Brief introduction: installation and debugging process of composite spinning multifunctional testing machine

The installation and debugging process of the multi-functional testing machine for composite spinning needs to combine the equipment structure (such as spinning system, winding system, temperature control system, etc.) and functional characteristics, and is usually divided into five core links: preliminary preparation, equipment installation, system debugging, performance verification and delivery training. The process is briefly introduced as follows:

First, preliminary preparation: laying the foundation for installation

Site and environment confirmation

Check the size of the site (equipment operation space and maintenance passage need to be reserved) to ensure that the ground is flat (bearing capacity should meet equipment requirements, usually ≥ 500 kg/㎡);

Confirm the environmental conditions: the temperature is controlled at 20-28℃, the humidity is 40%-60%, there is no dust and corrosive gas, and strong vibration sources (such as adjacent heavy equipment) are avoided.

Material and technical preparation

Check the equipment parts (main engine, spinning assembly, winding device, electrical control cabinet, etc.), supporting tools (special wrench, calibration instrument) and spare parts to ensure no missing/damage;

Be familiar with the equipment manual, electrical schematic diagram and installation drawings, and make clear the connection requirements of various systems (such as heating, cooling and transmission).

Power and pipeline preset

Complete the pipeline laying and testing of power supply (such as 380V three-phase five-wire system, which requires independent grounding, with grounding resistance ≤4Ω), compressed air (pressure 0.6-0.8MPa, dry and oil-free) and cooling water (flow/temperature meets the requirements of temperature control system) in advance.

Second, equipment installation: accurate assembly in place

Host in place and fixed.

Use forklift/hoisting equipment to transport the main engine to the preset position, calibrate the levelness of the equipment (error ≤0.1mm/m) with a level meter, and then fix the base with expansion bolts to prevent vibration and displacement during operation.

Core component installation

Assemble the spinning system (spinneret, spinning tunnel, cooling air ring) and winding system (roller, winding roller, tension sensor) according to the drawing sequence, and ensure that the components are aligned (for example, the coaxiality of spinneret and tunnel center is ≤ 0.5 mm);

Connect the electrical pipelines (power line, control line and sensor signal line), and mark the interface number to avoid wrong connection; Connect the gas/liquid pipeline, and the interface should be sealed (such as using sealing ring) to prevent leakage.

Third, system debugging: sub-module inspection and optimization

Electrical system debugging

Check the insulation of the circuit before electrifying (measured by shaking table, insulation resistance ≥10MΩ), and make sure there is no short circuit/leakage;

Start the control cabinet, test the communication stability of PLC, touch screen and other control systems, and calibrate the accuracy of sensors (such as temperature sensors and tension sensors) (the error should meet the equipment standards).

Single machine function debugging

Test each subsystem separately:

Temperature control system: set the target temperature (such as spinning box 280-320℃), observe the heating rate and constant temperature stability, and the error should be ≤ 1℃;

Transmission system: start the roller and winding roller, and test the accuracy and stability of the rotating speed (such as 500-3000m/min) without jamming or abnormal sound;

Cooling/air supply system: open the cooling air ring and compress the air, and check whether the air volume/pressure reaches the standard and the air flow is evenly distributed.

Linkage debugging

Simulate the actual spinning process, start the whole link of "spinning-cooling-drafting-winding", and test the synergy of each system, such as whether the filament smoothly enters the cooling tunnel after spinning, whether the tension is stable during winding (fluctuation ≤ 2%), and there is no phenomenon of broken filament and hairy filament.

Fourth, performance verification: to ensure that the test requirements are met.

No-load commissioning

Run the equipment continuously for 24-48 hours without raw materials, monitor the stability of various system parameters (temperature, rotation speed and tension), and record whether there is any abnormality (such as abnormal sound and error report).

Load test (with material test)

Select standard raw materials (such as PET chips), carry out spinning test according to preset process parameters (spinning temperature, drafting ratio and winding speed), and test key indicators after producing samples:

Wire quality: diameter uniformity (error ≤5%), breaking strength and elongation;

Winding effect: whether the package is formed neatly, without loose loops and overlapping wires.

Functional compatibility verification

If the equipment supports multiple kinds of spinning (such as composite spinning and superfine denier spinning), it is necessary to switch different process parameters to test the fluency and parameter adaptability of function switching.

V delivery and training: complete the closed loop.

Commissioning report and acceptance

Sort out the debugging data (no-load/load operation records and sample inspection reports), form the Installation and Debugging Report, and check with users whether the equipment performance meets the contract requirements and confirm the acceptance.

Equipment cleaning and spare parts handover

Clean the residual raw materials/dust on the surface and inside of the equipment, sort out and hand over the remaining spare parts, special tools and technical data (instructions, drawings and calibration certificates).

Operation and maintenance training

Train user operators: equipment start-stop process, parameter setting and routine inspection (such as pipeline leakage inspection and sensor cleaning);

Training for maintenance personnel: troubleshooting common faults (such as temperature control failure and wire breakage alarm) and regular maintenance items (such as lubricating transmission parts and replacing filter elements).

Through the above process, it can ensure the stable and accurate operation of the composite spinning multifunctional testing machine and meet the requirements of subsequent tests or small batch production.