, commissioning and application of three mixers, and has accumulated certain experience and lessons.

1 Installation

Make sure all the necessary tools are ready before installation. If you need to prepare more than two sets of gas cutting tools and electric welding machines, you must also prepare a sledgehammer, hand chain hoist, crowbar, etc.

(2) Installing such a large and complex mixer has very high requirements for positioning. A 1cm error at the bottom will result in a difference of more than ten centimeters at the top. Therefore, before installation, the dimensions of the cement foundation must be rechecked, especially the positions of the anchor bolt holes should be precisely marked with cross ink lines, and then hoisted.

(3) One 50-ton crane and one 12-ton crane are used for hoisting. When hoisting, one should be familiar with and master the specific installation positions of each component. Especially for the accessories at high altitudes, they should be assembled on the ground to reduce the workload and danger in the air. If necessary, temporary foot pedals should also be made at high altitudes.

(4) When installing, work should be carried out in accordance with the principle of "primary before secondary, bottom before top, and easy before difficult". Due to the large amount of work involved in the installation of this set of equipment on the construction site, in order to shorten the installation time, various tasks must be carried out separately. For instance, the laying of asphalt, heat transfer oil pipelines, air pipes, cables and other tasks can all be conducted simultaneously. When installing, it is also necessary to strictly follow the installation process. Pipelines, lines, etc. must be both practical and aesthetically pleasing.

(5) After installation, the damaged surfaces of the equipment should be repainted to give people a beautiful appearance.

2 Debugging

After installation, the equipment needs to be debugged. When debugging, the principle of "starting from the zero to the whole, starting from the part to the whole" should be followed.

First, let each motor run independently to check if its operation and rotation direction are normal and if the mechanical rotating parts it drives are operating well. Then, run the several motors inside the related units in combination, closely monitor the operation conditions and observe if they are normal.

(2) The electronic scale should be calibrated with standard weights to ensure its accuracy is within 0.2%, and then the entire machine should be debugged.

(3) After the entire machine idles normally, it can be fed with materials for trial operation. By appraising the quality of the produced asphalt mixture and then appropriately adjusting the mixing parameters, the quality of the asphalt mixture can be brought to the best state. It is worth noting that the burner is a key part of the entire machine. Special attention should be paid to its debugging. In the early stage of production, it should be gradually adjusted to the best state according to the actual situation.

3 Applications

Each device has its own unique features. Now, we will introduce the application of this device on Bolai Road.

(1) The continuity of production must be maintained. Continuous production is an important aspect to ensure the stability of the quality of the mixture, because at the beginning of production, the temperature and gradation of the mixture all have a process of tending towards stability. In addition, since this equipment uses a cyclone dust collector in front of the bag filter bin, the dust recovered in the cyclone dust bin is all screened by the thermal lifting vibrating screen and enters the No. 1 hot material bin to mix with the sand. When the machine stops, the sand stops feeding, but these dusts continuously enter the No. 1 bin. The particles of these dusts range from 0.15 to 0.16mm, which is much smaller than the particle size of natural sand. If these dusts are not removed when the machine is restarted and it continues to be used, it will directly affect the mixing quality and may even produce substandard mixing materials. Therefore, in production, the number of startups and shutdowns should be minimized as much as possible.

(2) Adjust the mixing parameters correctly. Correctly adjusting the mixing parameters according to the production situation can make the control more precise, the mixing more uniform, and increase the service life of the mixer. For instance, in the production of SMA asphalt modified concrete, we carefully studied the timing of adding cellulose and the setting of dry and wet mixing times. Through multiple experiments, we summarized the best production process of first adding cellulose, then successively adding dry materials and stone powder, dry mixing for 8 seconds, and then wet mixing for 38 seconds. This has improved the quality of the mixing materials and production efficiency in the production process. This thus extends the service life of the machinery.