Application of KTR Mini Self-Recover Linear Displacement Sensor on Rubber Open Mill

Application of KTR Mini Self-Recover Linear Displacement Sensor on Rubber Open Mill

The two-roll open mill is core equipment for rubber and silicone plasticating and mixing. The roll gap directly controls the shearing and thinning effect of rubber stock, and consistent clearance determines the stability of mixed compound quality. Traditional mechanical limit monitoring suffers low precision and signal lag, easily causing roll gap deviation and uneven rubber thickness. Many rubber manufacturers adopt the KTR Mini Self-Recover Linear Displacement Sensor for real-time roll gap detection and closed-loop control, improving the precision of mixing processes.

The KTR linear displacement sensor features multiple advantages well-matched to open mill working conditions. It has a compact mini size, convenient for installation within narrow frame space. Built with a self-return spring, it fits pushrod-style equipment without complicated mounting or precise alignment. It delivers ultra-long service life, with mechanical cycles exceeding tens of millions. Rated IP54 protection, it resists dust and slight oil contamination in rubber workshops. It stays stable against external impact and vibration, adapting to continuous shaking during mill operation. It adopts direct cable outlet for simple wiring, and supports optional voltage/current (2-wire, 3-wire) modules or RS485 output for seamless PLC connection.

On-site installed on the roll gap adjustment mechanism of the open mill, the KTR sensor stretches and retracts synchronously with roll adjustment via its internal spring. It converts mechanical displacement of the roll gap into continuous electrical signals and transmits data to the main control system. With excellent repeat accuracy less than 0.01 mm, the system monitors and calibrates the roller clearance automatically. Operators set target gap values on the HMI, and the unit performs closed-loop regulation automatically to reduce repeated manual measurement and calibration.

After retrofitting, the roll gap control stability of the open mill is greatly enhanced. Thickness deviation of rubber compound is reduced, mixing uniformity improves and reject rates drop. Its compact structure requires little modification to original frames, suitable for both new and retrofitted open mills. Anti-vibration and dust-resistant performance enables long-term stable operation under dusty, continuously vibrating rubber workshop conditions, cutting maintenance downtime and helping rubber mixing lines achieve refined and automated production.