Rotary tablet press use:

The GZPS-660 dual-discharge high-speed rotary tablet press is a product of the British Manistee Company in the 1990s. After continuous technological innovation and improvement, it has a higher degree of automation, better operability, faster production speed, and more stable performance. Strong and lower working noise.

Its technology is at the leading domestic level. (It is different from other similar products in China. It is a double-discharge high-speed tablet press developed on the basis of the single-discharge tablet press of Kian Company in the 1980s, or a double-discharge high-speed tablet press that imitates the technology of Feite in the 1980s. ).

Features:

The main motor of the tablet press drives the turntable to rotate after being decelerated by a worm through an AC variable frequency stepless speed regulator. The rotation of the turntable causes the upper and lower punches to move up and down relative to each other under the action of the guide rail. Granules or powders are compressed into tablets through processes such as filling, pre-pressing, main pressing, and discharging.

During the whole tablet pressing process, the control system implements automatic control of the tablet weight through the detection, transmission, calculation, and processing of the pressure signal, automatic rejection of waste tablets, automatic sampling and fault display.

Technical Parameters

Configuration table of main electrical parts of double-discharge high-speed tablet press (Siemens model)

Random general tool list

Random special tools and wearing parts

Technical performance description of GZPS-660 series double-discharge high-speed tablet press

1. Product overview: GZPS series double-discharge high-speed tablet presses are mainly used in the pharmaceutical, chemical, food, electronics, metallurgy, daily necessities and other industries. This machine can press various granular raw materials into round tablets, special-shaped tablets, cartoon films, double-sided positioning and engraving films, etc. This series of products have the characteristics of high manufacturing precision, advanced automation level, fast production speed, stable and reliable use, and low working noise.

It can improve the production quality of medicines, improve the production environment, reduce labor intensity, reduce the loss of raw materials, and reduce production costs. It is an ideal equipment for pharmaceutical factories to implement production technology transformation and new projects and meet GMP requirements. The machine is a double-discharge mechanism with reasonable structure, high production efficiency, high pressure, good stability, and complete dust-proof facilities.

2. Product use conditions 2.1 Applicable granule conditions ●   Synthetic starch granules: The granules are uniform and not humid, and the proportion of fine powder (above 60 mesh) in the granules does not exceed one third. ●   Traditional Chinese medicine granules: The whole extract, semi-extract and raw powder granules are required to be non-moist and have certain fluidity. The hardness and uniformity requirements are not strict. ●   Particle size range: 12-60 mesh, with compressibility and fluidity. ●   Dry powder can also be used for tableting. ●   Not suitable for semi-solid, moist molecules and powders with extremely small particles (>100 mesh).




 

2.2 Molding time and maximum pressure
Molding time ≥20ms,
maximum molding pressure: ≤100KN;

2.3 The equipment
should be stored in a place where the relative humidity is not more than 86%, the room temperature is not more than 35℃, and there is a sheltered, rainproof and well-ventilated place.

2.4 Working environment conditions
GZPS series double-discharge high-speed tablet press should work in an environment with an ambient temperature of +10～35℃ and a relative humidity of <85%. Should meet the requirements of GMP.

2.5 The working power supply
adopts 380V, 50Hz, three-phase five-wire system, N line and PE line can not interfere with each other, and the total power is about 20KW.

3. Technical specifications of GZPS series double-discharge high-speed tablet press. Qualified product rate: The average tablet weight control accuracy is within ±2% (20 tablets/group). Single tablet weight control: when the tablet weight is less than 0.3g, the single tablet weight is within ±4%; when the tablet weight is ≥0.3g, the single tablet weight is within ±3%; the production qualified product rate is 100%. Material loss ≤0.5%.

Working principle: 1.1 Working principle: The stamping combination includes: punch plate combination, upper and lower punches, middle die, upper and lower pre-pressing wheels, upper and lower main pressing wheels, left and right filling devices, upper guide plate, lower guide cam, etc. The upper and lower punches and the middle die are evenly distributed on the circumference of the punch plate assembly. The punch combination is divided into three parts: upper, middle and lower. The upper and lower punches and the middle die are respectively installed in the punching holes on the perimeter of the punching disc. The upper punch is guided by a continuous cam guide, and the lower punch is guided by the downward cam guide, the guide for adjusting the filling depth, and the ejection guide. The tails of the upper and lower punches are embedded on a fixed curved guide rail. When the turntable rotates, the upper and lower punches move up and down along the curved track, and the process of pressing the tablet is completed by the pressing action of the pressing wheel. This machine is a double-discharge mechanism, which makes reasonable use of each station to alternately complete product filling, pre-pressing, main pressing, and product launching.

1.2 Work flow:
The work flow of the tablet press includes filling, dosing, pre-pressing, and main pressing to form tablets. The upper and lower punches are driven by the punch plate to move clockwise along the upper and lower guide rails respectively. When the punch moves to the filling section, the upper punch moves upward to bypass the forced feeder. At the same time, the lower punch moves downward due to the action of the pull-down cam. At this time, the surface of the lower punch exactly forms a cavity in the hollow mold, and the powder particles are stirred into the cavity through the forced feeder impeller. When the lower punch passes the lowest point of the pull-down cam, overfilling is formed. The punch plate continues to move, and when the lower punch passes the cam, it gradually moves upward, and pushes the excess powder particles in the cavity out of the middle die hole and enters the quantitative section. The surface of the filling cam is level, the lower punch keeps the horizontal movement state, and the surplus powder particles on the upper surface of the middle mold are scraped out by the quantitative scraper, so that the filling amount of powder particles in each middle mold hole is kept consistent. In order to prevent the powder in the middle mold hole from being thrown out, a cover plate is installed after the quantitative scraper. When the middle mold hole is removed from the cover plate, the upper punch enters the middle mold hole. When the punch passes the pre-pressing wheel, it completes the pre-compression action; then continues to pass the main pressing wheel to complete the compaction action; finally, through the film ejecting cam, the upper punch moves up, the lower punch pushes up, and the compressed tablets are pushed out and enter The tablet output device completes a tablet pressing process. The machine has a double-discharge structure, and the punching plate assembly realizes two of the above-mentioned actions every revolution.

1. Structural features: The
main structure of the machine mainly includes bottom plate, front and rear pillars, turbine box, base, punch plate combination, upper support column, top plate, large and small pressure wheels, upper top plate, plexiglass door, protective plate, and control cabinet , And other parts. The bottom plate, the front and rear supports, the base and the turbine box are connected by bolts to form a fixed frame, which constitutes the foundation of the tablet press, and the turbine box is fixed on the base. Based on the base, the film ejection cam, the upper support column, the upper pressing wheel, the lower pressing cam, the filling adjustment mechanism, the cover plate, the pre-pressing wheel, and other components are installed on the base. The lower ends of the four pillars are fixed on the base, and the upper end has an upper top plate to form a stable frame structure with extremely high bending resistance and torsion resistance. Two column-type tension sensors are installed in the front right and rear left support columns to detect the pressure of the pressure roller. The upper top plate is connected with the upper rail plate. Two sets of pre-pressing wheels are installed on the upper rail plate. Two sets of main pressing wheels are installed on the upper top plate and the support column; four plexiglass doors are installed on the four sides of the upper top plate, and are equipped with telescopic bolts for easy opening. The telescopic bolts provide support and locking force for the opening and closing of the glass door. Frame structure, reasonable structure, convenient operation and cleaning, and more stable equipment operation.

2. Main drive system:
2.1. Drive system: Main drive system: its function is to provide power for the tablet press. The main drive system not only provides sufficient torque but also has adjustable speed. Even in the event of a large impact load, the speed is still stable and reliable. The main drive system mainly includes high-power AC motors, frequency converters, large and small pulleys, synchronous toothed belts, hand wheels, turbine worm gear reducers, main drive helical gears, internal gears, and helical gears. The machine adopts frequency conversion technology, which has the advantages of energy saving and consumption reduction, reliable control, stable operation and low noise. The inverter itself has multiple protection functions such as over voltage, low voltage and over current. The output parameters can be used to monitor the actuators. Once an abnormality occurs, the protection function will operate, the inverter will stop output, and the fault code will be displayed at the same time to indicate the cause of the fault, ensuring the safe and reliable operation of the motor. The output shaft of the main motor is directly connected to the large pulley through a flat key, and the large pulley transmits power to the small pulley through a toothed belt. The small pulley drives the worm to rotate, and the worm drives the turbine to rotate. The other end of the turbine output shaft is equipped with a small helical gear, and the small helical gear drives the inner ring gear connected with the punch plate assembly. Make the punch plate assembly rotate around the central axis. The handwheel is generally used when changing the die or repairing the machine. Due to the adoption of the synchronous toothed belt, the slip rate of the belt is reduced and the equipment noise is reduced.

2.2 Turbine and worm reducer: The worm and worm reducer is a key component of the main drive. The turbine reducer can reduce the speed and increase the torque. The number of worm heads of this machine is four, and the speed ratio is large. The machining of turbines and vortex rods adopts precision tooth profile grinding treatment, and the machining accuracy is up to 6 levels. The turbine and worm have been precisely installed when the equipment leaves the factory, and no adjustment is required.

3. Forced feeding system:
the composition of forced feeding device:
mainly composed of feeding motor, feeding turbine reducer, coupling, forced feeding device, barrel, connecting pipe, feeding platform, and leveling mechanism.
The feeding motor and turbo reducer are installed in the lower part of the machine base. The output shaft of the turbo reducer is connected with the input shaft of the gear box of the forced feeder through a coupling. The input shaft drives the gear shaft to rotate, and the lower part of the gear box has two output shafts, respectively equipped with two impellers, and the gear drives the two impellers to rotate. There is a blanking trough at the bottom of the feeder shell, and the lower part of the blanking trough coincides with the surface of the middle punching plate, and is used to fill the material in the feeder into the middle mold. The front end of the feeder blanking trough is equipped with two receiving scrapers, which are used to recover the material on the surface of the middle punching plate to the feeder. There are stop handles on both sides of the feeder, which can be quickly connected with the feeding platform.

4. Single chip rejection and batch rejection system:
4.1 Single chip rejection: The system compares the set and detection pressures, if the upper limit or lower limit is exceeded, an execution signal will be issued to reject a single unqualified tablet to the waste channel . (Optional)

4.2 Batch rejection: switch the solenoid valve for the channel, automatically transfer to the waste channel, and reject the unqualified drugs in batches. The film ejection system consists of a reject and ejection device, a film ejection tank and a film hopper. The design quality of the system program is the prerequisite for improving the accuracy of product control. Only good program design, selection of high-precision sensors and fine assembly adjustments can achieve accurate and error-free actions.

5. Weight adjustment mechanism: It
adopts precision screw rod linkage inclined surface jacking mechanism to control the filling guide with high adjustment accuracy and no return.

6. Lubrication system: (See the equipment lubrication chapter for specific instructions)
This machine has four sets of lubrication systems. Circulating lubrication system, thin oil lubrication system, electric dry oil lubrication system. Manual dry oil lubrication system.
6.1. Circulating filter lubrication system (lubricated by continuously running lubrication pump) lubrication location: drive helical gear and bearing, main shaft.
6.2 Thin oil lubrication system (intermittent micro-flow automatic pressure thin oil lubrication system) lubrication position: mainly the lubrication of the upper and lower punch bodies.
6.3 The lubrication position of the electric dry oil lubrication system: mainly the lubrication of the upper and lower punch body heads. 6.4 Lubrication position of manual dry oil lubrication system: main and pre-pressure wheel bearings.

7. Hydraulic system: The
hydraulic system adopts a block structure, and its function is to support and buffer to facilitate main pressure adjustment and pressure overload protection. It includes hydraulic pump station, pressure limiting valve, one-way throttle valve, accumulator, pressure sensor, main pressure cylinder, hydraulic pipeline and joints.
The working principle of the hydraulic system: The
system controls the safety overload mechanism that specifies the maximum pressure level when manufacturing a specific tablet. When an overload occurs, the oil in the main overload cylinder is transferred to the accumulator (at this time, the lower bracket is allowed to move down), thereby compressing the nitrogen in the accumulator. When the overload condition has been removed, the accumulator re-injects oil into the overload cylinder, thereby returning the system to its original state.

8. Dust removal system: In order to remove the dust in the tablet press room in time and reduce the abrasion of the powder on the punch, the machine is equipped with a special dust collection device. At the same height as the upper punch plate, a U-shaped dust cover is provided on the side of the pressure roller. An observation hole is provided on the dust cover for easy observation. Plexiglass dust cover is also provided on the feeding position. From a functional point of view, the above punch plate is the boundary. The upper part of the tablet press is completely sealed, which effectively prevents dust and powder from polluting and wearing the top of the punch. In this closed room, due to the presence of positive air pressure, dust and powder are difficult enter. A push-pull dust cover is used for dust prevention of the lower punch to prevent dust and powder from contaminating and abrading the lower punch. The lower dust cover is easy to disassemble, and it can be removed by pulling it gently for easy cleaning.

 

9. No hand wheel operating system: no hand wheel operation, synchronous motor controls the main pressure and filling control execution, and the action scale value is displayed in real time.

10. Electrical control system 10.1 Introduction to electrical control system The pressure detection part of the electrical control system of the GZPK series tablet press is the tablet weight detection and control device of the tablet press, that is, the punch pressure is detected by the tension sensor, and the central control unit PLC detects and Analyze and judge, adjust the filling depth of the tablet press according to the predetermined control mode, and realize the automatic control of the tablet filling volume of the tablet press. At the same time, it plays a role of safety protection for the supply of the tablet press mold and powder. It can greatly improve the qualification rate of tablets, thereby reducing production costs. The system is simple to operate, convenient to maintain, high in control accuracy, and stable and reliable in operation.
 

10.2 Selection of electrical materials
This machine uses Siemens S7-200smart series programmable controller as the control center, and is equipped with analog modules and remote data communication interfaces. The operating unit uses Siemens 10 "color touch screen. The host inverter and feeding inverter are both It adopts Siemens products. The executive system adopts the products of internationally renowned brand companies to ensure the stability and reliability of the electrical control system.

10.3 Main functions
(1) The main machine of the tablet press and the feeding motor are driven by frequency converters. In production use, the production speed can be continuously adjusted as required.
(2) With automatic control of tablet weight, automatic identification of waste tablets (optional single-chip rejection) and batch rejection functions. The average tablet weight control accuracy is within ±2%. Single tablet weight control: when the tablet weight is less than 0.3g, the single tablet weight is within ±4%; when the tablet weight ≥0.3g, the single tablet weight is within ±3%;
(3) Automatic fault detection and shutdown Alarm function: fault alarm is divided into hardware and software alarm. When a failure occurs, the pop-up failure window can promptly and accurately display the cause of the failure and the time of occurrence. The system adopts Chinese operation display interface, which can display: main production page, parameter configuration page, equipment output page, alarm page, punch pressure page and many other display operation pages.

10.4 Electrical safety system
Our company's products have passed the international CE certification. This machine strictly complies with the safety regulations of the IEC International Electrotechnical Organization. When the equipment leaves the factory, it will test the system's insulation withstand voltage, grounding continuity, and safety signs. 380V, 50Hz, three-phase five-wire system is adopted, and the N line and PE line will never interfere with each other.

11. Selection of materials The machine selects the materials used in strict accordance with GMP requirements. The surfaces of the moving parts in the tablet press room of the equipment are not painted or electroplated, and the parts in contact with drugs such as the middle punching plate, the feeder chassis, the operating surface, and the ejection guide The tank, cabinet body and protective door are all made of stainless steel. The pressing plate is polytetrafluoroethylene.