What is the debugging process of high-performance fiber winder equipment?

Debugging of high-performance fiber winder is the core link to ensure regular fiber winding and forming, stable tension and up-to-standard quality. It is necessary to follow the progressive process of "single machine component debugging-system linkage debugging-ribbon process debugging-stability verification", and at the same time adapt the parameters according to the characteristics of different types of high-performance fibers (carbon fiber, aramid fiber, ultra-high molecular weight polyethylene fiber, etc.). The following is a detailed process that can be directly used in the equipment debugging manual:

I. Preparation before commissioning

Basic state confirmation

First, check the mechanical accuracy of equipment installation, and confirm that the levelness of the frame and the coaxiality of each unit have reached the standard, and the radial runout of the roller shaft is ≤ 0.02 mm; Check the wiring firmness of the electrical system, with insulation resistance ≥2MΩ and grounding resistance ≤4Ω, and the pressure of the pneumatic system is stable at 0.6MPa-0.8MPa without air leakage; Clean the impurities and burrs on the wire path of the equipment to avoid scratching the fiber. At the same time, confirm that the temperature and humidity (20℃-25℃, humidity 50%-60%) and cleanliness of the site meet the requirements of high-performance fiber production.

Preparation of tools and consumables

Prepare high-precision tensiometer, dial indicator, tachometer and other testing tools, as well as simulated silk yarn (such as ordinary polyester yarn) and high-performance fiber for actual production; Load the preset basic parameter program of the equipment in advance, including winding speed, initial tension, winding diameter compensation coefficient, etc., to provide a benchmark for debugging.

Second, the single core components debugging

Debugging of transmission and roller system

First, carry out no-load trial operation of each roller shaft, manually turn the car to confirm that the traction roller, the guide roller and the take-up roller rotate without jamming and abnormal sound, and then start the motor drive, and calibrate the linear speed of the traction roller through the tachometer to ensure that the speed fluctuation is ≤ 0.2%, and there is no delay in the speed switching response of different gears; Re-measure the radial runout of the winding roller with a dial indicator. If the deviation exceeds the standard, adjust the position of the bearing seat or replace the bearing to correct it, so as to ensure the stability of the fiber transmission track.

Debugging of tension control unit

The tension system is the core of the winder. First, debug the calibration accuracy of the tension sensor, hang the standard weight on the sensor end, and verify that the deviation between the displayed tension value and the actual value is ≤±0.3N；; Then test the responsiveness of the tension actuator (magnetic powder brake/clutch, servo motor), set different target tensions in the range of 5N-15N, and observe the feedback data of the sensor to ensure that there is no overshoot or lag in the tension rising/falling process, and the static tension fluctuation is ≤±0.5N.

Debugging of winding chuck and auxiliary device

Debug the clamping/loosening action of the winding chuck, and confirm that its clamping force on the paper tube/I-wheel is uniform, without loosening or clamping injury, and the concentricity deviation of the chuck is ≤ 0.05 mm; Test the broken wire detection sensor, electrostatic eliminator, dust removal air knife and other auxiliary devices. The broken wire sensor needs to trigger the shutdown within 0.5s after the fiber breaks, and the electrostatic eliminator can control the static electricity on the fiber surface within 500V to ensure the production safety.

Third, the system linkage logic debugging

Timing linkage debugging of each unit

Simulate the complete winding process, and debug the linkage time sequence of unwinding, traction, tension control and winding unit: set the unwinding speed of unwinding unit to match that of traction unit to avoid fiber being too tight or too loose; When the winding diameter increases from the initial value to the maximum value, it is verified that the winding diameter compensation system can automatically adjust the winding speed and tension torque and maintain the fiber tension constant.

Control system program debugging

Call different winding programs on the touch screen or industrial computer to verify the stability of parameter switching, including winding speed (usually 50m/min-300m/min for high-performance fiber), taper tension coefficient (set for different fiber types, such as carbon fiber taper coefficient 0.8-0.95), shutdown protection logic, etc. If the equipment is equipped with the communication module of PLC and MES system, it is necessary to test the real-time data upload to ensure that the data such as winding tension, speed and winding weight can be accurately collected.

Four, with material process parameters debugging

Simulated silk thread test run

Firstly, the simulated silk thread is used for debugging the belt material, and the thread threading path needs to pass through the guide roller, the tension detection roller, the thread separator and the winding chuck in turn according to the technological requirements, so as to ensure that the silk thread does not cross or bend; Start the equipment at a low speed (30m/min-50m/min), observe the winding and forming state of the silk thread, and ensure that the flatness deviation of the end face is ≤1mm, and there are no overlapping wires and jumpers. At the same time, record the tension fluctuation data, and fine-tune the tension compensation coefficient, so that the whole tension can be stabilized within the target value of ±0.5N.

Actual fiber process adaptation

Replace it with high-performance fibers (such as carbon fiber and aramid fiber) actually produced, and adjust the core parameters according to the fiber characteristics: for carbon fiber with high modulus and low elongation, set the initial tension of 5N-8N, the winding speed of 100m/min-200m/min, and the taper tension coefficient of 0.9, so as to avoid fiber tensile damage caused by excessive tension; For flexible aramid fiber, reduce the initial tension to 3N-5N, and appropriately increase the spacing of yarn splitters to prevent tow winding.

After small-batch trial winding, check the quality of the fiber coil: there are no staggered layers on the end face and no flying yarn on the edge, the density of the fiber coil is uniform, and the tensile strength of the monofilament has no obvious attenuation (the deviation from the strength of the precursor is less than or equal to 3%). If there is loose layer, it is necessary to increase the taper tension coefficient; In case of fiber stretching, the initial tension or winding speed should be reduced.

V. Stability and Productivity Verification

Long-term continuous commissioning

Carry out continuous winding test for 2-4 hours, and monitor the running state of the equipment: bearing temperature ≤60℃, motor temperature rise ≤30℃, and equipment running noise ≤ 70 dB; Record the data of tension fluctuation, winding speed and winding diameter change in the whole process to ensure that there is no continuous parameter drift, and the fiber coil yield is ≥99%.

Multi-specification compatibility debugging

Replace paper tubes with different diameters (such as 3 inches and 6 inches) and fibers with different deniers for testing, and verify the adaptability of the equipment to multi-specification products, so as to ensure that the winding can be stable without greatly adjusting parameters after switching specifications, and the winding quality meets the standards.

Six, debugging acceptance and parameter curing

Index verification

Check the core indicators item by item according to the technical agreement, including tension control accuracy (fluctuation ≤±0.5N), winding speed stability (fluctuation ≤ 0.2%), fiber roll end flatness (deviation ≤1mm) and equipment continuous operation failure rate (≤0.5%/8h), to ensure that all indicators meet the standards.

Parameter solidification and data archiving

The optimized parameters (tension value, winding speed, taper coefficient, etc.) after debugging are classified and stored in the equipment control system to form a process parameter library of different fibers; Organize debugging records, test reports, parameter lists and other materials, complete debugging and acceptance, and deliver them to field operators.