How to install and debug the multifunctional intelligent spinning experimental machine?

This point you are concerned about is particularly critical! The core of the installation and debugging of the multifunctional intelligent spinning experimental machine is to ensure the accurate positioning of the equipment, the coordinated stability of the system and the adaptation of the parameters to the spinning requirements. It is necessary to operate according to the process of "basic preparation → step-by-step installation → fine debugging → verification and acceptance", focusing on controlling the linkage accuracy between the intelligent module and the mechanical parts.

First, the installation preparation points

Adaptability between site and environment: the installation ground should be flat and firm, with bearing capacity ≥800kg/㎡, and equipment operation space (around ≥1.2 meters) and maintenance passage should be reserved; The ambient temperature is controlled at 15-30℃ and the humidity is 40%-60%, so as to avoid dust, vibration sources (such as large machine tools) and corrosive gases, and prevent the accuracy of the intelligent sensor from being affected.

Equipment and material inspection: unpacking to check the integrity of the main engine, spinning components (nozzles, metering pumps), intelligent control system (touch screen, data acquisition module), heating unit, cooling system and other components, and check that the fuselage and precision components are not damaged during transportation; Prepare suitable spinning raw materials (such as polymer chips and spinning solution), special lubricating oil, seals and other consumables in advance.

Hydroelectric pretreatment: Connect three-phase alternating current (voltage fluctuation ≤ 3%) that meets the equipment requirements, and equip with independent grounding device (grounding resistance ≤4Ω) to avoid electromagnetic interference with intelligent module; Compressed air should be filtered and dried (water content ≤ 0.01g/m, pressure stable at 0.6-0.8mpa); The cooling water system is connected in place, the water temperature is controlled at 18-22℃, and the flow rate meets the equipment standard.

Second, the core installation operation precautions

1. Installation of mechanical parts

Main engine positioning: use a spirit level to calibrate the equipment level, and the horizontal error of the fuselage is ≤0.1mm/m, and adjust the anchor bolts to avoid vibration deviation during operation; Connect the spinning components (nozzle, metering pump and drafting roller), ensure that the installation surface is clean and free of impurities, and tighten the fastening bolts diagonally several times to prevent the components from deforming.

Spinning channel assembly: accurately install spinneret (coaxial with the center of receiving device ≤0.02mm), and adjust the distance between cooling air ring and spinneret (conventional 5-10mm, fine-tuned according to raw material characteristics); Check the parallelism of the drafting roller (error ≤0.01mm) to ensure that the roller surface is clean and scratch-free, so as to avoid affecting the fiber traction uniformity.

Auxiliary system connection: seal the pipeline interface (raw material conveying pipe, cooling water pipe) to prevent leakage; Install waste recycling device to ensure smooth collection of spinning waste and avoid accumulation affecting equipment operation.

2. Intelligent system and electrical installation

Connection between lines and modules: check the wiring in the electrical box to ensure that the intelligent sensors (temperature, pressure and speed sensors), servo motors and data acquisition modules are firmly connected, and the signal transmission line is away from the power line to reduce interference; Connect the touch screen with the host control system to test the communication stability.

Debugging of safety devices: check the emergency stop button, safety door, overload protection and other devices to ensure that the equipment stops immediately after triggering, and the intelligent system records fault information synchronously; Verify alarm functions (such as over-temperature and over-pressure alarm) to ensure timely and accurate response.

Third, the key steps of fine debugging

1. No-load debugging (cooperation between core verification machinery and intelligent system)

System preheating: start the equipment, preheat the heating unit according to the operating rules (temperature error ≤ 1℃), and the intelligent system sets the heating rate (conventional 2-5℃/min) to avoid local overheating; Run at no-load for 30-60 minutes, monitor the parameters such as temperature, speed and pressure of all components, and confirm the accuracy of data acquisition (error ≤0.5%) through the touch screen.

Mechanical action test: run the spinning process manually or at low speed (metering pump → spinning → drafting → winding) to observe that all components are free from jamming and abnormal sound; The intelligent system tests the functions of automatic speed regulation and parameter switching, and verifies the response speed of drafting multiple and winding speed adjustment (≤0.1s).

2. Load debugging (adapting raw materials and process, core verifying spinning effect)

Raw material adaptation: configure spinning raw materials according to experimental requirements (for example, melt spinning raw materials are dried until the water content is less than or equal to 0.05%, and the concentration of solution spinning raw materials is accurately adjusted according to the formula), and set the raw material delivery rate through the intelligent system to ensure the stable supply.

Debugging of process parameters: starting from low speed and low load (such as spinning speed of 50-100m/min), gradually adjust parameters such as temperature, pressure and drawing multiple, and the intelligent system records data such as fiber diameter and strength in real time; Every time a group of parameters are adjusted, the fiber properties are sampled and tested until the experimental requirements are met (for example, the fiber diameter uniformity error is ≤ 5%).

Intelligent function optimization: debug data storage and curve analysis functions to ensure the traceability of spinning process parameters; Test the automatic correction function (such as automatic adjustment of drafting deviation) to verify the correction accuracy of abnormal parameters by intelligent system.

3. Stability verification: after continuous load operation for 2-4 hours, the intelligent system monitors and records the fluctuation of key parameters to ensure no obvious deviation; Check the quality (diameter uniformity, surface smoothness) of fiber products, and there are no problems such as burrs and broken ends.

IV. Acceptance and matters needing attention in the later period

Acceptance criteria: the equipment runs stably (vibration ≤0.02mm/s, noise ≤ 70 dB); The intelligent system has accurate parameter control and complete data acquisition; The spinning finished product meets the experimental requirements, and the continuous operation is trouble-free.

Post-finishing: clean the equipment surface and pipeline, and maintain the precision parts (spinneret and sensor); Record the installation and debugging parameters (raw material formula, process parameters, intelligent system settings) and test results in detail, and form a debugging report.

Personnel training: instruct operators to be familiar with the operation of intelligent system (parameter setting, data export and troubleshooting), and strictly follow the operation procedures to avoid equipment failure caused by misoperation.