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First, equipment technology overview
Our company has always been committed to technology development for many years. It constantly carries out technical accumulation and improves the technological content in the process of equipment manufacturing. After three years of careful planning and production. In December 2002, it produced a complete set of production line equipment that is close to the international similar products and succeeded in one test run.
The success of the BOPP unit of Far East's biaxially oriented flat-film step-stretching method marks the decision of Far East Corp. Xiong Zheng that the decision to jointly develop the national industry in BO film production is due to cooperation with Guilin Electronics and complementary advantages. of. On this occasion, we also thanked a large number of domestic engineering and technical personnel who support the localization of the BO film production line to provide valuable experience for the development of the domestically produced double-draw film production line. In the successful BOPP unit of the Far East Company, we can see the expertise of the production line that will soon digest and absorb the expertise of the world's advanced companies, and fully consider the characteristics of China's manufacturing technology, its stability, reliability, automation level and product quality. It has approached the level of similar imported production lines.
In the first BOPP production line of our company's production team, we use a serial host and two auxiliary machines to form a production line that can produce three-layer coextruded films. The varieties include: flat film, matte film, pearl film. , single-sided heat seal film, double-sided heat seal film. Its thickness range is 15~50μm, width is 4.2m, mechanical maximum speed is 180m/min, productivity is calculated based on thickness 20μm, and its output is 5800t/y.
Second, the overall selection of production lines features:
1. The operation and control of the production line are all controlled by a programmable controller. Speed ​​control and pressure control are applied to the extrusion unit transmission to ensure high drive accuracy for the main extruder and cold drum to ensure the uniformity of the longitudinal tolerance of the film. Longitudinal stretching uses single-point stretching with a small gap. The stretching ratio is arbitrarily set and adjustable from 1:1 to 1:7. A tension sensor is used for speed coordination between a cold drum and a longitudinally pulled slow roller and a horizontal pull, and between a fast pull and a horizontal pull. The speed from the cold drum to the traction unit is given a speed chain relationship to ensure that the line speed of the production line is coordinated. In order to improve the stability and reliability of the entire production line, we have adopted the Siemens S7 series of high-level programmable controllers, all drive systems use Siemens SEMEREGKK6R24 full digital speed control device, and equipped with a PROFIBUS field bus communication card, can directly Networking and PLC controllers form a fieldbus network. The operator can directly monitor or adjust various process parameters such as temperature, pressure, speed, stretch ratio, etc., and the production process requires various forms of rapid speed change and automatic adjustment. , Equal adjustment, program action, back and forth tracking, etc.
2. In order to ensure the continuous and stable production of the production line, the matching equipment we selected, such as die head, thickness gauge, corona treatment, motor, reducer, etc., are products of well-known manufacturers at home and abroad.
3. It is generally believed that the movement speed of each major working mechanism of the drawing unit should have an accuracy and stability of about 0.5%. In the transmission of this equipment, we have not adopted the feedback of the speeding generator in order to improve the accuracy of the control. Encoder feedback, its control speed accuracy can be increased by 10 times. This ensures the stability of the working mechanism and the stability and accuracy of the stretching ratio.
4. During the stretching process, whether the crystallization and orientation are uniform and whether the degree is appropriate depends on the uniformity and stability of the material temperature. In order to ensure the accuracy of the temperature field. Our longitudinal drawing uses heat transfer oil, and the horizontal drawing machine also uses oil heating. Temperature is detected by platinum resistance, input to PLC and PID operation. Output 4 ~ 20MA analog signal, control proportional flow control valve to achieve temperature control, temperature controller using S7 ~ 400FM455 temperature control template, each block FM455 can simultaneously control 16 temperature points, you can use PID control, but also It adopts fuzzy logic control and adaptive function. The temperature control parameters can be self-tuned.
Third, the production line process program matching features
1, raw material configuration and delivery system
In order to ensure the uniformity and stability of the ingredients, we chose the formulation and delivery plan of the United States Marshall Company, which uses the volumetric method to measure and ensure accurate calculation. Strictly matching the ratio of main and auxiliary materials, the system is equipped with a perfect mixing device to ensure the uniformity of the mixing of main and auxiliary materials, the system also has a negative pressure device, the original and auxiliary materials are used for negative pressure, suction method for raw materials Transport, reduce the formation of powder.
2. Extruder system
Extruder system We have focused on the main extruder. We have considered two solutions for the main extruder. The first is to use a tandem extruder solution. The second is to use a single extruder and a metering pump solution. We believe that both of these options are feasible solutions and are adopted in foreign introduction of production lines. Finally, we tentatively choose the form of tandem extruder.
Main and auxiliary extruders We have specially designed a belt type continuous automatic screen changing device. The main extruder also uses column type long-term filters. It has a large filter area. After these two measures are taken, it will be very good. Extending the continuous production cycle of the production line, reducing the number of on-off operations, extending the time of continuous production, increasing production efficiency, reducing raw material consumption, and greatly improving production.
3, cast film forming system
î—¥ î—¥ In this system, we use a sink cold air knife type caster. The diameter of the cold roll is 1.2m. The bidirectional counterflow spiral jacket is used to circulate through the frozen water, thus ensuring the surface temperature uniformity and stability of the cold roll. According to the requirements of film-drawing process, the smoothness and smoothness of the cast film is one of the keys to the quality of the film. The treatment of the roll surface in equipment manufacturing is the most important task of our manufacturing process. Preheat roll, stretch roll, and qualitative roll, all using our company's patented technology, super-precision grinding device, this technology guarantees a high degree of smoothness of the roller surface and extremely high mirror roll, ensuring the smoothness of the diaphragm Smooth, improve the quality of the film.
We know that the closest dependence on the equipment is the uniformity of the film: macroscopic thickness uniformity and microscopic uniformity, so we chose the NDC thickness measurement with an EDI die. The die selected for this system was imported from the United States EDI company and matched with the NDC infrared thickness gauge of the United States. Through the thermal expansion bolts in the die head, the film thickness was controlled to ensure the stable and reliable operation of the entire device.
4, longitudinal stretching system
The system has 10 preheating rolls, 4 stretching rolls, and 2 setting rolls. The longitudinal pulling force and the temperature field required for stretching are all given by the speed change and temperature of a series of rolls in the vertical stretching machine. . This pull-pull scheme has been adopted by many BOPP manufacturers imported from abroad. The process is mature and reliable. The general pull-up system of BOPP manufacturers is oil-heated. The heat source comes from electric heating. In order to save the production cost of BOPP, our company can pull The oil boiler is used for two purposes. The hot oil produced by the oil boiler is mainly sent into the horizontal pull oven for heating, and the other part is sent into the longitudinal drawing as the longitudinal drawing heating source, ie, one furnace for two purposes. The heating system is provided with a set of temperature control device for completing Longitudinal pull temperature requirements, from a technical point of view, these two programs can be done, but according to different conditions for selection.
5, horizontal pull system
横 横 横 铗 横 铗 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 导轨 导轨. Each carcass has undergone precision machining of 56 processes and has good interchangeability. Strict material guarantee and heat treatment process make the chain have high mechanical properties. Smooth low dryness. In the horizontal pull system, we adopt four-zone preheating, three-zone stretching, four-zone setting, and one-zone cooling. The system is heated by a 1.5 million kcal oil boiler heating oil to heat the cross-drawing heating zone. The control is controlled by the computer, the temperature control is stable and reliable, the error is between plus and minus 1 degree, and it meets the technological requirements.
î—¥ î—¥ We still affirmed the form of electric heating, two heating options can be selected according to the situation.
We have carried out a variety of structural tests on the static pressure tank used for the horizontal pull. We have determined the structure of the tank according to the differences in the characteristic curve of the centrifugal fan and the principles of fluid mechanics. After the actual measurement, the pressure is stable and uniform.
6, Traction winding system
î—¥ î—¥ In this system, we focused on the corona treatment, which is related to whether the BOPP film surface tension is large or not, and whether the surface tension is uniform. We choose this corona treatment device to ensure the quality of the film. Schumann's corona treatment equipment in order to meet post-processing requirements such as printing.
î—¥ î—¥ Three aspects of the winding system drive are particularly focused, A. To ensure that the film tension is kept constant throughout the winding process, or as the roll diameter increases, the film tension decreases according to a certain rule (tension taper control). B. Guarantee continuous and uninterrupted rewinding and automatic rewinding. When the rewinding roll is full, automatic roll change procedure will be initiated. The film will be cut off and smoothly transitioned to alternate take-up roll rewinding, take-up roll and backup rewinding roll Between the tension control and speed control conversion. C. The winding roller adopts two working modes of contact winding and gap winding, but it must be ensured that the follow roller can automatically retreat with the increase of the winding diameter. In contact with the winding, it is ensured that the pressure of the follow roller is constant and adjustable.
IV. Status and Expectations of Domestic BOPP Equipment
î—¥ î—¥ December 16, 2002 pre-test machine, a total of 3 hours and 25 minutes, from the squeezing to the film took only 2 hours and 35 minutes, from the film speed, filming speed is unexpected we measured thickness After the feedback control is applied, the thickness tolerance of the large roll film is between 1% and 2%. As a result of the three-year struggle of Far Eastern employees with such achievements, we have also discovered some problems through this test machine, and we are constantly improving.
Although our BOPP film production line is mature and successful, it still has a certain gap compared with the world's advanced level, mainly because the 5000-1 million tons/year production line is still under development. The production line cannot yet produce the highest grade of BOPP film. Despite this, we have a clear advantage over the imported line.
First, flexibility. The equipment can be configured and designed according to user requirements and habits, including different plant and public works settings. It can save energy and investment while ensuring normal film production.
Second, the obvious price advantage. Domestic prices are one-third of imported singles. Depreciation of equipment and interest on investment loans account for a large proportion of the product price. Therefore, the domestic line can reduce the cost of the product film in a larger range. Increased competitiveness.
Third, our 5,000-ton/year production line has certain scale benefits. It also can be flexibly converted to various types of products.
Fourth, domestic lines have a faster construction cycle. Better and faster after-sales service. And spare parts are easy to solve, and maintenance costs are extremely low.
Far East's BOPP production line has the advantage of combining China's national conditions. It should adapt itself more to the needs of foreign companies than to foreign companies in terms of environmental adaptation and user needs. However, we must also see that there are many deficiencies in our production line. We hope that our domestic counterparts will jointly take care of the development of China's BO film production line technology.
To jointly promote national industries and contribute to China's BO film industry.
Our company has always been committed to technology development for many years. It constantly carries out technical accumulation and improves the technological content in the process of equipment manufacturing. After three years of careful planning and production. In December 2002, it produced a complete set of production line equipment that is close to the international similar products and succeeded in one test run.
The success of the BOPP unit of Far East's biaxially oriented flat-film step-stretching method marks the decision of Far East Corp. Xiong Zheng that the decision to jointly develop the national industry in BO film production is due to cooperation with Guilin Electronics and complementary advantages. of. On this occasion, we also thanked a large number of domestic engineering and technical personnel who support the localization of the BO film production line to provide valuable experience for the development of the domestically produced double-draw film production line. In the successful BOPP unit of the Far East Company, we can see the expertise of the production line that will soon digest and absorb the expertise of the world's advanced companies, and fully consider the characteristics of China's manufacturing technology, its stability, reliability, automation level and product quality. It has approached the level of similar imported production lines.
In the first BOPP production line of our company's production team, we use a serial host and two auxiliary machines to form a production line that can produce three-layer coextruded films. The varieties include: flat film, matte film, pearl film. , single-sided heat seal film, double-sided heat seal film. Its thickness range is 15~50μm, width is 4.2m, mechanical maximum speed is 180m/min, productivity is calculated based on thickness 20μm, and its output is 5800t/y.
Second, the overall selection of production lines features:
1. The operation and control of the production line are all controlled by a programmable controller. Speed ​​control and pressure control are applied to the extrusion unit transmission to ensure high drive accuracy for the main extruder and cold drum to ensure the uniformity of the longitudinal tolerance of the film. Longitudinal stretching uses single-point stretching with a small gap. The stretching ratio is arbitrarily set and adjustable from 1:1 to 1:7. A tension sensor is used for speed coordination between a cold drum and a longitudinally pulled slow roller and a horizontal pull, and between a fast pull and a horizontal pull. The speed from the cold drum to the traction unit is given a speed chain relationship to ensure that the line speed of the production line is coordinated. In order to improve the stability and reliability of the entire production line, we have adopted the Siemens S7 series of high-level programmable controllers, all drive systems use Siemens SEMEREGKK6R24 full digital speed control device, and equipped with a PROFIBUS field bus communication card, can directly Networking and PLC controllers form a fieldbus network. The operator can directly monitor or adjust various process parameters such as temperature, pressure, speed, stretch ratio, etc., and the production process requires various forms of rapid speed change and automatic adjustment. , Equal adjustment, program action, back and forth tracking, etc.
2. In order to ensure the continuous and stable production of the production line, the matching equipment we selected, such as die head, thickness gauge, corona treatment, motor, reducer, etc., are products of well-known manufacturers at home and abroad.
3. It is generally believed that the movement speed of each major working mechanism of the drawing unit should have an accuracy and stability of about 0.5%. In the transmission of this equipment, we have not adopted the feedback of the speeding generator in order to improve the accuracy of the control. Encoder feedback, its control speed accuracy can be increased by 10 times. This ensures the stability of the working mechanism and the stability and accuracy of the stretching ratio.
4. During the stretching process, whether the crystallization and orientation are uniform and whether the degree is appropriate depends on the uniformity and stability of the material temperature. In order to ensure the accuracy of the temperature field. Our longitudinal drawing uses heat transfer oil, and the horizontal drawing machine also uses oil heating. Temperature is detected by platinum resistance, input to PLC and PID operation. Output 4 ~ 20MA analog signal, control proportional flow control valve to achieve temperature control, temperature controller using S7 ~ 400FM455 temperature control template, each block FM455 can simultaneously control 16 temperature points, you can use PID control, but also It adopts fuzzy logic control and adaptive function. The temperature control parameters can be self-tuned.
Third, the production line process program matching features
1, raw material configuration and delivery system
In order to ensure the uniformity and stability of the ingredients, we chose the formulation and delivery plan of the United States Marshall Company, which uses the volumetric method to measure and ensure accurate calculation. Strictly matching the ratio of main and auxiliary materials, the system is equipped with a perfect mixing device to ensure the uniformity of the mixing of main and auxiliary materials, the system also has a negative pressure device, the original and auxiliary materials are used for negative pressure, suction method for raw materials Transport, reduce the formation of powder.
2. Extruder system
Extruder system We have focused on the main extruder. We have considered two solutions for the main extruder. The first is to use a tandem extruder solution. The second is to use a single extruder and a metering pump solution. We believe that both of these options are feasible solutions and are adopted in foreign introduction of production lines. Finally, we tentatively choose the form of tandem extruder.
Main and auxiliary extruders We have specially designed a belt type continuous automatic screen changing device. The main extruder also uses column type long-term filters. It has a large filter area. After these two measures are taken, it will be very good. Extending the continuous production cycle of the production line, reducing the number of on-off operations, extending the time of continuous production, increasing production efficiency, reducing raw material consumption, and greatly improving production.
3, cast film forming system
î—¥ î—¥ In this system, we use a sink cold air knife type caster. The diameter of the cold roll is 1.2m. The bidirectional counterflow spiral jacket is used to circulate through the frozen water, thus ensuring the surface temperature uniformity and stability of the cold roll. According to the requirements of film-drawing process, the smoothness and smoothness of the cast film is one of the keys to the quality of the film. The treatment of the roll surface in equipment manufacturing is the most important task of our manufacturing process. Preheat roll, stretch roll, and qualitative roll, all using our company's patented technology, super-precision grinding device, this technology guarantees a high degree of smoothness of the roller surface and extremely high mirror roll, ensuring the smoothness of the diaphragm Smooth, improve the quality of the film.
We know that the closest dependence on the equipment is the uniformity of the film: macroscopic thickness uniformity and microscopic uniformity, so we chose the NDC thickness measurement with an EDI die. The die selected for this system was imported from the United States EDI company and matched with the NDC infrared thickness gauge of the United States. Through the thermal expansion bolts in the die head, the film thickness was controlled to ensure the stable and reliable operation of the entire device.
4, longitudinal stretching system
The system has 10 preheating rolls, 4 stretching rolls, and 2 setting rolls. The longitudinal pulling force and the temperature field required for stretching are all given by the speed change and temperature of a series of rolls in the vertical stretching machine. . This pull-pull scheme has been adopted by many BOPP manufacturers imported from abroad. The process is mature and reliable. The general pull-up system of BOPP manufacturers is oil-heated. The heat source comes from electric heating. In order to save the production cost of BOPP, our company can pull The oil boiler is used for two purposes. The hot oil produced by the oil boiler is mainly sent into the horizontal pull oven for heating, and the other part is sent into the longitudinal drawing as the longitudinal drawing heating source, ie, one furnace for two purposes. The heating system is provided with a set of temperature control device for completing Longitudinal pull temperature requirements, from a technical point of view, these two programs can be done, but according to different conditions for selection.
5, horizontal pull system
横 横 横 铗 横 铗 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 横 导轨 导轨. Each carcass has undergone precision machining of 56 processes and has good interchangeability. Strict material guarantee and heat treatment process make the chain have high mechanical properties. Smooth low dryness. In the horizontal pull system, we adopt four-zone preheating, three-zone stretching, four-zone setting, and one-zone cooling. The system is heated by a 1.5 million kcal oil boiler heating oil to heat the cross-drawing heating zone. The control is controlled by the computer, the temperature control is stable and reliable, the error is between plus and minus 1 degree, and it meets the technological requirements.
î—¥ î—¥ We still affirmed the form of electric heating, two heating options can be selected according to the situation.
We have carried out a variety of structural tests on the static pressure tank used for the horizontal pull. We have determined the structure of the tank according to the differences in the characteristic curve of the centrifugal fan and the principles of fluid mechanics. After the actual measurement, the pressure is stable and uniform.
6, Traction winding system
î—¥ î—¥ In this system, we focused on the corona treatment, which is related to whether the BOPP film surface tension is large or not, and whether the surface tension is uniform. We choose this corona treatment device to ensure the quality of the film. Schumann's corona treatment equipment in order to meet post-processing requirements such as printing.
î—¥ î—¥ Three aspects of the winding system drive are particularly focused, A. To ensure that the film tension is kept constant throughout the winding process, or as the roll diameter increases, the film tension decreases according to a certain rule (tension taper control). B. Guarantee continuous and uninterrupted rewinding and automatic rewinding. When the rewinding roll is full, automatic roll change procedure will be initiated. The film will be cut off and smoothly transitioned to alternate take-up roll rewinding, take-up roll and backup rewinding roll Between the tension control and speed control conversion. C. The winding roller adopts two working modes of contact winding and gap winding, but it must be ensured that the follow roller can automatically retreat with the increase of the winding diameter. In contact with the winding, it is ensured that the pressure of the follow roller is constant and adjustable.
IV. Status and Expectations of Domestic BOPP Equipment
î—¥ î—¥ December 16, 2002 pre-test machine, a total of 3 hours and 25 minutes, from the squeezing to the film took only 2 hours and 35 minutes, from the film speed, filming speed is unexpected we measured thickness After the feedback control is applied, the thickness tolerance of the large roll film is between 1% and 2%. As a result of the three-year struggle of Far Eastern employees with such achievements, we have also discovered some problems through this test machine, and we are constantly improving.
Although our BOPP film production line is mature and successful, it still has a certain gap compared with the world's advanced level, mainly because the 5000-1 million tons/year production line is still under development. The production line cannot yet produce the highest grade of BOPP film. Despite this, we have a clear advantage over the imported line.
First, flexibility. The equipment can be configured and designed according to user requirements and habits, including different plant and public works settings. It can save energy and investment while ensuring normal film production.
Second, the obvious price advantage. Domestic prices are one-third of imported singles. Depreciation of equipment and interest on investment loans account for a large proportion of the product price. Therefore, the domestic line can reduce the cost of the product film in a larger range. Increased competitiveness.
Third, our 5,000-ton/year production line has certain scale benefits. It also can be flexibly converted to various types of products.
Fourth, domestic lines have a faster construction cycle. Better and faster after-sales service. And spare parts are easy to solve, and maintenance costs are extremely low.
Far East's BOPP production line has the advantage of combining China's national conditions. It should adapt itself more to the needs of foreign companies than to foreign companies in terms of environmental adaptation and user needs. However, we must also see that there are many deficiencies in our production line. We hope that our domestic counterparts will jointly take care of the development of China's BO film production line technology.
To jointly promote national industries and contribute to China's BO film industry.
Plastic Artificial Turf Production Line
Yazhijiang Plastic Industry Co., Ltd. , http://www.plastic-granulator-manufacturer.com