How can we debug the spinning machine after installation?

The commissioning of spinning machine after installation is the key link to ensure the normal operation of the equipment. The following are the detailed commissioning steps:

A, mechanical part debugging

Transmission system debugging

Motor debugging: firstly, start the motor separately and check whether the rotation direction of the motor is correct. This can be judged by observing whether the rotating direction of the motor shaft is consistent with the design requirements of the equipment. For example, for the motor that drives the spinning spool, its rotation direction should make the spool rotate in the direction that can normally wind fibers. At the same time, pay attention to whether the starting current of the motor is within the rated range, and generally the starting current should not exceed 5-7 times of the rated current. An ammeter can be used to monitor the starting current of the motor.

Belt and chain debugging: check the tension of belt and chain. For the belt, apply a certain pressure (generally 10-15N) to the middle of the belt with your fingers, and the deflection of the belt should be within a certain range (such as 10-15mm). For the chain, the tension of the chain can be adjusted by adjusting the tensioner, and the activities between the links should be flexible without sticking.

Gear transmission debugging: check the meshing condition of the gear, the tooth surface contact of the gear should be uniform, and the contact spots along the tooth width direction should be no less than 60%-70%. Red lead powder and other pigments can be applied to the tooth surface of one gear, and then the gear is rotated to observe the pigment distribution on the tooth surface of the other gear to judge whether the contact is good or not.

Spinning assembly debugging

Spinning box debugging: check the temperature control system in the spinning box. Turn on the heating device, and use a thermometer (such as thermocouple thermometer) to monitor the temperature at different positions in the spinning box to ensure that the temperature can rise evenly and stabilize at the set value. For example, for polyester spinning, the spinning box temperature may need to be stabilized at around 280-290℃. The temperature deviation should be controlled within 2-3℃ at different positions.

Debugging of metering pump: Manually move the shaft of metering pump to check whether it rotates smoothly. Then turn on the motor of the metering pump, let the metering pump run at a lower speed, and check whether the output flow of the spinning solution is accurate. The measuring cylinder and stopwatch can be used to measure the output of spinning solution in a certain period of time and compare it with the theoretical calculation value. The flow error should be controlled within 3%-5%.

Debugging of spinneret: Check whether the spinneret is firmly installed and whether the spinneret hole is unobstructed. You can use compressed air or special cleaning solution to clean the spinneret to ensure that there is no blockage. To observe whether the spinning solution sprayed by the spinneret is uniform can be judged by placing a clean board under the spinneret, briefly turning on the supply of spinning solution and checking the distribution of spinning solution on the board.

Debugging of cooling device

Commissioning of air cooling device: start the fan and check whether the air volume and air pressure of the fan meet the requirements. You can use an anemometer to measure the wind speed at the outlet of the cooling duct and calculate the air volume according to the cross-sectional area of the duct. For different spinning processes, the air volume requirements are different, which should generally reduce the temperature of fibers in the cooling air duct to a suitable range. For example, for some synthetic fiber spinning, the temperature of the fiber after leaving the cooling duct should be reduced to about 60-80℃. At the same time, it is necessary to check whether the air distribution in the air duct is uniform, so as to avoid the situation that the local wind speed is too high or too low.

Commissioning of water cooling device: start the cooling water circulation system and check the flow and pressure of cooling water. Use flowmeter and pressure gauge to measure the flow and pressure of cooling water respectively, which should meet the design requirements of cooling device. For example, for the cooling of the cooling roller, the flow of cooling water should ensure that the surface temperature of the cooling roller is stable within the set temperature range (such as 30-40℃), and the pressure should generally be between 0.2-0.4MPa. At the same time, check the cooling device for water leakage.

Second, the electrical part debugging

Control system debugging

PLC (programmable logic controller) debugging: check whether the input and output signals of PLC are normal. By manually triggering sensors (such as limit switches, temperature sensors, etc.), observe whether the input indicator light corresponding to PLC is on, and check whether the output signal of PLC can correctly control actuators (such as motors, valves, etc.). You can use programming software to monitor the PLC program online, and check the running status of the program and the values of variables.

Touch screen debugging: check whether the display of the touch screen is normal and whether the operation interfaces can be switched correctly. Test whether buttons, input boxes and other controls on the touch screen can work normally. For example, set spinning speed, temperature and other parameters on the touch screen to check whether the equipment can operate according to the set parameters.

Frequency converter debugging: debug the frequency converter that drives the motor. Set the basic parameters of the inverter, such as the rated power, rated current and rated speed of the motor. Then through the inverter panel or control system, gradually increase the speed of the motor to check whether the speed control of the motor is accurate. The speed error should be controlled within 1%-2%. At the same time, check whether the functions of overload protection and overcurrent protection of the inverter are normal.

Sensor debugging

Debugging of temperature sensor: put the temperature sensor in an environment with known temperature (such as hot water or oil bath with temperature measured by a standard thermometer), and compare the measured value of the temperature sensor with the measured value of the standard thermometer. The error should be within the allowable range (such as 1-2℃). For the temperature sensor installed on the spinning machine, check its temperature measurement stability during the operation of the equipment.

Debugging of tension sensor: Apply a known tension to the tension sensor (it can be applied by mechanical devices using standard weights), and check whether the output signal of the tension sensor has a linear relationship with the applied tension. During the operation of the spinning machine, observe whether the output signal of the tension sensor can accurately reflect the tension change of the fiber, and the tension measurement error should be controlled within 5%-10%.

Debugging of speed sensor: By comparing with standard speed measuring equipment (such as photoelectric velocimeter), check the accuracy of speed measurement of spinning reel and other rotating parts by speed sensor. The error of speed measurement should be controlled within 1%-2%.

Third, the process parameters debugging

Parameter debugging of spinning solution

Temperature adjustment: adjust the temperature of spinning solution according to the requirements of spinning process. Through the temperature control system in the spinning box, the temperature of spinning solution is stabilized in a suitable range. Different spinning materials and processes require different spinning solution temperatures. For example, for nylon spinning, the spinning solution temperature may need to be controlled at around 260-270℃.

Viscosity adjustment: control the viscosity of spinning solution by adding appropriate additives or adjusting the concentration of spinning solution. Viscometer can be used to measure the viscosity of spinning solution to meet the requirements of spinning process. For example, in polyester spinning, the viscosity of spinning solution should generally be controlled within a suitable range to ensure fiber quality and spinning stability.

Spinning speed debugging

Start debugging at a lower spinning speed and gradually increase the spinning speed. In the process of increasing spinning speed, the fiber forming and tension change were observed. The adjustment of spinning speed can be realized by controlling the motor speed by frequency converter. For example, in the initial debugging, the spinning speed can be set to 500-1000m/min, and then the speed can be gradually increased according to the fiber quality, but the fiber quality should be ensured to meet the requirements, such as fiber strength, uniformity and other indicators.

Cooling parameter debugging

According to the fiber performance requirements and spinning speed, the parameters of the cooling device are adjusted. For air cooling, adjust the air volume and air pressure of the fan; For water cooling, adjust the flow and temperature of cooling water. By observing the cooling effect of the fiber, such as the crystallinity and orientation of the fiber, the optimal cooling parameters are determined. For example, in the production of high-strength fibers, a lower cooling temperature and a larger cooling air volume may be needed to promote the rapid cooling and proper crystallization of fibers.

In the process of debugging, it is necessary to record all parameters and equipment operation in detail, so as to optimize equipment operation and production process in the future.