I. Advantages of the core mixing principle (the most core feature)
Relying on the combined motion of orbital revolution and rotation, 2 to 4 sets of mixing arms revolve around the center of the cylinder, while the blades themselves rotate at high speed, forming a fully covered three-dimensional mixing trajectory:
1. 360° no mixing dead zone
Every 5 to 6 seconds, the blade trajectory fully covers all areas of the cylinder bottom, wall, and center. The accompanying side scraper continuously clears the accumulated material on the cylinder wall, ensuring no blind spots in the center and no material piling in the corners. This completely solves the problems of residual mixing and uneven local mixing in traditional horizontal/single vertical shaft agitators.
2. Three-dimensional mixing, top-notch homogeneity
The material simultaneously undergoes convection, diffusion, kneading, and gentle shearing, achieving extremely high macro and micro mixing uniformity. The coefficient of variation of concrete strength is less than 3%, and the mixing uniformity can reach over 98%. It can disperse steel fibers, chopped fibers, and ultra-fine silica fume, preventing fiber agglomeration. It is a standard equipment for UHPC, refractory castables, and fiber concrete.
3. Short mixing cycle and high production capacity
Ordinary materials can achieve qualified homogeneity in 30 to 60 seconds, which is 30% shorter than that of a double horizontal shaft mixer. With the same volume, the batch turnover is faster, making it suitable for continuous production lines of prefabricated components and refractory materials.
II. Performance characteristics of the powertrain system
1. High-torque hardened gear planetary gearbox
Power is evenly distributed to each planetary mixing shaft, ensuring no slipping under heavy loads and sufficient output torque. It is suitable for mixing dry, hard, high-viscosity materials with low water-binder ratios that are difficult to mix. The operation noise is low, and it exhibits strong stability under harsh working conditions.
2. Overload protection design
Equipped with a standard elastic coupling and an optional hydraulic coupler, it can buffer the impact when materials get stuck, protecting the reducer and motor from damage and significantly reducing the failure rate of transmission components.
3. Compact transmission structure with small footprint
The entire machine is vertically arranged and highly integrated. With the same discharge capacity, it occupies 40% less space compared to a double horizontal shaft configuration. The layout of the factory building is flexible, making it suitable for compact production lines in prefabrication factories and refractory material workshops.
III. Advantage of broad-spectrum material adaptability (extremely high universality)
It is compatible with a full range of materials, including dry materials, semi-dry materials, plastic high-viscosity slurries, ultra-fine powders, and fiber-reinforced materials, offering multiple uses in one machine:
Building materials: UHPC (Ultra-High Performance Concrete), prefabricated component concrete, permeable bricks, self-leveling mortar, grouting materials, fiber concrete;
Refractory Metallurgy: refractory castables, spray coatings, aluminum-magnesium-carbon bricks, and graphite mixtures for steel plants;
Others: ceramic body, glass raw material, chemical powder, mine filling material, solid waste stabilization treatment material.
It supports flexible production for multiple varieties and small batches. To change materials, only the speed and mixing duration need to be adjusted, without the need to replace core components.
IV. Characteristics of wear resistance, durability, and easy maintenance of the structure
1. Long service life of wearing parts
The mixing blades feature a parallelogram wear-resistant structure, allowing for a 180° flip for secondary use after wear. The wear-resistant lining is made of high-chromium alloy/tungsten carbide overlay welding, ensuring a single blade’s service life of over 8,000 hours and reducing the cost of accessory replacement.
2. Clean unloading with minimal residue
The bottom hydraulic/pneumatic discharge door features 1 to 3 discharge ports, and the discharge scraper simultaneously cleans the bottom of the cylinder, ensuring a material residue rate of ≤0.5% and reducing raw material waste. The discharge speed is fast, and the automated production line operates smoothly without material blockage.
3. Convenient maintenance and cleaning
Large-sized safety access door with mechanical safety lock, ensuring mandatory power cut-off during maintenance to prevent accidental start-up; optional high-pressure automatic cleaning system, featuring multiple nozzles for full coverage inside the cylinder, allowing for rapid material change and cleaning, thus avoiding cross-contamination of different materials.
4. Reliable sealing without leakage
The combination of multiple labyrinths on the planetary shaft end and a skeleton oil seal ensures no leakage of slurry or material during long-term wet mixing operations, maintaining a clean workshop and reducing wear and tear on bearings and gears caused by dust ingress.
V. Comprehensive advantages in production and utilization
1. The quality of finished products is stable, reducing the scrap rate
The homogeneity is uniform, without local slurry deficiency, aggregate stratification, or fiber agglomeration. The strength and appearance consistency of prefabricated parts and refractory products have been greatly improved, and the rate of defective products has significantly decreased.
2. Low energy consumption, energy-saving, and high efficiency
Short mixing cycle + efficient power matching, resulting in lower power consumption per unit of material compared to traditional mixers; low-speed gentle mixing reduces aggregate crushing and preserves the original gradation of the material.
3. Strong automation adaptability
The complete machine is equipped with a PLC fully automatic control system, which can be connected to the batching system, mold production line, and weighing system. It supports remote data monitoring, speed adjustment, and scheduled mixing, and is compatible with smart factory assembly lines.
4. Strong adaptability to working conditions
It can operate continuously for 24 hours with heavy-duty production, high temperature resistance, and dust resistance; it supports customized vacuum mixing, low temperature mixing, and explosion-proof models, and is suitable for new materials and stringent processes in specialty chemical industries.
VI. Comparing the core differentiated advantages of double-horizontal shaft mixers
1. Highly homogenous special materials (UHPC, refractory materials, fiber materials) are rolled and processed using dual horizontal shafts, achieving an irreplaceable fiber dispersion effect;
2. Without a central mixing blind area, the mixing effect of fine powder and highly viscous materials is better;
3. Smaller footprint and more flexible workshop layout;
4. With less material residue, production with multiple formula switches is cleaner;
5. The mixing torque for dry, hard, and ultra-dry materials is sufficient, making it less prone to machine stalling.
