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立式、卧式、斜式、斜卧式四种三辊XBZD100/70-900斜式多层共挤片材机组
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管理员 shiela
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上次发言:
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收藏(0)片材作业指导书

片材作业指导书

1目的

规范片材工序的操作过程,使操作工掌握其工艺方法。

2适用范围

片材工序及片材机的操作。

3内容

3.1开机前

3.1.1给需加油润滑的部位加油;

3.1.2检查水路有无漏水现象;

3.1.3检查各加热区温控表是否符合工艺设定要求;

3.1.4接通电源检查各加热区电热温控是否正常及各个变频器操作面板的速度控制是否处于“0位”。

注:螺杆料筒温度未到设定温度严禁起动主机,以免损坏设备。

3.1.5清理机台及地面卫生。

4操作方法

4.1加热:

4.1.1先加热过滤网部分以及第六区;

4.1.2过滤网部分温度升高到180℃时开始加热模头。

4.1.3在前五区的加热温度加热到150℃时开冷却水塔。

4.2擦拭辊筒

4.2.1用柔软干净的碎布,擦拭滚筒,擦滚筒应从辊筒转出的方向擦拭,同时应注意安全,不东张西望和别人聊天,思想要集中;

4.2.2若滚筒表面粘有污物,用白矿油浸湿碎布,细心认真的擦拭;

4.2.3保持滚筒干净光亮后才可牵引片材。

4.3烘干搅拌

4.3.1在加热过程中,领回原料及生产常用物品。并做好生产统计记录;

4.3.2根据生产技术要求,进行烘干;

4.3.3按照技术要求进行准确的配比搅拌。

4.4更换过滤网

4.4.1各加热区的温度达到设定要求时更换过滤网;

4.4.2在更换过滤网时,启动油泵电机,待压力到设定值。(自然关闭)点动换网按钮,拉出换网多孔板,装上准备好的过滤网。

4.5准备牵引片材

4.5.1各加热区温度达到设定温度时,保温二十分钟;

4.5.2料斗加料,启动主机,应从OHZ慢慢加速,在此时注意观察主电机电流表指数,如果电流猛升而模头不出料,要马上停机进行检查,看是否加热区域受热不够,塑料没有完全软化造成主机阻力过大,以防止螺杆及模头等部位损坏,如果电流平稳上升,即加热正常可以开机牵引生产;

4.5.3塑料挤出模头时,用专用铜片伸入模唇内反复清理刮去藏在模唇的烧焦物,待见光亮的片材挤出为止,停止主机;

4.5.4推动辅机至模唇的位置,并起动辊筒电机及收卷牵引电机;

4.5.5再启动主机,从OHZ慢慢加速,挤出的塑胶便借辊筒转动挤压过去,随着辊筒转动的方向,便可牵引成功。

4.5.6`牵引成功后,应保持辊缝之间有适量的余胶并且两边的边角料切割不会太宽或太窄,如会,就要推动辅机找到最佳位置,并按工艺要求调好片材厚度.与宽度。

4.5.7正常生产过程中要保持余胶量适当一致,不能时多时少,从而保持片材厚度不会变化,保证片材不出现花纹,余胶过多,两边切割边角料过宽,不仅造成浪费,而且使片材表面不光滑,出现大波浪花纹或者出现粒粒泪点等现象,余胶过少,两边边角料切割不到,同时片材厚度变薄,片材表面会出现条状花纹或波浪形花纹。

注:根据片材的厚薄调整余胶大小,一般片材薄余胶小,片材厚余胶大。

4.5.8料斗加料时小心谨慎,因片材机无熔体泵所有要保持料斗盛有一定的原料,从而保持下料的压力不会改变,从而保持余胶稳定。

4.5.9在机械运作正常时,原料配制与生产开机时要求一样,另外多观察,控制台上所有仪表有无异常变化,例如:生产正常情况下主机电流保持在180A之间。

4.5.10生产过程中根据生产工艺技术需要,擦拭辊筒时从辊筒的转出方向用手指捏至少量碎布从辊筒的左右两端来回轻轻擦拭。

4.5.11当设备经一定时间的连续工作后(视主机电流的升高或降低;所流片材有无黑点、杂物)应及时更换过滤网。更换过滤网时先启动油泵电机,待到设定压力后(电机停)即可按上下换网开关。

4.5.12收卷好的片材重量约100-250公斤左右即可更换(不得超过250公斤),更换后称片材重量,并标明片材规格.重量、生产人等记录。

4.5.13出现异常紧急停机后应马上把上辊提起,并清理三辊之间余胶,以免压坏辊筒.

4.5.14正常停机时先停主机,待三辊余胶压延完方可停三辊电机,然后再停收卷.

4.5.15保持机台周围地面卫生,定时清理卫生。

5工艺标准


5.1PP片材:

5.1.1透明度:符合高透明标准。

5.1.2光泽度:流出片材色泽鲜明,亮度极佳,无花纹、无斑点、无杂质。

51.3重量要求:每一卷片材重量不能超过250kg,不能少于100kg。

5.1.4片材厚度准许偏差±0.02mm。

51.5收卷要整齐,堆放要整齐并套袋防止灰尘。

5.1.6原料配制要按规定标准,以保证片材的质量。

5.1.7片材宽度准许偏差±0.02mm。

5.1.8厚度在0.70mm0.82mm的片材,边角料宽度允许在8 mm12 mm之内.0.87mm0.92mm的片材,边角料宽度允许在 10mm17 mm之内.1mm以上的片材,边角料宽度允许在17mm20mm之内。


5.2PS片材(略)

5.3降解片材(略)

 

6达标产量

根据不同的机台,不同的规格,产量达标应以主电机电流、频率为基础,例如:生产0.70mm—1.00mm以内厚度的片材达标产量为:

1号片材机:主电机电流为????A???kg/小时。

2号片材机:主电机电流为??--??A??kg/小时。

生产其它规格片材达标产量另行通知。

7故障分析及其排除

7.1片材断裂

原因:

7.1.1机身或机头温度偏低。

7.1.2模唇开度小。

7.1.3牵引速度太快。

解决方法:

7.1.4适当升高温度。

7.1.5调节螺栓,增加开度。

7.1.6减少牵引速度。

7.2厚薄不均

原因:

7.2.1机身温度低,塑化不均。

7.2.2机头温度不均匀。

7.2.3模唇开度不均匀。

7.2.4阻流块调节不当。

7.2.5牵引速度不稳定。

解决方法

7.2.6适当提高机身温度,使塑化均匀。

7.2.7合理调整各区温度。

7.2.8合理调节阻流块。

7.2.9重新调节模唇开度。

7.2.10检查牵引压紧程度,并使其速度稳定。

7.3纵向出现条纹

原因:

7.3.1模唇划伤。

7.3.2模唇内堵塞杂质。

7.3.3三辊机辊筒表面划伤。

7.3.4传动链条变形跳动

解决方法:

7.3.5研磨模唇平直表面。

7.3.6清理模唇。

7.3.7调换或修磨辊筒。

7.3.8更换链条。

7.4气泡

原因

7.4.1温度过高。

7.4.2原料有水份或有易挥发物。

解决方法

7.4.3适当降温,防止分解。

7.4.4进行预烘,除出水份和挥发物。

7.5表面发黑或变色线条、斑点

原因:

7.5.1机头温度高。

7.5.2机头有死角,物料停滞分解。

7.5.3机头内有杂质阻塞。

7.5.4辊筒表面有拆除物。

解决办法

7.5.5适当降温,防止分解。

7.5.6清理机头,修除流道死角。

7.5.7清理机头,清除杂质。

7.5.8擦拭辊筒并检查配方。

7.6表面粗糙并出现横向降纹

原因

7.6.1物料塑化不好。

7.6.2三辊间余料太多。

7.6.3模唇开度不均匀。

7.6.4压光辊压力太大。

7.6.5三辊机距模唇间距过大。

解决方法:

7.6.6适当提高塑化温度,延长塑化时间。

7.6.7减少螺杆转速或提高牵引速成度。

7.6.8调整模唇间隙。

7.6.9增加压光辊的间距。

7.6.10尽量缩小两者的间距。

7.7板面凹凸不平或光泽不好

原因:

7.7.1机头温度偏低。

7.7.2压光辊温度偏低。

7.7.3压光辊表面不光洁。

7.7.4辊筒之间无一定量的存料。

7.7.5原料中含有水份。

解决方法:

7.7.6提高机头温度。

7.7.7提高压光辊温度。

7.7.8调换或抛光压光辊。

7.7.9适当提高螺杆转速度或降低牵引速度。

7.7.10干燥原料。

7.8片材一边厚一边薄或“跑偏”

原因

7.8.1模唇开度不一。

7.8.2三辊间距不一。

7.8.3牵引辊间距不一。

解决方法

7.8.4调整模唇开度。

7.8.5调整辊筒的间距。

7.8.6调整牵引辊的间距。

7.9片材中间比两边薄。

原因:

7.9.1模头中间部位加热温度偏低。

7.9.2模唇中间部位开度偏小。

7.9.3模唇中间部位有堵塞现象。

解决方法

7.9.4提高模唇中间部位温度。

7.9.5调整模唇中间部位开度。

7.9.6清理模唇。


8相关文件









9相关记录

片材生产记录

10附件

11片材工艺标准

序号

区域

类别

温度

备注

1

1区控温

标准温度

220

 

关键限值

217-225

 

2

2区控温

标准温度

225

 

关键限值

222-230

 

3

3区控温

标准温度

230

 

关键限值

227-235

 

4

4区控温

标准温度

235

 

关键限值

232-240

 

5

5区控温

标准温度

240

 

关键限值

237-245

 

6

滤网控温

标准温度

245

 

关键限值

242-250

 

7

模头右控温

标准温度

200

 

关键限值

197-205

 

8

模头中控温

标准温度

195

 

关键限值

192-200

 

9

模头左控温

标准温度

200

 

关键限值

197-205

 

10

三辊温度(上辊)

标准温度

15-45

 

关键限值

15-45

 

11

三辊温度(中辊)

标准

20-60

 

关键限值

20-60

 

12

三辊温度(下辊)

标准

15-55

 

关键限值

15-55

 

13

片材厚薄度

关键限值

±0.03mm

 

 






12 配料工艺标准

规格名称

杯重

片材规格

配比

单位:斤

搅拌时间

10+1)分钟

A级杯标准配比


B级杯标准配比

实际时间

关键限值

聚丙烯

聚乙烯

二次料

聚丙烯

聚乙烯

二次料

10

10±1

15克四角

1

64×70

0

0

100

0

0

100%

10

10±1

18.5克四角

1.1

64×70

0

0

100

0

0

100%

10

10±1

25克光头

1.2

64×82

100

5

0

0

0

100%

10

10±1

30克光头

1.3

64×87

100

5

0

0

0

100%

10

10±1

30克橄榄

1.3

64×87

50

10

50

0

2

100%

10

10±1

35克心型

1.7

64×77

50

5

50

0

0

100%

10

10±1

40克碗型

2

64×92

100

5

0

0

0

100%

10

10±1

70克圆底

2.5

64×75

100

5

0

0

0

100%

10

10±1

70克葵花

2.4

64×70

50

10

50

0

0

100%

10

10±1

42克六角

2

64×92

50

10

50

0

0

100%

10

10±1

100克桶杯

4

64×125

100

0

0

0

0

100%

10

10±1

200克水果

7

64×130

100

5

0

0

0

100%

10

10±1

80克碗型

3.3

64×95

100

5

0

0

0

100%

10

10±1

甜杯酒225


0

0

100%

0

0

100%

10

10±1

甜酒杯265


0

0

100%

0

0

100%

10

10±1


0

0

0

0

0

100%

10

10±1


0

0

0

0

0

100%

10

10±1


0

0

0

0

0

100%

10

10±1


0

0

0

0

0

100%

10

10±1


0

0

0

0

0

100%

10

10±1


0

0

0

0

0

100%

10

10±1

送花(0)臭鸡蛋(0)引用回复2019-07-12 20:45 [1楼]
会员 Tina123
等级:
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上次发言:
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Work instructions of sheet

 

1. Purpose

Standardize the operation process of sheet material, so that operators can master the process method.

2 scope of application

Sheet process and sheet machine operation.

3 content

3.1 before starting

3.1.1 add oil to the parts to be lubricated;

3.1.2 check whether there is water leakage;

3.1.3 check whether the temperature control meter of each heating zone conforms to the requirements of process setting;

3.1.4 turn on the power to check whether the electric heating temperature control in each heating area is normal and whether the speed control of each frequency converter operation panel is in "0 position".Note: it is forbidden to start the main engine before the screw barrel temperature reaches the set temperature to avoid damage to the equipment.

3.1.5 cleaning machine and ground health.

4 operation method4.1 heating:

4.1.1 first heat the filter part and the sixth zone;

4.1.2 heat the die head when the temperature of part of filter screen rises to 180℃.

4.1.3 open the cooling water tower when the heating temperature in the first five zones reaches 150℃.

4.2 wipe roller

4.2.1 wipe the roller with a soft and clean rag. The roller shall be wiped from the direction of the roller turning out, and pay attention to safety. Do not look around and chat with others.

4.2.2 if there is dirt on the surface of the drum, wet the broken cloth with white mineral oil and wipe it carefully;

4.2.3 do not pull sheet until the roller is clean and bright.

4.3 drying and stirring

4.3.1 in the heating process, retrieve raw materials and production of common items.And make production statistics record;

4.3.2 drying according to production technical requirements;

4.3.3 stir accurately according to technical requirements.

4.4 replace the filter

4.4.1 replace the filter when the temperature of each heating zone reaches the set requirements;

4.4.2 when the filter is replaced, start the oil pump motor until the pressure reaches the set value.(natural close) click the screen change button, pull out the screen change porous plate, and install the prepared filter screen.

送花(0)臭鸡蛋(0)引用回复2019-07-22 14:35 [2楼]
会员 Tina123
等级:
上等兵
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2/68
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172
经验值:
172
上次发言:
08-04 10:24

4.5 prepare the traction sheet

4.5.1 when the temperature of each heating zone reaches the set temperature, keep it warm for 20 minutes;

4.5.2 hopper charging, it should start the host, OHZ speed slowly, look at this time the main motor current meter index, if soar and die head is not discharging current, to immediately stop check to see if enough heating area is heated, plastic not fully softened host resistance is too large, in order to prevent damage of screw and die top part, if the current rising steadily, the normal heating can start drawing production;

4.5.3 when the plastic extrusion die head is inserted into the lip of the die with a special copper piece, repeatedly clean and scrape the burnt matter hidden in the lip of the die, and stop the main engine until the sheet material is extruded;

4.5.4 push the auxiliary machine to the position of mold lip, and start the roller motor and winding traction motor;

4.5.5 restart the main engine and accelerate slowly from OHZ. The extruded plastic will be extruded through the roller rotation. With the direction of roller rotation, traction can be successful.

4.5.6 after successful traction, appropriate amount of residual glue should be maintained between the roll seam and the cutting of the scraps on both sides should not be too wide or too narrow. If so, push the auxiliary machine to find the best position and adjust the thickness and width of the sheet according to the process requirements.Resin

4.5.7 more than normal production process to keep appropriate is consistent, not much less, will not be changed so as to keep the sheet thickness, sheet not be patterns, more than too much glue, both sides cutting scrap is too wide, not only wasteful, but also make the sheet surface is not smooth, a big wave patterns or grains phenomenon such as tears, too little glue, on both sides of leftover material cutting, sheet thickness thinning at the same time, the surface of the sheet will be strips or wavy pattern.Note: the size of residual glue is adjusted according to the thickness of the sheet.

4.5.8 be careful when feeding the hopper. As there is no melt pump in the sheet machine, it is necessary to keep certain raw materials in the hopper so as to keep the feeding pressure unchanged and maintain the residual glue stability.

4.5.9 when the mechanical operation is normal, the preparation of raw materials shall be the same as the requirements when the production starts up. In addition, observe more to see whether all the meters on the control platform have abnormal changes. For example, the current of the host machine is maintained between 180A under normal production conditions.

4.5.10 in the production process, according to the needs of production technology, when wiping the roller, pinch it with your finger from the direction of the roller to a small amount of rags and gently wipe it back and forth from the left and right ends of the roller.

4.5.11 after the continuous operation of the equipment for a certain period of time (depending on the increase or decrease of the host current;Whether there are black spots and sundries on the flow sheet) should be replaced in time.When replacing the filter screen, first start the oil pump motor, and then press the up and down switch when the pressure is set (the motor stops).

4.5.12 the rolled sheet weight is about 100-250 kg and can be replaced (no more than 250 kg). After replacement, the sheet weight shall be measured and the sheet specification shall be indicated.

4.5.13 after abnormal emergency shutdown, the upper roller shall be lifted immediately and the residual glue between the three rollers shall be cleaned to avoid crushing the roller.

4.5.14 stop the main engine when it is normally stopped, and stop the motor after three rolls of residual rubber calendering, and then stop winding.

4.5.15 keep the ground around the machine clean and clean regularly.

5 process standard

5.1 PP sheet:

5.1.1 transparency: meet high transparency standards.

5.1.2 gloss: the outflow sheet has bright color and excellent brightness, without patterns, spots or impurities.

5.1.3 weight requirements: the weight of each coil shall not exceed 250kg, and shall not be less than 100kg.

5.1.4 allowable deviation of sheet thickness ±0.02mm.

5.1.5 roll up neatly, stack neatly and bag to prevent dust.

5.1.6 preparation of raw materials should follow the prescribed standards to ensure the quality of sheet materials.

5.1.7 allowable deviation of sheet width ±0.02mm.

5.1.8 for sheet materials with thickness of 0.70mm and 0.82mm, the width of scraps is allowed to be within 8 mm and 12 mm; for sheet materials with thickness of 0.87mm and 0.92mm, the width of scraps is allowed to be within 10mm and 17mm; for sheet materials with thickness of 1mm and above, the width of scraps is allowed to be within 17mm and 20mm.

5.2PS sheet material (omitted)

5.3 degraded sheet (omitted)

6. Standard output

According to different machines and different specifications, the standard output should be based on the current and frequency of the main motor. For example, the standard output of sheet materials with a thickness of 0.70mm -- 1.00mm is:No. 1 sheet mill: the current of main motor is??-??A,?????Kg/h.No. 2 sheet machine: the current of main motor is??-????A,??????Kg/h.

Standard output of sheet materials of other specifications will be notified separately.

7. Fault analysis and troubleshooting

7.1 sheet fractureThe reason:

7.1.1 low body or head temperature.

送花(0)臭鸡蛋(0)引用回复2019-07-22 14:35 [3楼]
会员 Tina123
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7.1.2 small die lip opening.

7.1.3 too fast traction speed.Solutions:

7.1.4 appropriately raise the temperature.

7.1.5 adjust bolts to increase opening.

7.1.6 reduce traction speed.

7.2 uneven thicknessThe reason:

7.2.1 low body temperature and uneven plasticization.

7.2.2 uneven head temperature.

7.2.3 uneven mold lip opening.

7.2.4 improper adjustment of the choke block.

7.2.5 unstable traction speed.

The solution

7.2.6 appropriately raise the temperature of the fuselage to ensure even plasticization.

7.2.7 reasonable adjustment of district temperature.

7.2.8 adjust the choke block reasonably.

7.2.9 re-adjust the lip opening of mold.

7.2.10 check the tightening degree of traction and make its speed stable.

7.3 longitudinal stripes appear

The reason:

7.3.1 mold lip scratches.

7.3.2 blocking impurities in die lip.

7.3.3 scratches on the surface of roller of three-roll machine.

7.3.4 deformation and runout of transmission chain

Solutions:

7.3.5 flat surface of grinding die lip.

7.3.6 clean mold lip.

7.3.7 replace or repair roller.

7.3.8 replace the chain.

7.4 the bubbles

Reason

7.4.1 high temperature.

7.4.2 the raw materials contain moisture or volatile substances.The solution

7.4.3 properly cool down to prevent decomposition.

7.4.4 pre-bake to remove moisture and volatiles.

7.5 dark or discolored lines and spots on the surfaceThe reason:

7.5.1 high head temperature.

7.5.2 the machine head has dead Angle and material stagnation decomposition.

7.5.3 impurities in the head block.

7.5.4 removal objects are found on the surface of roller.The solution

7.5.5 properly cool down to prevent decomposition.

7.5.6 clean the machine head and repair dead Angle of flow passage.

7.5.7 clean the head and remove impurities.

7.5.8 wipe roller and check formula.

7.6 rough surface with transverse striationwhy

7.6.1 poor plasticization of materials.

7.6.2 too much surplus material between three rollers.

7.6.3 uneven mold lip opening.

7.6.4 too high pressure of calender roll.

7.6.5 the distance between the lip of the three-roll machine distance die is too large.Solutions:

7.6.6 appropriately increase the plasticizing temperature and extend the plasticizing time.

7.6.7 reduce screw speed or improve traction speed.

7.6.8 adjust the lip gap of die.

7.6.9 increase the spacing of calender rollers.

7.6.10 minimize the gap between the two.

7.7 uneven surface or poor lusterThe reason:

7.7.1 low head temperature.

7.7.2 low pressure roller temperature.

7.7.3 the surface of the roller is not clean.

7.7.4 there is no quantitative stock between rollers.

7.7.5 raw materials contain water.Solutions:

7.7.6 raise the head temperature.

7.7.7 increase the pressure roller temperature.

7.7.8 replace or polish the calender roll.

7.7.9 increase the screw rotation speed or reduce the traction speed.

7.7.10 dry raw materials.

7.8 thick and thin sheets or "off-track"why

7.8.1 die lip opening is different.

7.8.2 different spacing between three rollers.

7.8.3 traction roller spacing is different.The solution

7.8.4 adjust mold lip opening.

7.8.5 adjust the spacing of rollers.

7.8.6 adjust the spacing of traction rollers.

7.9 the middle of the sheet is thinner than the sides.The reason:

7.9.1 the heating temperature of the middle part of die head is low.

7.9.2 the opening of the middle part of die lip is too small.

7.9.3 there is blockage in the middle part of mold lip.The solution

7.9.4 raise the temperature of the middle part of die lip.

7.9.5 adjust the opening of the middle part of die lip.

7.9.6 clean mold lip.

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