CN103862649B - 一种中性硅酮密封胶的自动线生产方法及装置 - Google Patents

一种中性硅酮密封胶的自动线生产方法及装置 Download PDF

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CN103862649B
CN103862649B CN201410075976.5A CN201410075976A CN103862649B CN 103862649 B CN103862649 B CN 103862649B CN 201410075976 A CN201410075976 A CN 201410075976A CN 103862649 B CN103862649 B CN 103862649B
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Abstract

本发明公开了一种中性硅酮密封胶的自动线生产方法及装置，包括粉料投放装置、捏合机、双螺杆挤出机、静态混合器、储能压机装置、螺杆喂料装置和冷却器。在捏合机的输出端设置有第一恒压罐6、在冷却器5设置有第二恒压罐20。第一恒压罐6上设置有失重式计量装置7；整个生产线PLC系统整体自动监测与控制，在失重式计量装置7和高粘度计量泵8接入PLC采样和控制点，PLC系统对失重式计量装置7采集的物料流动重量数据和高粘度计量泵8采集的物料流动体积数据进行相互验证，控制高粘度计量泵8的实际转速。解决了工艺过程中的工艺的物料流动均一性，稳定了产品质量，实现自动化连续生产。

Description

一种中性硅酮密封胶的自动线生产方法及装置
技术领域
本发明涉及工业胶体制备,尤其硅酮密封胶生产方法及装置技术领域。
背景技术
中性硅酮胶广泛应用于建筑、电子、机械、日用化工等领域，现有技术生产中性硅酮胶的方法中，通常使用捏合机将107胶、粉料进行加热、分散、混合，然后通过三滚机做出基料，再将基料、白油、硅油、交联剂、助剂加入搅拌机或者强力分散机中做出大桶胶，最后通过分装设备包装成成品胶。整个过程属于间歇开放式生产，有生产效率低、质量控制难、能耗大、浪费大等缺点。以中国专利ZP20081673963为代表的新密封胶生产方法在一定程度上改变了这种状况，但这种生产方法仍存在许多的不足。首先，鉴于中性硅酮胶生产原料的高密度低粘度特性，受环境温度变化及物料干稠状态变化的影响，物料在整个生产线的流态不稳定，易于出现断料的体积空隙，破坏后续环节工艺的均一性而出现目标产品质量的波动，现有技术无法对此现象予以自动的调节；其次，现有技术包装设备只能根据生产速度来进行包装，在生产线因为速度压力的变化时无法作出相应的调整，且无法在系统停止后运行。
发明内容
鉴于现有技术的以上的不足，本发明旨在提供一种全自动中性硅酮密封胶生产线生产方法，使之有效克服现有技术的上述缺陷。
本发明的目的是通过如下的手段实现的。
一种中性硅酮密封胶的自动线生产方法，以107胶、硅油和白油为主要原料生产中性硅酮密封胶，包括如下主要步骤；
1）、在捏合机1中，对通过称重计量装置定量供料的107胶、硅油和白油进行混合、分散及加热得到液体料；将粉料投入粉料投放装置中，通过输送螺杆9将粉料输送至捏合机中与液体料混合与分散，得到基料；
2）由1）所得基料输入第一恒压罐6后通过高粘度计量泵8输入双螺杆挤出机3中混合、加热与脱水，并在双螺杆挤出机中再次与硅油、白油、交联剂与助剂进行混合，并将此混合料输送至静态混合器4；
3）将2）所得混合料在静态混合器4中与第二助剂、第三助剂混合，通过冷却器5冷却之后送至第二恒压罐20作为目标产品暂存，第二恒压罐20将目标产品稳定匀速输出至包装设备完成成品包装从而完成自动生产；
所述第一恒压罐6上设置有失重式计量装置7；整个生产线PLC系统整体自动监测与控制，在失重式计量装置7和高粘度计量泵8接入PLC采样和控制点，PLC系统对失重式计量装置7采集的物料流动重量数据和高粘度计量泵8采集的物料流动体积数据进行相互验证，联动控制高粘度计量泵8的实际转速。
本发明的目的还在于，为上述生产方法提供便利的实施装置，其方案为：一种中性硅酮密封胶的自动生产装置，由捏合机1、粉料投放装置2、输送螺杆9、第一恒压罐6、高粘度计量泵8、双螺杆挤出机3、静态混合器4、冷却器5与第二恒压罐20构成的自动生产线；其中双螺杆挤出机3设置有加入白油、硅油、交联剂与助剂的入口（13、14、15及16）；静态混合器设置有加入助剂的入口（17、18与19）；粉料投放装置2与输送螺杆9连接；输送螺杆9的出口与捏合机1连接；捏合机1的出口与第一恒压罐6连接；第一恒压罐6与高粘计量泵8连接；高粘计量泵8与双螺杆挤出机3连接；双螺杆挤出机3的出口与静态混合器4连接；静态混合机与冷却器5连接，冷却器与第二恒压罐20连接；
对失重式计量装置7可对物料流动重量数据和物料流动体积数据进行相互验证并控制高粘度计量泵8的实际转速的PLC系统在失重式计量装置7和高粘度计量泵8接入有采样和控制点。
采用本发明的方法和设备，与现有的中性硅酮密封胶生产方法与装置相比，具有明显的优点。
由于整个生产线PLC系统整体自动监测与控制，在失重式计量装置7和高粘度计量泵8接入PLC采样和控制点（如图2中的A和B两个取样点），PLC系统对失重式计量装置7采集的物料流动重量数据和高粘度计量泵8采集的物料流动体积数据进行相互验证，联动控制高粘度计量泵8的实际转速。有效地校正了高粘度计量泵8出现“空体积流量”误差，当“空体积流量”产生时，高粘度计量泵8和失重式计量装置7分别向PLC系统输送的流量数据出现差异，PLC系统将控制提高高粘度计量泵8的实时转速以消除“空体积流量”误差，保证了后续各工位的流量均匀，杜绝了人为控制与操作中的潜在的质量隐患，极大的提升了产品的质量的稳定性。
此外，生产线上分别设置在捏合机出口的第一恒压罐6和设置在冷却器出口的第二恒压罐20对整个生产线提供了简单易行的缓冲和流量稳定功能，为本发明方法的实施创造了良好的条件
采用本发明方法可真正实现全自动化封闭生产，提高了生产的效率，极大节省了人工、能耗与产品中转过程中的浪费，并避免了在中转过程中由于产品暴露在空气中造成的产品结皮、结粒与外界粉尘或其他物质污染。
附图说明
图1是本发明工艺方法的工作框图。
图2是本发方法与装置的工艺流程图。
图3是图2中储能压机装置结构图。
具体实施方式
下面结合附图对本发明作进一步说明。
发明的工作框图和工艺流程分别如图1和图2所示。本发明工艺流程的主要设备是：捏合机1、粉料投放装置2、输送螺杆9、第一恒压罐6、高粘度计量泵8、双螺杆挤出机3、静态混合器4、冷却器5与第二恒压罐20。双螺杆挤出机3设置有加入白油、硅油、交联剂与助剂的入口13、14、15及16。静态混合器设置有加入助剂的入口17、18与19。粉料投放装置2与输送螺杆9连接，输送螺杆9的出口与捏合机1连接，捏合机1的出口与第一恒压罐6连接，第一恒压罐6与高粘计量泵8连接，高粘计量泵8与双螺杆挤出机3连接，双螺杆挤出机3的出口与静态混合器4连接，静态混合机与冷却器5连接，冷却器与第二恒压罐20连接。失重式计量装置7设置在第一恒压罐6外部。
输送螺杆9为全封闭式粉料输送装置，通过螺杆旋转将粉料输送至捏合机1中，结构简单，适用于各种粉料。
双螺杆挤出机3设置有2个真空口11与12，进行抽真空处理，抽除水分、气泡及低分子挥发物。
高粘度计量泵8设置有精确计量系统，并通过PLC与第一恒压罐6连接，两者之间通过PLC控制系统相互控制与修正。
本发明的第一恒压罐6和第二恒压罐20具有相似的结构，现以第二恒压罐20为例予以叙述。如图3所示，第二恒压罐20由自控液压站21、轴22、压盘23、压缸24与支架底座25构成。自控液压站21可以自动控制并调节压机压力，使压力一直稳定，压盘23可以在压缸24缸体中上下往复运动。第二恒压罐20工作过程如下：自控液压站21自动控制压盘23调节压缸24内部压力，使压力稳定，成品料通过冷却器5冷却之后由第二恒压罐20底部入口26注入压缸24中，压缸23内部的成品料由出口27以恒定的压力输出至包装机中。
本发明提供的中性硅酮密封胶自动生产装置生产过程如下：
含有107胶、硅油、白油的液体原料由输送螺杆9输入捏合机1中搅拌捏合，由粉料投放装置2输入的粉体原料输入捏合机1中与液体原料捏合、搅拌与分散，得到基料；得到的基料进入第一恒压罐6中称重计量，由高粘度计量泵8精确、连续的输入到双螺杆挤出机3中，基料在双螺杆挤出机3中加热、真空脱水、脱低分子后加入硅油、白油调节产品稠度，并与交联剂、助剂混合、分散，经双螺杆挤出机3混合的物料从出口出来后通过静态混合器4与新添加的助剂再次充分混合，经静态混合机器4充分混合后的产品通过冷却5降温至30℃-40℃输入至第二恒压罐20中，再由第二恒压罐20稳定的供给至包装系统成为不同包装的中性硅酮密封胶产品。
采用本发明的方法与装置，快速稳定的将中性硅酮密封胶由原料生产至产品，并节约了人工、能耗与产品浪费，产品质量稳定，原料适用面广，在较宽的条件范围内都能获得很好生产效果。

Claims (4)

1.一种中性硅酮密封胶的自动线生产方法，以107胶、硅油和白油为主要原料生产中性硅酮密封胶，包括如下主要步骤；
1)、在捏合机(1)中，对通过称重计量装置定量供料的107胶、硅油和白油进行混合、分散及加热得到液体料；将粉料投入粉料投放装置(2)中，通过输送螺杆(9)将粉料输送至捏合机中与液体料混合与分散，得到基料；
2)由1)所得基料输入第一恒压罐(6)后通过高粘度计量泵(8)输入双螺杆挤出机(3)中混合、加热与脱水，并在双螺杆挤出机中与硅油、白油、交联剂及助剂进行混合，并将此混合料输送至静态混合器(4)；
3)将2)所得混合料在静态混合器(4)中与第二助剂、第三助剂混合，通过冷却器(5)冷却之后送至第二恒压罐作为目标产品暂存，第二恒压罐将目标产品稳定匀速输出至包装设备完成成品包装从而完成自动生产；
所述第一恒压罐上设置有失重式计量装置(7)；整个生产线PLC系统整体自动监测与控制，在失重式计量装置(7)和高粘度计量泵(8)接入PLC采样和控制点，PLC系统对失重式计量装置采集的物料流动重量数据和高粘度计量泵采集的物料流动体积数据进行相互验证，控制高粘度计量泵的实际转速。
2.根据权利要求1所述之中性硅酮密封胶的自动线生产方法，其特征在于，所述恒压罐由自控液压站(21)、轴(22)、压盘(23)、压缸(24)与支架底座(25)构成。
3.根据权利要求1所述之中性硅酮密封胶的自动线生产方法，其特征在于，所述PLC系统控制双螺杆挤出机(3)和静态混合器(4)上各交联剂与助剂的入口的物料流入量。
4.一种中性硅酮密封胶的自动生产装置，由捏合机(1)、粉料投放装置(2)、输送螺杆(9)、第一恒压罐(6)、高粘度计量泵(8)、双螺杆挤出机(3)、静态混合器(4)、冷却器(5)与第二恒压罐(20)构成的自动生产线；其中双螺杆挤出机(3)设置有加入白油、硅油、交联剂与助剂的入口(13、14、15及16)；静态混合器设置有加入助剂的入口(17、18与19)；粉料投放装置2与输送螺杆(9)连接；输送螺杆的出口与捏合机连接；捏合机的出口与第一恒压罐连接；第一恒压罐与高粘计量泵连接；高粘计量泵与双螺杆挤出机连接；双螺杆挤出机的出口与静态混合器连接；静态混合机与冷却器连接，冷却器与第二恒压罐连接；第一恒压罐(6)上设置有失重式计量装置(7)；
可对物料流动重量数据和物料流动体积数据进行相互验证并控制高粘度计量泵(8)的实际转速的PLC系统在失重式计量装置(7)和高粘度计量泵(8)接入有采样和控制点。
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