What are the installation and debugging steps of POY/FDY multifunctional spinning testing machine?
Preparation before installation
Site preparation: choose a flat, dry, well-ventilated and enough space to place the spinning testing machine. Ensure that the ground of the site can bear the weight of the equipment, and the surrounding environment meets the operation requirements of the equipment, such as temperature and humidity within a certain range, avoiding direct sunlight and excessive dust.
Equipment inspection: Before installation, carefully check whether all parts of the equipment are complete and damaged. The inspection contents include extruder, spinning box, side blowing device, drafting device, winding device and other main components, and check whether the connecting bolts and pipe joints of all components are in good condition.
Preparation of tools and materials: Prepare tools needed for installation, such as wrenches, screwdrivers, level meters, etc. It is also necessary to prepare auxiliary materials such as connecting pipes, wires and sealing materials.
Equipment installation steps
Basic installation: firstly, place the main equipment (including extruder and other main parts) in the pre-selected site position, and adjust the levelness of the equipment with a level to ensure the smooth installation of the equipment. For large equipment, it may be necessary to use anchor bolts to fix the equipment on the ground to prevent vibration and displacement of the equipment during operation.
Component connection
Pipeline connection: connecting various pipelines in the spinning process, such as melt conveying pipeline and cooling air pipeline. When connecting, ensure that the pipe joints are well sealed to prevent melt leakage or cooling air leakage. For the melt pipe, it may be necessary to heat and keep warm to keep the melt flowing. At this time, it is necessary to pay attention to the correct installation and connection of the heating device.
Electrical connection: Connect the wires according to the electrical wiring diagram of the equipment, including the wiring of the main motor, heating device, sensor, controller and other components. The wiring process should strictly abide by the electrical safety specifications, ensure that the wires are firmly connected and well grounded, and avoid potential safety hazards such as electric leakage.
Mechanical connection: install and connect spinning box, side blowing device, drafting device and winding device and other components. Ensure that the transmission parts (such as belts, chains, etc.) between the components are connected correctly, the tension is appropriate, and the relative position accuracy of the components meets the requirements. For example, the position of the spinneret and the side blowing device should ensure that the filaments can be cooled evenly.
Pre-commissioning inspection
Cleaning inspection: Before commissioning, check the inside and outside of the equipment again for sundries, dust, etc., and clean the equipment, especially the spinning channel, spinneret and other key parts to ensure that there are no blockages, so as not to affect the spinning quality.
Lubrication inspection: check the lubrication of all moving parts of the equipment, such as bearings and gears, and add a proper amount of lubricant to ensure that the equipment can be well lubricated during operation and reduce wear.
Safety device inspection: check whether all kinds of safety devices of the equipment are installed in place and can work normally, such as emergency stop button, protective door switch, temperature and pressure alarm device, etc., to ensure the safety of the equipment during debugging and operation.
Debugging steps
No-load debugging
Motor debugging: firstly, turn on the motors of the equipment, such as extruder motor, drafting motor and winding motor, and check whether the rotation direction of the motors is correct, whether the operation is stable, and whether there is abnormal vibration and noise. Run the motor under no-load condition for a period of time, usually 30 minutes to 1 hour, and observe the temperature rise of the motor to ensure that the motor is within the normal working temperature range.
Transmission system debugging: check the transmission conditions of various transmission parts of the equipment, such as belts, chains and gears. Observe whether there are abnormal phenomena such as slipping and jumping in the transmission parts, and adjust the tension of the transmission parts to ensure the transmission efficiency and stability. At the same time, check the matching accuracy between the moving parts, such as the synchronization between the drafting roller and the winding roller.
Heating system debugging
Temperature control and debugging: turn on the heating device to heat up the extruder, spinning box and other parts that need to be heated. Set different temperature parameters through the temperature control system of the equipment, observe whether the heating device can raise the temperature according to the set temperature, and check whether the feedback from the temperature sensor is accurate. When the temperature reaches the set value, check whether the heating device can automatically keep the constant temperature, and the temperature fluctuation range should be within the allowable error range.
Heating uniformity debugging: use multiple temperature sensors or thermal imagers to check the heating uniformity of the heating part of the equipment, such as whether the temperature of each section of the extruder screw is uniform and whether the temperature distribution in the spinning box is reasonable. In the case of uneven heating, it is necessary to adjust the power distribution of the heating device or the position of the heating element to ensure that the melt can be heated and plasticized uniformly in the equipment.
Melt conveying debugging
Pressure control and debugging: install a pressure sensor on the melt conveying pipeline, start the extruder, and convey a small amount of polymer melt to the spinning box at a low speed. Observe the pressure change in the process of melt conveying, and adjust the rotating speed of the melt conveying pump or the opening of the pressure regulating valve through the pressure control system of the equipment to keep the melt conveying pressure stable and the pressure fluctuation should be less than the set threshold.
Melt flow debugging: measure the melt flow by means of flowmeter or weighing method, and adjust the rotation speed of melt delivery pump or other flow control devices to make the melt flow meet the set spinning process requirements. In the process of debugging, we should pay attention to the influence of melt temperature and pressure on the flow rate to ensure the accuracy and stability of melt flow rate.
Spinning debugging
Debugging of side blowing: Turn on the side blowing device and adjust the wind speed, direction and temperature of the side blowing. Check whether the parameters of side blowing meet the process requirements by anemometer, anemometer and other tools, so as to ensure that the filaments can be evenly cooled and initially solidified under the action of side blowing. Generally speaking, the wind speed of side blowing can be adjusted between 0.3 and 1.5 m/s, and the temperature can be adjusted according to factors such as polymer materials and spinning speed.
Drafting debugging: start the drafting device and set the drafting multiple and speed. The tension sensor is used to monitor the tension change of the filament in the drafting process, and the rotation speed and drafting force of the drafting roller are adjusted, so that the filament can be drawn evenly according to the set drafting multiple. In the debugging process, attention should be paid to the accuracy and stability of the drafting multiple to avoid uneven stretching or breakage of the wire.
Winding debugging: turn on the winding device and adjust the winding speed and tension. Observe the arrangement of tow in the winding process to ensure that the tow can be wound neatly on the winding drum. At the same time, the winding tension is adjusted by the tension control system to keep the winding tension stable, so as to avoid the phenomenon that the tow is slack or too tight in the winding process and affect the quality of the coil. In the winding process, the reciprocating speed and stroke of the winding head can also be adjusted as needed to control the width and shape of the wire coil.
