D20-PS 隔離輸入通道模塊

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D20-PS 隔離輸入通道模塊

主機聯(lián)動生產(chǎn)線的主機部分為XJF-D150×120銷釘機筒冷喂料雙復合擠出機機組,主要由兩臺銷釘機筒冷喂料擠出機(包括φ150×16D擠出機和φ120×14D擠出機)、150/120二復合液壓機頭、液壓動力系統(tǒng)、溫控系統(tǒng)、兩臺供料機(包括φ150擠出機供料機和φ120擠出機供料機)、鋼架平臺、整體底座、電氣控制系統(tǒng)等組成。液壓機頭流道尺寸(大寬度×厚度):480×20mm 2.2輔線本聯(lián)動裝置主要由接取輸送裝置、冷卻輥道及測寬裝置、上坡運輸帶I、胎側(cè)貼過渡膠片裝置、上坡運輸帶Ⅱ、噴淋冷卻裝置、下坡運輸帶、定長裁斷裝置、二次吹風及快速分離輥道、單條終檢秤、人工拾取輥道裝置、胎側(cè)過橋運輸帶、卷取運輸帶、四工位卷取裝置及生產(chǎn)線電氣控制系統(tǒng)等組成,與XJF-D150×120兩復合銷釘機筒冷喂料擠出機組配套使用,主要用于子午線輪胎的胎側(cè)膠復合擠出成雙條(或單條)以及其后的接取、冷卻、裁斷或卷取等。 3 二復合擠出機組二復合擠出機組是整條聯(lián)動線的核心,其性能的好壞直接關(guān)系到制品的質(zhì)量,影響到制品的擠出溫度以及斷面的尺寸。國內(nèi)外的擠出機大都存在著擠出溫度偏高的現(xiàn)象,尤其對壓型擠出機更是如此;另外對于擠出較小斷面的胎側(cè)制品,存在機頭壓力過高,雙條擠出左右不對稱等現(xiàn)象。這是兩個必須解決的問題,在此根據(jù)調(diào)試中的經(jīng)驗作一個小結(jié)。 3.1 溫度的控制該擠出機溫控裝置分為九段溫控單元,分別對擠出機機頭的上模、中模、下模、120擠出機和150擠出機的機筒擠出段、塑化段、螺桿分別進行工藝溫度控制,以適應擠出生產(chǎn)過程的工藝要求。溫控單元段的溫度設(shè)定太低,膠料在機筒內(nèi)的流動性不好,一方面造成機頭壓力過高,另一方面易使擠出胎側(cè)的表面出現(xiàn)冷斑,而溫控單元段的溫度設(shè)定太高又直接提高了制品的擠出溫度。調(diào)試中不妨做以下對比試驗: φ150/φ120擠出機二復合液壓機頭擠出制品塑化段擠出段螺桿上模中模下模溫度現(xiàn)象溫度較低 45 ℃ 45 ℃ 60 ℃ 50 ℃ 50 ℃ 50 ℃ 110-113℃ 表面出現(xiàn)冷斑，機頭壓力偏高。溫度中等 65 ℃ 65 ℃ 75 ℃ 65 ℃ 65 ℃ 65 ℃ 114-118℃ 表面光滑，端面上溫度較為一致。溫度偏高 85 ℃ 85 ℃ 90 ℃ 85 ℃ 85 ℃ 85 ℃ 120-125℃ 表面發(fā)藍，且冒有大量的青煙。由上表可見,通過試驗給溫控裝置確定一個適宜的設(shè)定值是很必要的。另外銷釘機筒上的銷釘一方面對膠料有著剪切與混煉的作用,另一方面還在膠料與溫控介質(zhì)問起到熱傳導的作用。調(diào)整銷釘?shù)呐挪紝χ破返臄D出溫度有一定的影響,但是范圍較小,一般在1～2℃之間。 3.2 口型與流道的修配銷釘機筒冷喂料擠出機經(jīng)過了多年發(fā)展,技術(shù)上相對來說較為成熟,一般說來調(diào)試工作量不是太大。但是由于膠料的流體特性及配方的差異直接影響到膠料的擠出性能,不同用戶的工藝要求和參數(shù)也會有比較大的不同,這就決定了液壓機頭在現(xiàn)場需要很大的修配工作量才能使得流道與口型能夠擠出滿足工藝要求的制品來。為了減少現(xiàn)場的修配工作量,口型與流道的修配必須明確一個合理的次序,以避免重復性的工作和口型板和流道板的報廢: (1) 修磨流道板,以在不帶口型板的情況下擠出膠片的斷面為規(guī)則的矩形為準。修磨量一次不要過大,盡量避免由于補焊造成流道板變形; (2) 在流道擠出均勻的情況下,合理修磨預口型,使膠料能順暢地過渡到口型處而不至于堵膠,增大機頭壓力; (3) 根據(jù)膠料的膨脹率和收縮率確定口型板的開型尺寸,一般口型板的開型由用戶廠家有經(jīng)驗的工藝人員來完成; (4) 如果前三項都嘗試過,膠料擠出還是不理想,可以考慮對配方作適當調(diào)整,同樣可以改善擠出質(zhì)量。因為螺桿是有旋向的,熔融的膠料經(jīng)螺桿由機筒壓入流道時,左右兩側(cè)在流量與流速上必然存在著差異,這一差異就需要通過修磨流道板中間的阻尼塊來消除。在擠出雙條胎側(cè)時,流道兩側(cè)微小的不均勻會造成兩條胎側(cè)斷面尺寸和擠出速度的不同,口型斷面尺寸越小時這種情況越明顯。這就需要花上大量時間做細致的工作去解決此問題。在剛開始擠出雙條胎側(cè)或小規(guī)格制品時,由于口型尺寸小,膠料溫度較低,往往會造成機頭壓力驟然升高,機頭因過載保護常使主機停機。我們在主操作臺上增設(shè)了“低速啟動”和“正常啟動”切換按鈕,開機時先以配方設(shè)定值40%的速度“低速啟動”運行,機頭壓力沖擊不至于過高,在擠出一段之后出膠趨于順暢,機頭壓力降低并穩(wěn)定下來,然后再切換到“正常啟動”狀態(tài),就不會出現(xiàn)機頭報警停機了。 3.3 均勻供膠擠出機如果喂料不均勻?qū)⒅苯佑绊懙秸麠l聯(lián)動線的連續(xù)穩(wěn)定的生產(chǎn)。喂料不均可能造成制品出現(xiàn)夾雜氣泡,尺寸變化等,故供料機要能自動調(diào)整供料速度,適應擠出機連續(xù)均勻地擠出。同時,要避免喂人太大的膠團,防止喂料口堵膠。 4 聯(lián)動裝置備機臺闊的協(xié)調(diào) 聯(lián)動生產(chǎn)線的自動化、聯(lián)動化性能如何就看其內(nèi)部機臺間的協(xié)調(diào)能力如何。The host part of the host linkage production line is XJF-D150 × The 120 pin barrel cold feed double compound extruder unit mainly consists of two pin barrel cold feed extruders (including φ one hundred and fifty × 16D Extruder and φ one hundred and twenty × 14D extruder), 150/120 two composite hydraulic head, hydraulic power system, temperature control system, two feeders (including φ 150 Extruder feeder and φ 120 extruder feeder), steel frame platform, integral base, electrical control system, etc. Hydraulic head runner size (maximum width × Thickness): 480 × 20mm 2.2 The linkage device of auxiliary line is mainly composed of receiving conveyor, cooling roller table and width measuring device, uphill conveyor belt I, tire sidewall transition film device, uphill conveyor belt II, spray cooling device, downhill conveyor belt, fixed length cutting device, secondary air blowing and quick separation roller table, single final inspection scale, manual pickup roller table device, tire sidewall bridge conveyor belt, coiling conveyor belt It is composed of four station coiling device and production line electrical control system, and XJF-D150 × 120 Two compound pin barrel cold feed extruding units are used together, mainly for compound extruding of sidewall rubber of radial tire into double strips (or single strips) and subsequent receiving, cooling, cutting or coiling. 3 Two compound extrusion unit Two compound extrusion unit is the core of the whole linkage line. Its performance directly affects the quality of products, the extrusion temperature of products and the size of cross section. Most of the extruders at home and abroad have the phenomenon of higher extrusion temperature, especially for the press extruders; In addition, for the sidewall products with small cross section, the die pressure is too high, and the twin extrusion is asymmetric. These are two problems that must be solved. Here is a summary based on the experience in debugging. 3.1 Temperature control The extruder temperature control device is divided into nine temperature control units, which respectively control the process temperature of the upper die, middle die, lower die of the extruder head, the barrel extrusion section, plasticizing section and screw of the 120 and 150 extruders to meet the technological requirements of the extrusion production process. The temperature of the temperature control unit section is set too low, and the fluidity of the rubber material in the barrel is not good. On the one hand, the pressure of the die head is too high, on the other hand, it is easy to cause cold spots on the surface of the extrusion tire side. The temperature of the temperature control unit section is set too high, which directly increases the extrusion temperature of the products. The following comparative tests may be conducted during commissioning: φ 150/ φ The temperature of the upper die, middle die and lower die of the screw in the plasticizing section of the extrusion section of the second composite hydraulic die of the 120 extruder is lower. The temperature is 45 ℃, 45 ℃, 60 ℃, 50 ℃, 50 ℃, 50 ℃, 110 ℃ and 113 ℃. Cold spots appear on the surface, and the pressure of the die is higher. The temperature is medium 65 ℃ 65 ℃ 75 ℃ 65 ℃ 65 ℃ 65 ℃ 65 ℃ 114-118 ℃, the surface is smooth, and the temperature on the end face is relatively consistent. The temperature is 85 ℃, 85 ℃, 90 ℃, 85 ℃, 85 ℃, 85 ℃, 120 ℃ and 125 ℃ too high. The surface is blue and there is a lot of smoke. It can be seen from the above table that it is necessary to determine an appropriate setting value for the temperature control device through tests. In addition, the pins on the external pin barrel, on the one hand, play a role in shearing and mixing the rubber, and on the other hand, play a role in heat conduction between the rubber and the temperature control medium. The arrangement of adjusting pins has a certain influence on the extrusion temperature of products, but the range is small, generally between 1 ℃ and 2 ℃. 3.2 Mouth and runner repair The pin barrel cold feed extruder has been developed for many years and is relatively mature in technology. Generally speaking, the debugging workload is not too large. However, due to the difference of the fluid characteristics and formula of the compound, the extrusion performance of the compound will be directly affected, and the process requirements and parameters of different users will also be quite different, which determines that the hydraulic head needs a lot of repair work on site to make the runner and die can extrude products that meet the process requirements. In order to reduce the on-site repair workload, a reasonable order must be defined for the repair of the die and runner to avoid repetitive work and the scrapping of the die plate and runner plate: (1) The runner plate shall be polished, and the section of the extruded film without the die plate shall be the regular rectangle. The amount of grinding shall not be too large at one time, and the deformation of runner plate caused by repair welding shall be avoided as far as possible; (2) Under the condition of uniform extrusion of the runner, the pre die shall be grinded reasonably, so that the rubber can be smoothly transferred to the die without plugging, and the die pressure shall be increased; (3) The opening size of the die plate shall be determined according to the expansion rate and shrinkage rate of the rubber material. Generally, the opening of the die plate shall be completed by the experienced technicians of the user manufacturer; (4) If the first three items have been tried, the rubber extrusion is still not ideal. You can consider making appropriate adjustments to the formula, which can also improve the extrusion quality. Because the screw has a rotation direction, when molten rubber is pressed into the runner from the barrel through the screw, there must be a difference between the flow rate and flow rate on the left and right sides. This difference needs to be eliminated by grinding the damping block in the middle of the runner plate. When extruding twin sidewalls, small unevenness on both sides of the runner will cause differences in the section size and extrusion speed of the two sidewalls. The smaller the section size of the die, the more obvious this situation is. This requires a lot of time and careful work to solve this problem. At the beginning of extruding double sidewalls or small size products, due to the small size of the die and the low temperature of the rubber compound, the pressure of the head will often rise suddenly, and the head will often shut down the main engine due to overload protection. We have added "low speed start" and "normal start" switch buttons on the main operating platform. When starting up, we first "low speed start" at the speed of 40% of the formula setting value, so that the pressure impact of the head is not too high. After extruding a section, the rubber outlet tends to be smooth, the head pressure decreases and stabilizes, and then switches to the "normal start" state, so that the head alarm and shutdown will not occur. 3.3 The continuous and stable production of the whole linkage line will be directly affected if the feeding of the uniform feeding extruder is uneven. Uneven feeding may cause bubbles and size changes in the products, so the feeder must be able to automatically adjust the feeding speed to adapt to the continuous and uniform extrusion of the extruder. At the same time, it is necessary to avoid feeding too large a rubber ball to prevent the feeding mouth from plugging. 4. Coordination of linkage equipment, the automation and linkage performance of the linkage production line depends on the coordination ability between its internal machines.

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