片材作業指導書
1目的
規范片材工序的操作過程，使操作工掌握其工藝方法。
2適用范圍
片材工序及片材機的操作。
3內容
3.1開機前
3.1.1給需加油潤滑的部位加油；
3.1.2檢查水路有無漏水現象；
3.1.3檢查各加熱區溫控表是否符合工藝設定要求；
3.1.4接通電源檢查各加熱區電熱溫控是否正常及各個變頻器操作面板的速度控制是否處于“0位”。
注：螺桿料筒溫度未到設定溫度嚴禁起動主機，以免損壞設備。
3.1.5清理機臺及地面衛生。
4操作方法
4.1加熱：
4.1.1先加熱過濾網部分以及第六區；
4.1.2過濾網部分溫度升高到180℃時開始加熱模頭。
4.1.3在前五區的加熱溫度加熱到150℃時開冷卻水塔。
4.2擦拭輥筒
4.2.1用柔軟干凈的碎布,擦拭滾筒，擦滾筒應從輥筒轉出的方向擦拭，同時應注意安全，不東張西望和別人聊天，思想要集中；
4.2.2若滾筒表面粘有污物，用白礦油浸濕碎布，細心認真的擦拭；
4.2.3保持滾筒干凈光亮后才可牽引片材。
4.3烘干攪拌
4.3.1在加熱過程中，領回原料及生產常用物品。并做好生產統計記錄；
4.3.2根據生產技術要求，進行烘干；
4.3.3按照技術要求進行準確的配比攪拌。
4.4更換過濾網
4.4.1各加熱區的溫度達到設定要求時更換過濾網；
4.4.2在更換過濾網時，啟動油泵電機,待壓力到設定值。（自然關閉）點動換網按鈕,拉出換網多孔板，裝上準備好的過濾網。
4.5準備牽引片材
4.5.1各加熱區溫度達到設定溫度時，保溫二十分鐘；
4.5.2料斗加料，啟動主機，應從OHZ慢慢加速，在此時注意觀察主電機電流表指數，如果電流猛升而模頭不出料，要馬上停機進行檢查，看是否加熱區域受熱不夠，塑料沒有完全軟化造成主機阻力過大，以防止螺桿及模頭等部位損壞，如果電流平穩上升，即加熱正常可以開機牽引生產；
4.5.3塑料擠出模頭時，用專用銅片伸入模唇內反復清理刮去藏在模唇的燒焦物，待見光亮的片材擠出為止，停止主機；
4.5.4推動輔機至模唇的位置，并起動輥筒電機及收卷牽引電機;
4.5.5再啟動主機，從OHZ慢慢加速，擠出的塑膠便借輥筒轉動擠壓過去，隨著輥筒轉動的方向，便可牽引成功。
4.5.6`牽引成功后，應保持輥縫之間有適量的余膠并且兩邊的邊角料切割不會太寬或太窄，如會，就要推動輔機找到最佳位置，并按工藝要求調好片材厚度.與寬度。
4.5.7正常生產過程中要保持余膠量適當一致，不能時多時少，從而保持片材厚度不會變化，保證片材不出現花紋，余膠過多，兩邊切割邊角料過寬，不僅造成浪費，而且使片材表面不光滑，出現大波浪花紋或者出現粒粒淚點等現象，余膠過少，兩邊邊角料切割不到，同時片材厚度變薄，片材表面會出現條狀花紋或波浪形花紋。
注：根據片材的厚薄調整余膠大小，一般片材薄余膠小，片材厚余膠大。
4.5.8料斗加料時小心謹慎，因片材機無熔體泵所有要保持料斗盛有一定的原料，從而保持下料的壓力不會改變，從而保持余膠穩定。
4.5.9在機械運作正常時，原料配制與生產開機時要求一樣，另外多觀察，控制臺上所有儀表有無異常變化，例如：生產正常情況下主機電流保持在180A之間。
4.5.10生產過程中根據生產工藝技術需要，擦拭輥筒時從輥筒的轉出方向用手指捏至少量碎布從輥筒的左右兩端來回輕輕擦拭。
4.5.11當設備經一定時間的連續工作后（視主機電流的升高或降低；所流片材有無黑點、雜物）應及時更換過濾網。更換過濾網時先啟動油泵電機，待到設定壓力后（電機停）即可按上下換網開關。
4.5.12收卷好的片材重量約100-250公斤左右即可更換（不得超過250公斤），更換后稱片材重量，并標明片材規格.重量、生產人等記錄。
4.5.13出現異常緊急停機后應馬上把上輥提起，并清理三輥之間余膠,以免壓壞輥筒.
4.5.14正常停機時先停主機,待三輥余膠壓延完方可停三輥電機,然后再停收卷.
4.5.15保持機臺周圍地面衛生,定時清理衛生。
5工藝標準
5.1PP片材：
5.1.1透明度：符合高透明標準。
5.1.2光澤度：流出片材色澤鮮明，亮度極佳，無花紋、無斑點、無雜質。
51.3重量要求：每一卷片材重量不能超過250kg，不能少于100kg。
5.1.4片材厚度準許偏差±0.02mm。
51.5收卷要整齊，堆放要整齊并套袋防止灰塵。
5.1.6原料配制要按規定標準，以保證片材的質量。
5.1.7片材寬度準許偏差±0.02mm。
5.1.8厚度在0.70mm和0.82mm的片材,邊角料寬度允許在8 mm和12 mm之內.0.87mm和0.92mm的片材,邊角料寬度允許在 10mm和17 mm之內.1mm以上的片材,邊角料寬度允許在17mm和20mm之內。
5.2PS片材（略）
5.3降解片材（略）
6達標產量
根據不同的機臺，不同的規格，產量達標應以主電機電流、頻率為基礎，例如：生產0.70mm—1.00mm以內厚度的片材達標產量為：
1號片材機：主電機電流為？？—？？A，???kg/小時。
2號片材機：主電機電流為？？--？？A，??kg/小時。
生產其它規格片材達標產量另行通知。
7故障分析及其排除
7.1片材斷裂
原因：
7.1.1機身或機頭溫度偏低。
7.1.2模唇開度小。
7.1.3牽引速度太快。
解決方法：
7.1.4適當升高溫度。
7.1.5調節螺栓，增加開度。
7.1.6減少牽引速度。
7.2厚薄不均
原因：
7.2.1機身溫度低，塑化不均。
7.2.2機頭溫度不均勻。
7.2.3模唇開度不均勻。
7.2.4阻流塊調節不當。
7.2.5牽引速度不穩定。
解決方法
7.2.6適當提高機身溫度，使塑化均勻。
7.2.7合理調整各區溫度。
7.2.8合理調節阻流塊。
7.2.9重新調節模唇開度。
7.2.10檢查牽引壓緊程度，并使其速度穩定。
7.3縱向出現條紋
原因：
7.3.1模唇劃傷。
7.3.2模唇內堵塞雜質。
7.3.3三輥機輥筒表面劃傷。
7.3.4傳動鏈條變形跳動
解決方法：
7.3.5研磨模唇平直表面。
7.3.6清理模唇。
7.3.7調換或修磨輥筒。
7.3.8更換鏈條。
7.4氣泡
原因
7.4.1溫度過高。
7.4.2原料有水份或有易揮發物。
解決方法
7.4.3適當降溫，防止分解。
7.4.4進行預烘，除出水份和揮發物。
7.5表面發黑或變色線條、斑點
原因：
7.5.1機頭溫度高。
7.5.2機頭有死角，物料停滯分解。
7.5.3機頭內有雜質阻塞。
7.5.4輥筒表面有拆除物。
解決辦法
7.5.5適當降溫，防止分解。
7.5.6清理機頭，修除流道死角。
7.5.7清理機頭，清除雜質。
7.5.8擦拭輥筒并檢查配方。
7.6表面粗糙并出現橫向降紋
原因
7.6.1物料塑化不好。
7.6.2三輥間余料太多。
7.6.3模唇開度不均勻。
7.6.4壓光輥壓力太大。
7.6.5三輥機距模唇間距過大。
解決方法：
7.6.6適當提高塑化溫度，延長塑化時間。
7.6.7減少螺桿轉速或提高牽引速成度。
7.6.8調整模唇間隙。
7.6.9增加壓光輥的間距。
7.6.10盡量縮小兩者的間距。
7.7板面凹凸不平或光澤不好
原因：
7.7.1機頭溫度偏低。
7.7.2壓光輥溫度偏低。
7.7.3壓光輥表面不光潔。
7.7.4輥筒之間無一定量的存料。
7.7.5原料中含有水份。
解決方法：
7.7.6提高機頭溫度。
7.7.7提高壓光輥溫度。
7.7.8調換或拋光壓光輥。
7.7.9適當提高螺桿轉速度或降低牽引速度。
7.7.10干燥原料。
7.8片材一邊厚一邊薄或“跑偏”
原因
7.8.1模唇開度不一。
7.8.2三輥間距不一。
7.8.3牽引輥間距不一。
解決方法
7.8.4調整模唇開度。
7.8.5調整輥筒的間距。
7.8.6調整牽引輥的間距。
7.9片材中間比兩邊薄。
原因：
7.9.1模頭中間部位加熱溫度偏低。
7.9.2模唇中間部位開度偏小。
7.9.3模唇中間部位有堵塞現象。
解決方法
7.9.4提高模唇中間部位溫度。
7.9.5調整模唇中間部位開度。
7.9.6清理模唇。
8相關文件
無
9相關記錄
片材生產記錄
10附件
11片材工藝標準
|
序號 |
區域 |
類別 |
溫度 |
備注 |
|
1 |
1區控溫 |
標準溫度 |
220℃ |
|
|
關鍵限值 |
217-225℃ |
|
||
|
2 |
2區控溫 |
標準溫度 |
225℃ |
|
|
關鍵限值 |
222-230℃ |
|
||
|
3 |
3區控溫 |
標準溫度 |
230℃ |
|
|
關鍵限值 |
227-235℃ |
|
||
|
4 |
4區控溫 |
標準溫度 |
235℃ |
|
|
關鍵限值 |
232-240℃ |
|
||
|
5 |
5區控溫 |
標準溫度 |
240℃ |
|
|
關鍵限值 |
237-245℃ |
|
||
|
6 |
濾網控溫 |
標準溫度 |
245℃ |
|
|
關鍵限值 |
242-250℃ |
|
||
|
7 |
模頭右控溫 |
標準溫度 |
200℃ |
|
|
關鍵限值 |
197-205℃ |
|
||
|
8 |
模頭中控溫 |
標準溫度 |
195℃ |
|
|
關鍵限值 |
192-200℃ |
|
||
|
9 |
模頭左控溫 |
標準溫度 |
200℃ |
|
|
關鍵限值 |
197-205℃ |
|
||
|
10 |
三輥溫度（上輥） |
標準溫度 |
15-45℃ |
|
|
關鍵限值 |
15-45℃ |
|
||
|
11 |
三輥溫度（中輥） |
標準 |
20-60℃ |
|
|
關鍵限值 |
20-60℃ |
|
||
|
12 |
三輥溫度（下輥） |
標準 |
15-55℃ |
|
|
關鍵限值 |
15-55℃ |
|
||
|
13 |
片材厚薄度 |
關鍵限值 |
±0.03mm |
|
|
|
|
|
|
|
12 配料工藝標準
|
規格名稱 |
杯重 克 |
片材規格 |
配比 單位：斤 |
攪拌時間 （10+1）分鐘 |
||||||
|
A級杯標準配比
|
B級杯標準配比 |
實際時間 |
關鍵限值 |
|||||||
|
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克光頭 |
1.2 |
64×82 |
100 |
5 |
0 |
0 |
0 |
100% |
10 |
10±1 |
|
30克光頭 |
1.3 |
64×87 |
100 |
5 |
0 |
0 |
0 |
100% |
10 |
10±1 |
|
30克橄欖 |
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克圓底 |
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
臭雞蛋
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.
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.
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.