What should be paid attention to when installing and debugging the fiber cutter of intelligent spinning equipment?

Matters needing attention in installation and debugging of fiber cutter of intelligent spinning equipment

The core function of the fiber cutter for intelligent spinning equipment is to accurately cut continuous spinning fibers into set lengths (such as chopped fibers and fixed-length fibers), and its installation and debugging quality directly affects the fiber cutting accuracy, length consistency and equipment operation stability. Focusing on the four core dimensions of equipment positioning accuracy, transmission system coordination, electrical control matching degree and safety protection reliability, the key issues should be controlled in three stages: installation, debugging and trial operation:

First, the core points for attention in the installation stage

Positioning and calibration of foundation and equipment

According to the equipment instruction, the special concrete foundation should be poured, and the strength of the foundation should meet the load-bearing requirements of the equipment. At the same time, damping pads or grooves should be installed to isolate the vibration interference of other equipment in the spinning production line. Vibration will lead to the displacement of the cutter group and affect the precision of fiber length determination.

When the equipment is installed, a spirit level shall be used to calibrate the levelness of the fuselage, and the vertical and horizontal horizontal errors shall be ≤ 0.1 mm/m; The feed inlet of the cutter should be accurately butted with the discharge outlet of the upstream spinning equipment, and the coaxiality deviation should be less than or equal to ≤0.5mm, so as to avoid deviation and stretching during fiber conveying.

The equipment maintenance space shall be reserved, and the operation distance ≥800mm shall be reserved on the maintenance side of the tool set and the side of the electrical control cabinet to ensure the convenience of tool replacement and component maintenance in the later period.

Specification for assembly of mechanical parts

Knife assembly: the cutting knives are divided into fixed knives and moving knives. Before assembly, the sharpness and flatness of the blade should be checked, and there are no cracks and curling defects; The meshing clearance between the moving knife and the fixed knife should be adjusted strictly according to the technological requirements (usually 0.02-0.05mm). Too large clearance will easily lead to fiber tearing and burr, while too small clearance will aggravate tool wear.

Installation of transmission system: check the coaxiality of coupling of motor, reducer and cutter shaft, and the deviation is ≤ 0.03mm; The transmission chain or synchronous belt needs to be adjusted to a proper tension. If it is too loose, it will slip easily, which will lead to the fluctuation of cutting speed. If it is too tight, it will increase the bearing load. All transmission parts need to be filled with special lubricating oil, and the oil level meets the calibration requirements.

Installation of feeding and discharging devices: the feeding rollers should be parallel and uniform in pressure to avoid tensile deformation caused by uneven stress during fiber transportation; The speed of the discharge conveyor belt should match the cutting speed to prevent fiber accumulation or secondary stretching after cutting.

Wiring and grounding of electrical system

The electrical control cabinet should be far away from the wet and dusty areas and keep a distance of ≥500mm from the cutting machine body; Strong current (motor power cord) and weak current (sensor signal line and control signal line) are laid separately, and the weak current line needs to pass through the shielding tube to avoid the length detection sensor and servo motor from losing control due to electromagnetic interference.

The equipment shall be reliably grounded, and the grounding resistance shall be ≤4Ω, so as to prevent the accumulation of static electricity and breakdown of electrical components, and at the same time protect the safety of operators-static electricity is easy to be generated in the process of spinning fiber conveying, and poor grounding will cause the fiber to be adsorbed on the cutter set or conveyor belt, which will affect the continuity of cutting.

When installing the lines of emergency stop buttons, safety light curtains and other safety devices, separate wiring and redundancy treatment are required to ensure stable signal transmission and avoid the failure of safety devices.

Second, the core points for attention in the debugging stage

Mechanical parameter debugging and precision calibration

Calibration of cutting length: set the cutting length according to the production demand, and accurately calibrate the cutting accuracy by adjusting the matching ratio between the speed of servo motor and the feeding speed and combining the feedback data of length detection sensors (such as encoders and photoelectric sensors). When debugging, 100 chopped fibers are sampled and tested, and the length deviation should be ≤±0.5mm (high-precision cutting is required to be ≤±0.2mm), and the CV value of the length variation coefficient should be ≤3%.

Optimization of the meshing state of the cutter group: inching the cutter group to observe the meshing track between the moving cutter and the fixed cutter to ensure that there is no jamming and abnormal sound; Cut off a small amount of fiber during trial operation, and check the quality of the incision, without burr, bevel and tearing, otherwise, it is necessary to readjust the clearance of the cutter group or the angle of the blade.

Feed pressure adjustment: adjust the feed roller pressure according to the fiber material (such as polyester, nylon and viscose fiber). Brittle fiber needs to be reduced in pressure to prevent fracture, while tough fiber needs to be moderately pressurized to ensure smooth transportation and avoid unstable cut length caused by fiber slippage.

Electrical control and intelligent system debugging

Parameter matching and program setting: enter the fiber material, target cutting length, production speed and other parameters in the intelligent control system, debug the linkage logic between the servo motor and the feeding system, ensure that the motor speed changes synchronously with the feeding speed, and realize the closed-loop control of "fixed length cutting".

Sensor calibration: calibrate the sensitivity of length detection sensor, feeding sensor and overload protection sensor, and set a reasonable detection threshold; For example, the overload protection sensor needs to trigger the shutdown in time when the cutter block is jammed to prevent the motor from burning or the cutter block from being damaged.

Man-machine interaction interface debugging: test the functions of touch screen parameter setting, operation status display, fault alarm, etc. to ensure convenient operation and accurate data display; Back up the control system program after debugging, so as to prevent the program from losing or misoperation leading to parameter disorder.

Safety protection system test

Test the effectiveness of emergency stop button, safety light curtain and protective cover interlocking device: when the safety light curtain is blocked, the equipment needs to be stopped immediately; When the protective cover is not closed, the equipment cannot be started; After the emergency stop button is pressed, it is necessary to cut off all power supplies and restart the program after reset.

Debugging overload protection and material jam alarm function: simulate the fault scenes such as material jam and fiber blockage of the cutter group, check whether the equipment can stop in time and send out alarm signals to avoid equipment damage.

Iii. Matters needing attention in commissioning and acceptance stage

No-load commissioning

No-load running time is ≥2 hours, during which the running status of all parts of the equipment shall be checked: there is no abnormal noise of the cutter group, no vibration and heating of the transmission system, and the bearing temperature is ≤ 60℃; The electric control system has no alarm, the servo motor runs smoothly, and the speed fluctuation is ≤ 1%.

Check the operation coordination of the feeding and discharging devices, make sure that the conveyor belt has no deviation and slippage, and the fiber guide device has no risk of scratching fibers.

Load test run

According to the actual production conditions, the fiber is put into load trial operation, and the running time is ≥8 hours. The key monitoring is: cutting off the fiber length consistency and notch quality; The equipment is stable in operation, and there is no material jam or broken knife; Temperature rise of electrical system, temperature of components in control cabinet ≤45℃.

Record the trial operation data, including cutting length deviation, production speed, equipment failure rate, etc., and compare with the design index, and the nonconformities need to be adjusted in time.

Acceptance and delivery specification

After the commissioning reaches the standard, arrange the installation and debugging records, equipment parameter list, safety operation procedures and other materials and hand them over to the producer; Train operators to ensure that they master operating skills such as parameter setting, troubleshooting and tool replacement.

Define the equipment warranty period and later maintenance plan, such as tool replacement cycle, lubricating oil replacement frequency, sensor calibration cycle, etc.

Fourth, general precautions

Material and environmental control

The fiber used for debugging should be consistent with the fiber actually produced, so as to avoid the distortion of debugging parameters caused by the difference of fiber thickness and toughness; The ambient temperature of the workshop is controlled at 20-28℃ and the humidity is 55%-65%, so as to prevent the fiber from moisture absorption and deformation or static electricity generation.

Personnel operation specification

The installation and debugging shall be carried out by professional technicians. Non-professional personnel are forbidden to disassemble the tool set and adjust the electrical parameters. During debugging, operators should wear labor protection articles to avoid being injured by high-speed knife sets or conveyor belts.

Establishment of equipment maintenance account

Record the installation and debugging time, parameter setting, commissioning data and other information, and establish equipment maintenance ledger; Make clear the replacement standard of tool wear and the lubrication cycle of transmission parts, and provide the basis for daily maintenance in the later period.