What problems should we pay attention to during the installation and adjustment of our intelligent spinning machine?

The installation and adjustment of intelligent spinning machine is a complicated process. The following are some problems that need attention:

First, the preparation before installation

Site requirements

Space layout: The spinning machine needs enough space for installation and operation. It is necessary to ensure that the area of the workshop can accommodate the main equipment and auxiliary equipment (such as winding device and oiling device) of the spinning machine, and reserve enough passages to facilitate the operators to walk around, maintain the equipment and transport raw materials and finished products. Generally, the channel width should not be less than 1.5-2m.

Ground carrying capacity: Spinning machines are usually heavy, especially large intelligent spinning machines. Ensure that the ground of the installation site has enough bearing capacity to bear the weight of the equipment. Generally speaking, the bearing capacity of the ground is not lower than the weight of the equipment plus the dynamic load generated during operation. For example, if the self-weight of the spinning machine is 10 tons, and it may generate 2-3 tons of dynamic load during operation, then the ground bearing capacity should reach at least 13 tons/square meter.

Environmental conditions: temperature and humidity have a significant impact on the spinning process. The ideal working temperature of spinning machine is generally between 20 and 30 degrees Celsius, and the relative humidity is between 40% and 60%. If the temperature is too high, the viscosity of spinning solution may decrease, which will affect the forming quality of fiber. Excessive humidity may make the fiber absorb moisture and affect its physical properties. In addition, the site should be kept clean to prevent impurities such as dust from entering the spinning system and affecting the fiber quality.

equipment inspection

Integrity of parts: Before installation, it is necessary to carefully check whether all parts of the spinning machine are complete. Check the number of parts one by one according to the packing list of the equipment, including main parts such as spinning head, metering pump, transmission parts, electrical control cabinet, and various small parts such as bolts and nuts. For the missing parts, contact the supplier in time.

Appearance quality inspection: check whether the appearance of the equipment is damaged. Check whether the equipment shell is deformed, scratched, and painted; Check whether there are foreign objects, scratches or corrosion in the spinning head, pipes and other parts. For example, if the spinneret hole inside the spinning head is blocked or damaged, it will directly affect the normal spinning.

Second, the mechanical installation

Foundation installation

Level adjustment: the installation foundation of spinning machine must be level. Use a high-precision level to detect and adjust the levelness of the equipment base, and the levelness error should generally be controlled within 0.1-0.2 mm per meter. If the equipment is not horizontal, it will lead to uneven stress on all components in the spinning process, increase equipment wear and even affect the spinning accuracy and stability.

Anchor bolt fixation: Install the anchor bolt correctly to ensure that the equipment is firmly fixed on the foundation. The specifications and installation positions of anchor bolts shall be operated in strict accordance with the equipment installation instructions. When tightening bolts, it should be carried out according to the specified torque, and generally it should be tightened step by step in a diagonal way to prevent the deformation of the equipment base.

Component assembly

Spinning head installation: Spinning head is the key component of spinning machine. When installing the spinning head, make sure that it is closely connected with the melt pipeline or solution pipeline without leakage. The spinneret holes of the spinning head should be vertical downward, and the spacing between the spinneret holes should meet the design requirements. For example, in the process of polyester spinning, the error of spinneret spacing may lead to adhesion or uneven distribution between fibers.

Installation of transmission parts: the installation of transmission parts such as motor, reducer and pulley should ensure their coaxiality. Excessive coaxiality error will lead to vibration and noise in the transmission process, and even damage the transmission parts. Generally, the coaxiality error is required to be controlled within 0.1-0.2mm.. At the same time, the belt or chain should be installed and tensioned correctly, and the appropriate tension should be adjusted to ensure the stability of transmission.

Installation of winding device: the installation position and accuracy of winding device directly affect the winding quality of fiber. To ensure that the winding shaft is parallel to the central axis of the spinning head, the parallelism error is generally less than 0.1 mm/m. Moreover, the tension control system of the winding device should be debugged accurately to ensure the uniform tension of the fiber in the winding process and avoid the phenomenon of loose winding or tight winding.

Third, the electrical system installation

Wiring requirements

Wiring: Laying the wiring according to the electrical design drawings. To distinguish the power line, control line and signal line, use appropriate cables respectively and mark them according to the specified color and number. Power cables should have sufficient current carrying capacity to avoid overheating during operation. For example, for the high-power motor drive circuit, the cross-sectional area of the required cable should be calculated according to the power of the motor.

Shielding and grounding: In order to prevent electromagnetic interference, some sensitive signal lines (such as signal lines of temperature sensors and pressure sensors) should be shielded and grounded. Grounding resistance should meet the requirements, generally not more than 4 ohms, to ensure the electrical safety of equipment and the accuracy of signal transmission.

Electrical equipment connection

Installation and debugging of control cabinet: the electrical control cabinet should be installed in a dry and well-ventilated place to avoid moisture and dust intrusion. When connecting the electrical components in the control cabinet, it is necessary to operate in strict accordance with the wiring diagram to ensure firm wiring and good contact. When debugging the control cabinet, no-load test should be carried out first to check whether the actions of various electrical components are normal, such as the pull-in and release of contactors and the actions of relays.

Connection of sensors and actuators: properly connect various sensors (such as temperature sensors, pressure sensors, speed sensors, etc.) and actuators (such as motors, valves, etc.). The installation position of the sensor should accurately reflect the measured parameters, for example, the temperature sensor should be installed at a position that can truly measure the temperature of the spinning melt. After the connection is completed, the sensor and actuator should be calibrated and debugged to ensure that their measurement accuracy and control accuracy meet the requirements of spinning process.

Fourth, debugging and calibration

No-load debugging

Operation inspection of mechanical parts: start the spinning machine under no-load condition and check the operation of various mechanical parts. Observe whether the motor, reducer, transmission belt or chain, spinning head, winding device and other parts have abnormal vibration and noise. For example, under normal circumstances, the motor should run smoothly with only slight uniform noise; If there is harsh noise or violent vibration, it may be that the motor is improperly installed or the bearing is damaged.

Electrical system function check: check whether the function of the electrical system is normal. By operating the buttons and switches on the control cabinet, check whether the start-stop and forward-reverse control of the motor are accurate; Check whether the signals of each sensor can be collected and displayed normally, such as whether the temperature display is accurate and whether the speed sensor can feed back the winding speed correctly.

Load debugging

Spinning process parameter setting: In the load debugging stage, appropriate process parameters should be set according to the requirements of spinning raw materials and products. Include spinning temperature, pressure, draw ratio, winding speed, etc. For example, when spinning nylon fiber, the spinning temperature is generally between 260 and 280 degrees Celsius, and the drawing ratio is between 3 and 5 according to the fineness of the fiber.

Product quality inspection and adjustment: during the load debugging process, the spun fiber should be inspected for quality. The test content includes physical performance indexes such as fineness, strength and elongation of fiber. According to the test results, the spinning process parameters are adjusted, such as adjusting the rotating speed of metering pump to control the fineness of fiber and adjusting the drafting ratio to improve the strength and elongation of fiber.

V. Safety precautions

Installation of protective devices: install necessary protective devices, such as pulley, chain protective cover, spinning head protective fence, etc. The protective cover should be firm and reliable, which can effectively prevent the operator from touching the moving parts and avoid mechanical injury accidents.

Emergency braking system test: debug and test the emergency braking system to ensure that the equipment can stop running quickly in an emergency. The emergency stop button should be installed in a conspicuous and easy-to-operate position, and after the emergency stop button is pressed, the equipment should be able to stop in the shortest time, and generally the braking time should not exceed 5 seconds.

Operator training: conduct safety training for operators to familiarize them with the operation process, safety precautions and emergency treatment methods of the equipment. Operators should operate in strict accordance with the operating procedures to avoid safety accidents caused by misoperation.