What should be paid attention to when installing and debugging the multifunctional composite intelligent spinning experimental equipment?

Matters needing attention in installation and debugging of multifunctional composite intelligent spinning experimental equipment

Multifunctional composite intelligent spinning experimental equipment integrates core modules such as multi-process spinning, intelligent regulation and control, on-line detection, etc., with precise structure and complicated electric control and fluid system. The installation and debugging should follow the principle of "environmental adaptation, precise alignment, step-by-step debugging, safety check and parameter calibration", and focus on controlling key links such as site environment, mechanical assembly, electrical connection, fluid pipeline and process debugging, so as to avoid equipment precision damage and process debugging caused by improper operation.

1. Before installation: prepare the site and materials to meet the requirements of precise operation of the equipment.

The site environment should be strictly controlled: the equipment should be placed in a flat, dry and vibration-free laboratory site, the ground should be hardened and a horizontal adjustment space should be reserved, and the levelness deviation should be ≤0.1mm/m, away from vibration sources such as air compressors and centrifuges, so as to avoid vibration affecting the spinning accuracy; The ambient temperature is controlled at 20~28℃, the relative humidity is 40%~60%, there is no dust and corrosive gas, and it is far away from open flames and strong electromagnetic interference (such as large transformers and high-frequency equipment) to prevent the failure of electric control module, pipeline corrosion or fiber sample pollution.

Basic facilities shall be implemented in advance: laying special power supply lines according to equipment requirements, equipped with independent leakage protector and regulated power supply (voltage fluctuation ≤ 5%), so as to avoid damage to precision electronic control components due to voltage instability; Reserve water supply and drainage interfaces (for wet/dry spinning process), the water quality should meet the standard of deionized water, and the drainage pipeline should be treated as anti-clogging; If the equipment contains high-temperature modules (such as melt spinning), it is necessary to reserve ventilation and heat dissipation space, and support a special fume hood for the laboratory to ensure the safety of high-temperature operation.

Pre-inspection of materials and tools: check that the specifications and models of all components of the equipment (mechanical frame, spinning module, metering pump, electric control cabinet, pipeline, testing elements, etc.) are consistent with the list, check that there is no transportation damage or missing parts, and protect precision accessories (such as spinneret and metering pump) to avoid scratches and bumps; Prepare special installation tools (torque wrench, level gauge, micrometer, pipe wrench, etc.). All tools are calibrated, and consumables such as seals, lubricating oil and insulating tape are prepared. It is forbidden to use non-original accessories.

Second, mechanical installation: accurate alignment to ensure the structural rigidity and coaxiality of the equipment.

Assembly of the frame and the module: when the frame is installed, it is calibrated point by point with a spirit level, leveled by adjusting the foot pads at the bottom to ensure that the frame does not tilt or shake, and the fastening bolts are tightened diagonally and symmetrically according to the design torque, and the locking marks are made; Each spinning module (melting, solution and electrostatic spinning module) is accurately aligned with the frame, and the installation gap is even, and the coaxiality deviation with the transmission mechanism (such as motor and drafting roller) is less than or equal to ≤0.02mm, so as to avoid abnormal operation sound and component wear due to insufficient coaxiality, which will affect the spinning accuracy.

Light protection for precision parts: Wear dust-free gloves when installing core precision parts such as spinneret, metering pump and filter, so as to avoid hand grease and dust pollution, and it is forbidden to knock with care; The spinneret should be installed horizontally, accurately butted with the spinning solution/melt outlet, and the gasket should be tightly attached without leakage; When installing the metering pump, ensure the flexible connection between the input and output shafts and the transmission mechanism, so as to avoid the abrasion of the pump body caused by hard contact and affect the metering accuracy of raw materials.

Debugging of transmission and support components: after installation, manually turn the motor, drafting roller, wire winder and other transmission components to check the smoothness of operation, and fill the bearing parts with special lubricating oil as required, with moderate oil quantity and no leakage; The positioning of the godet roller and the tension adjusting device of the wire winder is accurate, which ensures the smooth running of the silk thread, and there is no risk of scratching and jumping wires, and the tension adjusting range matches the equipment calibration value.

Third, the electrical and electronic control system connection: safety standards, to ensure accurate regulation.

Electrical connection shall be operated by a special person: professional electricians shall conduct wiring according to the electrical drawings of the equipment, and the power line, signal line and control line shall be laid separately, and marked properly to avoid mixed connection; The signal line adopts shielded wire, and both ends are grounded to prevent electromagnetic interference; Wiring terminals shall be fastened in place without looseness or virtual connection, and all electrical connection parts shall be insulated. It is forbidden to expose metal contacts.

Debugging of electric control cabinet and module: the electric control cabinet is placed in a ventilated and dry place, keeping a safe distance from the equipment main body, and the cabinet door is well sealed; After connection, check before electrifying, and use multimeter to detect the on-off and insulation resistance of the line (≥5MΩ). Only when there is no short circuit or leakage can power on; After power-on, it is tested that the indicator lights and display screens of each electronic control module (temperature control, speed regulation, measurement and detection) are normal, and the communication with the upper computer is smooth, and there is no signal delay or loss.

Verification of safety protection devices: check whether the safety devices such as emergency stop button, high temperature alarm, overload protection and leakage protection are sensitive and effective; The temperature sensor and thermocouple of high-temperature module (such as melting spinning machine barrel) are installed in place, and the temperature measurement is accurate; The high-voltage generator of electrostatic spinning module shall be well grounded, and the grounding resistance shall be ≤4Ω to avoid safety accidents caused by high-voltage leakage.

Iv. Installation of fluid pipeline and temperature control system: no leakage and accurate temperature control.

Priority is given to pipeline connection and sealing: the raw material conveying pipeline for solution spinning, the melt pipeline for melt spinning and the coagulation bath pipeline for wet spinning are connected according to material adaptability (for example, stainless steel pipe for high-temperature melt and PTFE pipe for solution), and the pipelines run straight without bending, thus reducing fluid resistance; Special gaskets (such as fluororubber pads) are used at the joint, and the fastening strength is moderate to avoid pipeline deformation caused by too loose leakage and too tight. After installation, pressure holding test is conducted (1.2 times the rated pressure of the equipment), and there is no leakage and pressure drop after pressure holding for 30 minutes.

Accurate calibration of temperature control system: check the fitting degree of heating ring and temperature sensor for temperature control parts such as melt spinning drum, spinning assembly and solution insulation pipeline step by step, and there is no virtual connection or missing installation; After power-on, conduct the temperature rise test of the empty furnace, and raise the temperature according to the set temperature gradient (such as 50℃, 100℃ and 180℃), and test the deviation between the actual temperature of each point and the set temperature, and the deviation shall be ≤ 1℃. If the deviation exceeds the standard, timely adjust the temperature control parameters and replace the damaged heating or temperature measuring elements.

Cycling test of raw materials and media: cleaning and drying the raw material storage tank and solidification bath after installation to avoid internal impurities polluting raw materials; Carry out empty pipeline circulation test, check that the raw material delivery pump and metering pump are running normally, the pipeline is free of blockage and liquid accumulation, and the flow rate matches the set value to ensure continuous and stable raw material transportation.

5. Step-by-step debugging: from single module to the whole system, verify the running status step by step.

No-load debugging of single module: the equipment debugging follows the principle of "first single module, then whole system, first no-load and then material". First, each spinning module, transmission system, temperature control system and detection system are debugged without load. The melt spinning module tests the heating and heat preservation accuracy with no load, the solution spinning module tests the fluency of the raw material conveying pipeline, the electrostatic spinning module tests the stability of the high-voltage generator, and the online detection module (such as linear densitometer and strength meter) tests the accuracy of data acquisition. After a single module runs normally, linkage debugging can be carried out.

System-linked no-load debugging: after the debugging of a single module is completed, the whole system is linked with no-load operation to test whether the signal transmission and action connection between modules are smooth, such as the synchronization between metering pump and spinning assembly, the speed matching between drafting roller and silk winder, and the linkage between temperature control system and raw material transportation; During operation, check that the equipment has no abnormal sound, no leakage, no overtemperature and overpressure, and the electronic control system has no alarm. The upper computer can monitor and adjust all parameters in real time.

Small-dose ribbon spinning trial debugging: before ribbon debugging, raw materials should be pretreated (such as drying, filtering and melting) to remove impurities and bubbles to avoid blocking the spinneret; Trial spinning is carried out by using low-dose easy-to-spin raw materials (such as conventional polyester and polylactic acid), and the spinning process parameters (temperature, pressure, speed and drafting ratio) are gradually adjusted, and the spinning forming state is observed, and the yarn is gradually adjusted from low speed to high speed to avoid yarn breakage and flying caused by parameter mutation; During the trial spinning process, it is important to check the spinning uniformity of spinneret, the metering accuracy of metering pump, and the real-time and accuracy of online detection data.

6. Calibration and verification of process parameters: accurate matching to ensure the reliability of experimental data.

Calibration of core process parameters one by one: for different processes such as melting, solution and electrostatic spinning, the key parameters are calibrated respectively, such as the corresponding relationship between the flow rate and rotation speed of metering pump, the deviation between the temperature of temperature control system and the set value, the matching between the speed of drafting roller and the drafting ratio, and the correlation between the voltage of high-voltage generator and the electrostatic spinning forming effect; In the calibration process, many parallel tests are conducted, data are recorded and parameter files are established to ensure the accuracy and repeatability of parameter adjustment.

Performance verification of spinning samples: After the ribbon trial spinning, collect fiber samples for basic performance testing (linear density, strength, elongation and uniformity), and compare the correlation between sample performance and process parameters. If the sample performance deviation exceeds the standard, timely check the equipment reasons (such as spinneret blockage, insufficient precision of metering pump and uneven drafting speed), and adjust the equipment parameters until the sample performance is stable and meets the experimental requirements.

On-line detection system calibration: professional calibration of on-line detection components (such as linear density meter, tension sensor and temperature sensor) matched with equipment to ensure the accuracy and traceability of detection data; After calibration, the test data are compared with the results of off-line testing equipment in the laboratory, and the deviation is controlled within the allowable range to ensure the reliability of subsequent experimental data.

VII. Safety and operation specifications: Control the whole process to avoid equipment damage and safety accidents.

Special protection for high-temperature and high-pressure modules: When debugging high-temperature modules such as melt spinning, wear high-temperature protective gloves and goggles, and it is forbidden to directly touch high-temperature components with hands; When debugging the high-voltage generator of electrostatic spinning module, keep a safe distance, and it is forbidden to touch the spinning head and high-voltage line during high-voltage operation; During the operation of the equipment, it is forbidden to open the protective cover plate and disassemble the pipeline and fittings without authorization.

Standardized treatment of raw materials and waste liquid: the spinning raw materials (such as polymer solution and molten material) used in the debugging process should be sealed and preserved to avoid volatilization and pollution; The waste liquid produced by wet spinning is collected and treated according to the requirements of environmental protection in the laboratory, and direct discharge is strictly prohibited; Clean up the residual raw materials in the pipeline and spinning assembly in time after the equipment is stopped to prevent solidification and blockage.

Equipment operation and emergency training: after commissioning, give special training to operators to familiarize them with the operation process, parameter adjustment methods and safety precautions of each module of the equipment; Make clear the position and usage of the emergency stop button and alarm device, and formulate the emergency treatment scheme for equipment failures (such as broken wires, leakage, overtemperature and other failures) to avoid equipment damage caused by improper operation in case of sudden failure.

Eight, after debugging: acceptance and data retention, to ensure the subsequent stable operation of equipment.

Strictly check the acceptance of all items: after commissioning, conduct the acceptance of all items according to the equipment technical agreement and acceptance standards, including the stability of equipment operation, the accuracy of process parameters, the performance of spinning samples, the reliability of online detection data, the effectiveness of safety protection devices, etc. Continuous no-load operation for 48 hours, with material operation for 24 hours, equipment failure-free, data deviation is qualified.

Complete retention of data and materials: arrange equipment installation and debugging data, including installation drawings, electrical wiring diagrams, parameter calibration records, trial spinning experimental data, equipment calibration reports, etc., and establish equipment technical files; Keep the original spare parts list, wearing parts specifications, equipment operation manual and maintenance procedures for subsequent equipment maintenance, spare parts replacement and process optimization.

Initial maintenance and operation disclosure: After commissioning, the equipment shall be thoroughly cleaned to remove residual raw materials, debris and stains, and the transmission parts and bearing parts shall be lubricated for the second time; Do a good job of operation disclosure to operators, and make clear the key points of daily maintenance of equipment (such as pipeline cleaning, spinning component maintenance, dust removal of electric control module, etc.). It is forbidden to change the core parameters of equipment and disassemble precision parts without authorization.

Nine, the core taboo: no illegal operation, put an end to equipment precision and safety hazards.

It is forbidden to install equipment in uneven, vibration and strong electromagnetic interference sites, and it is forbidden to directly connect power supply lines without voltage regulation protection;

It is forbidden to violently install precision parts (spinneret, metering pump), and it is forbidden to replace special accessories with non-original gaskets and lubricating oil;

It is forbidden to mix the electrical lines, and the signal lines are not grounded. It is forbidden to make insulation and on-off detection before electrifying, and it is forbidden for non-professionals to make electrical wiring.

It is forbidden to run the pipeline with materials without pressure maintaining test, and it is forbidden to debug the high-temperature module if the temperature rises too fast and the high-voltage module is not grounded.

It is forbidden to skip single module debugging and directly carry out system linkage, and it is forbidden to carry out the first trial spinning with materials with high viscosity and impurities;

It is forbidden to dismantle the protective device and touch the high temperature/high pressure parts without authorization when the equipment is running, and it is forbidden to directly discharge the waste liquid and stop the machine without cleaning the residual raw materials.