How to install high-performance fiber winder equipment?
High-performance fiber winder is the core equipment at the production end of high-performance fibers (such as carbon fiber, aramid fiber, ultra-high molecular weight polyethylene fiber, etc.). Its installation needs to take into account the mechanical stability, tension control accuracy and environmental adaptability of the equipment to ensure the regular formation and uniform tension of the wound fiber coil. The following is a detailed installation process that can be directly used in the on-site installation manual:
The installation of high-performance fiber winder should follow the core process of "basic pretreatment-equipment in place-system connection-precision calibration", and at the same time, it is necessary to strengthen the adaptation between environment and tension system in combination with the characteristics of high-performance fiber that is easily disturbed by environment. The specific steps are as follows:
Site and environment pretreatment before installation
High-performance fiber has strict requirements on environmental temperature, humidity and cleanliness. Before installation, it is necessary to confirm that the site meets the core conditions: the environmental temperature should be controlled at 20℃-25℃ and the relative humidity should be kept at 50%-60% to avoid the fiber from stretching or absorbing moisture due to temperature and humidity fluctuations; The site should be equipped with a clean dust removal system, and the concentration of suspended particles in the air should be ≤ 0.5 mg/m to prevent impurities from adhering to the fiber surface and affecting the quality; The ground in the equipment installation area shall be hardened, and the bearing capacity shall not be less than 1.5 times of the rated weight of the equipment (generally, the overall weight of the high-performance fiber winder is 1.2t-3t), and the ground flatness error shall be ≤2mm/m, and at the same time, a space of ≥1m for equipment maintenance and fiber transfer shall be reserved. In addition, it is necessary to lay an independent power supply line in advance, connect to a three-phase 380V/50Hz stable power supply, and equip with a voltage stabilizer. The voltage fluctuation range should be controlled within 5% to avoid the influence of voltage instability on the accuracy of the tension control system.
Positioning and fixing of equipment main body
Use forklift or crane to lift the winder body to the designated station smoothly, and use special lifting lugs for equipment when lifting. It is forbidden to directly lift precision parts such as roller shafts. After being in place, coarse adjustment shall be carried out through the horizontal adjustment foot cup at the bottom of the equipment, and the vertical and horizontal levelness of the equipment frame shall be detected with a high-precision level to ensure that the horizontal deviation is ≤ 0.05 mm/m; Then install the anchor bolts, and the bolts shall be embedded to the ground concrete layer ≥ 300 mm. After fastening, check the levelness again to prevent the equipment from being displaced due to vibration during operation. For the split winder (such as the split design of unwinding unit, traction unit and winding unit), it is necessary to calibrate the coaxiality of each unit based on the winding unit to ensure that the straightness deviation of fiber routing path is ≤0.1mm/m, so as to avoid additional tension fluctuation caused by path deviation during fiber transmission.
Core system connection and pre-commissioning inspection
Connect the power line, control line and communication cable according to the electrical schematic diagram of the equipment. After the wiring is completed, conduct insulation test, and the insulation resistance shall be ≥2MΩ. At the same time, check the grounding system, and the grounding resistance shall be ≤4Ω to prevent static accumulation from damaging the fiber. Connect the pneumatic system, connect 0.6MPa-0.8MPa dry compressed air, and install a three-stage oil-water separator in the air source to prevent water vapor and oil pollution from entering the air path and affecting the stability of the cylinder, tension valve and other components. After the mechanical and electrical connection is completed, conduct a comprehensive inspection before the no-load test run: manually rotate each roller shaft to confirm that there is no jamming or abnormal sound; Check whether the clamping and loosening actions of the winding chuck are smooth; Check whether the wiring of testing elements such as tension sensor and displacement sensor is firm, and ensure the normal signal transmission.
Precision component calibration and tension system debugging
First, calibrate the core precision parts of the winder: use a dial indicator to detect the radial runout of the winder, and the runout is required to be ≤ 0.02 mm. If the deviation exceeds the standard, it needs to be corrected by adjusting the bearing preload or replacing the roller shaft; Calibrate the linear speed accuracy of the traction roller, ensure that its speed fluctuation is ≤ 0.2%, and ensure the stable fiber transmission speed. Then focus on debugging the tension control system. First, connect the simulated fiber (ordinary silk thread of the same specification can be used), set the target tension value (the tension range of different high-performance fibers is quite different, such as carbon fiber is usually 5N-15N, aramid fiber is 3N-8N), adjust the output torque of the magnetic powder brake or servo motor through the tension controller, and observe the real-time feedback data of the tension sensor to ensure that the tension fluctuation range is controlled within ±0.5N. At the same time, the tension compensation system is calibrated. When the winding diameter gradually increases, it is necessary to verify whether the system can automatically adjust the torque to maintain a constant tension and avoid the fiber from stretching or relaxing due to sudden tension change.
Wire feeding path and installation of auxiliary devices
Install auxiliary devices such as yarn guide, tension roller and yarn separator according to the process requirements. The yarn guide needs to adjust the spacing according to the width of fiber tow to ensure that each tow is routed independently without winding; The comb teeth of the yarn separator should be kept smooth and burr-free, so as to prevent the fibers from being scratched. After the installation of the auxiliary device is completed, the solid yarn threading test is carried out, starting from the unwinding unit, passing through the traction roller, the tension detection roller and the yarn guide in turn, and finally being fixed on the winding chuck. During the threading process, the fiber should be kept naturally tensioned without bending or twisting. At the same time, fiber surface cleaning devices (such as anti-static brushes, dust removal air knives) and broken wire detection devices are installed, and the sensitivity of broken wire sensors is debugged to ensure that the equipment can stop immediately when the fiber breaks, thus reducing the generation of waste.
Linkage commissioning and acceptance
After completing all installation and calibration, carry out no-load linkage trial run for 2 hours continuously, and monitor the operating temperature, noise and vibration of all parts of the equipment. The bearing temperature is ≤60℃ and the operating noise of the equipment is ≤70dB. Subsequently, the trial operation with materials was carried out, and the small batch winding test was carried out with the actually produced high-performance fibers, and the winding molding quality was observed: the flatness deviation of the fiber roll end surface was required to be ≤1mm, and there were no defects such as overlapping wires, loose layers and jumpers; At the same time, the tension data and speed data in the winding process are recorded to ensure that all parameters meet the process requirements. After the commissioning reaches the standard, arrange the installation calibration records, test reports and other materials to complete the equipment installation and acceptance.
