CN115407734A - Full-flow intelligent control system for preparing polyether-ether-ketone filament - Google Patents
Full-flow intelligent control system for preparing polyether-ether-ketone filament Download PDFInfo
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- CN115407734A CN115407734A CN202211020904.1A CN202211020904A CN115407734A CN 115407734 A CN115407734 A CN 115407734A CN 202211020904 A CN202211020904 A CN 202211020904A CN 115407734 A CN115407734 A CN 115407734A
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- 239000004696 Poly ether ether ketone Substances 0.000 title claims abstract description 37
- 229920002530 polyetherether ketone Polymers 0.000 title claims abstract description 37
- 238000012544 monitoring process Methods 0.000 claims abstract description 97
- 238000004519 manufacturing process Methods 0.000 claims abstract description 58
- 238000009987 spinning Methods 0.000 claims abstract description 32
- 238000000034 method Methods 0.000 claims abstract description 25
- 239000000463 material Substances 0.000 claims abstract description 21
- 230000008859 change Effects 0.000 claims abstract description 20
- 230000007613 environmental effect Effects 0.000 claims abstract description 7
- 238000004804 winding Methods 0.000 claims description 56
- 238000001914 filtration Methods 0.000 claims description 37
- 238000001035 drying Methods 0.000 claims description 28
- 239000000155 melt Substances 0.000 claims description 21
- 239000007788 liquid Substances 0.000 claims description 20
- 238000004088 simulation Methods 0.000 claims description 19
- 238000001125 extrusion Methods 0.000 claims description 9
- 238000006243 chemical reaction Methods 0.000 claims description 5
- 230000007246 mechanism Effects 0.000 claims description 5
- 230000004044 response Effects 0.000 claims description 4
- JUPQTSLXMOCDHR-UHFFFAOYSA-N benzene-1,4-diol;bis(4-fluorophenyl)methanone Chemical compound OC1=CC=C(O)C=C1.C1=CC(F)=CC=C1C(=O)C1=CC=C(F)C=C1 JUPQTSLXMOCDHR-UHFFFAOYSA-N 0.000 abstract description 28
- 239000000835 fiber Substances 0.000 abstract description 24
- 230000008569 process Effects 0.000 abstract description 18
- 230000002159 abnormal effect Effects 0.000 abstract description 7
- 238000007689 inspection Methods 0.000 abstract description 6
- 238000004458 analytical method Methods 0.000 abstract description 4
- 238000007380 fibre production Methods 0.000 abstract description 4
- 238000012552 review Methods 0.000 abstract description 4
- 238000005516 engineering process Methods 0.000 abstract description 2
- 238000012423 maintenance Methods 0.000 description 17
- 239000002994 raw material Substances 0.000 description 13
- 239000003921 oil Substances 0.000 description 10
- 238000010586 diagram Methods 0.000 description 7
- 238000002425 crystallisation Methods 0.000 description 6
- 230000008025 crystallization Effects 0.000 description 6
- 238000010438 heat treatment Methods 0.000 description 4
- 238000000465 moulding Methods 0.000 description 3
- 230000002035 prolonged effect Effects 0.000 description 3
- 238000004140 cleaning Methods 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 230000001105 regulatory effect Effects 0.000 description 2
- 238000003756 stirring Methods 0.000 description 2
- 230000006978 adaptation Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000009474 hot melt extrusion Methods 0.000 description 1
- 229920002521 macromolecule Polymers 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000004017 vitrification Methods 0.000 description 1
- 238000004857 zone melting Methods 0.000 description 1
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/41865—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by job scheduling, process planning, material flow
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/32—Operator till task planning
- G05B2219/32252—Scheduling production, machining, job shop
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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- Manufacturing & Machinery (AREA)
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- General Physics & Mathematics (AREA)
- Automation & Control Theory (AREA)
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Abstract
The invention discloses a full-flow intelligent control system for preparing polyether-ether-ketone filaments, which relates to an intelligent spinning production technology and aims to solve the problems that a great deal of factors influencing temperature change in the process of producing PEEK fibers cause great difficulty, personnel are required to carry out timing inspection at high frequency, more manpower and material resources are consumed, process parameters cannot be stably controlled and the like, and the technical scheme is characterized in that: the method comprises the following steps: the parameter monitoring module is used for acquiring environmental parameters and real-time parameters of all production processes to output control parameters which are digital signals or analog signals; and the model building module is in data connection with the parameter monitoring module and receives the control parameters to build a data module. The invention establishes a database for the collected control parameters, can record the abnormal change of the control parameters, is convenient for operators to review and check the change of the equipment data in the whole process, carries out fault analysis, timely adjusts the equipment and improves the stability of fiber production.
Description
Technical Field
The invention relates to an intelligent spinning production technology, in particular to a full-flow intelligent control system for preparing polyether-ether-ketone filaments.
Background
Because PEEK macromolecule rigidity is stronger, have higher melting point and vitrification temperature, consequently its spinning temperature is higher, generally go on more than 380 ℃, and viscosity after the melting is high, when producing the PEEK fibre, the PEEK material influences the fibrous finished product characteristic of PEEK easily at the temperature variation of hot melt extrusion molding in-process, and the factor that influences temperature variation in the production PEEK fibre in-process is a great deal, and need handle the accuse to external environment and material in the volume production in-process, there is great degree of difficulty, need the high frequency to carry out regularly patrolling and examining, consume more manpower and materials, still be difficult to keep the fibrous stability of PEEK.
Therefore, a new solution is needed to solve this problem.
Disclosure of Invention
Aiming at the defects in the prior art, the invention aims to provide a full-flow intelligent control system for preparing a polyether-ether-ketone filament.
The technical purpose of the invention is realized by the following technical scheme: a full-flow intelligent control system for preparing polyether-ether-ketone filaments comprises:
the parameter monitoring module is used for acquiring environmental parameters and real-time parameters of all production processes to output control parameters which are digital signals or analog signals;
the model building module is in data connection with the parameter monitoring module and receives the control parameters to build a data module, and the data module comprises a production line simulation model and a parameter model matched with the production line simulation model and is used for drawing up standard threshold values of environmental parameters and real-time parameters;
the historical data module is communicated with the parameter monitoring module, receives the control parameters in real time and responds to the abrupt change of the control parameters to be different from the standard threshold value so as to store the current control parameters to the database;
the production process comprises the following steps: the device comprises a fluidized bed, a drying tower, a screw extruder, a filter, a spinning box, a metering pump, a spinning assembly, an oil pump, a hot roller and a winding machine, wherein the real-time parameters comprise a material level parameter, a temperature parameter, a pressure parameter and a speed parameter;
the parameter model comprises a material level model, a temperature model, a pressure model and a speed model when the material level parameter, the temperature parameter, the pressure parameter and the speed parameter are in a stable state, and the parameter monitoring module responds to the fact that the real-time parameter exceeds a standard threshold value to output an automatic early warning signal.
By adopting the technical scheme, the real-time monitoring is carried out on the production environment and the actual parameters of each production process through the parameter monitoring module, the control parameters of digital signals or analog signals are collected, in the actual production process, the parameter data are collected and stored as standard threshold values when the quality of finished products and the corresponding actual parameters are in stable states through finished product inspection and actual parameter comparison, meanwhile, a database is established for the collected control parameters, the abnormal change of the control parameters can be recorded, operators can conveniently review the change of equipment in the whole process and carry out fault analysis, meanwhile, when the real-time parameters exceed the standard threshold values, the parameter monitoring module outputs automatic early warning signals and can remind the operators, so that in the fiber production process, frequent inspection by the operators is not needed, the labor intensity of the operators is reduced, and the maintenance personnel can be helped to know the running state of the equipment through the recorded parameter changes when the operators are absent, and regular maintenance and adjustment can be carried out.
The invention is further configured to: the parameter monitoring module comprises a drying monitoring unit, the drying monitoring unit comprises a first temperature sensor, a dew point sensor, an air flow sensor and a material level sensor which are arranged in the drying tower, and the dew point sensor and the air flow sensor are electrically connected with an air inlet valve through a controller to adjust the dew point condition in the drying tower.
Through adopting above-mentioned technical scheme, set up dry monitoring unit, when the PEEK raw materials gets into crystallization and dry state, feed back the condition of dew point in the dry situation and the drying tower of PEEK raw materials, when the dew point changes, through with dew point transducer gather the change of parameter with the controller to control the intake valve, can realize the automated control to the dew point to adjust the degree of drying of PEEK raw materials, improve the quality of follow-up fibre monofilament.
The invention is further configured to: the parameter monitoring module further comprises a screw monitoring unit, the screw monitoring unit comprises a plurality of temperature sensors II and pressure sensors, the temperature sensors II are arranged in all sections of the screw extruder and are used for acquiring temperature line graphs and melt temperatures of all the sections, and the pressure sensors are respectively arranged at the outlet end of the screw extruder, the inlet of the filter and the outlet of the filter and are used for acquiring screw extrusion pressure, pre-filtering pressure and post-filtering pressure;
the pressure sensors are coupled through a controller, the controller receives the extrusion pressure, the pre-filtering pressure and the post-filtering pressure, and outputs a filtering pressure warning signal in response to the difference value between the pre-filtering pressure and the post-filtering pressure being greater than a set standard pressure reference.
By adopting the technical scheme, the temperature of each heating interval of the screw extruder is detected through the temperature sensor II, the temperature of each interval is accurately measured and recorded in real time, the real-time temperature of the whole screw extruder and the temperature change of each interval taking time as a transverse axis are drawn into curves, the accurate control of the temperature of the PEEK raw material in each stage process is realized, so that the finished product characteristics of the PEEK fiber are improved, the pressure of the screw extruder, the pre-filtering pressure and the post-filtering pressure of the filter are acquired through the pressure sensor, the working state of the filter can be judged according to the pressure difference between the pre-filtering pressure and the post-filtering pressure, operators and maintenance personnel can know the condition of the filter in advance, the filter is cleaned according to the blockage condition of the filter, the frequency of cleaning the filter by the maintenance personnel is reduced, the labor intensity is reduced, the production running time is prolonged, the capacity is improved, and the warning signal of filtering pressure is output when the difference value between the pre-filtering pressure and the post-filtering pressure is abnormally increased to be larger than the standard pressure through coupling with the controller, the warning signal is output, the warning signal of the operators is actively reminded, and the stability of the production is further kept.
The invention is further configured to: the parameter monitoring module further comprises a spinning manifold monitoring unit, the spinning manifold monitoring unit comprises a third temperature sensor and a pressure sensor, the third temperature sensor is used for acquiring the temperature of a heat-conducting medium of the manifold, the third temperature sensor is used for monitoring the temperature of the heat-conducting medium to ensure that the temperature of the melt is in a specified temperature range, the pressure sensor is used for acquiring the melt pressure of each spinning position in the manifold, updating a pressure line diagram of the assembly pressure in real time, and timely giving an alarm when the assembly pressure fluctuates greatly or exceeds a threshold value suddenly.
By adopting the technical scheme, the temperature of the heat-conducting medium of the box body is monitored by the temperature sensor III, and when the temperature difference value is about 1 ℃ with the set temperature, the heating is adjusted in time, so that the temperature of the melt is ensured to be within the specified temperature range, the fluctuation is small, and the stability of monofilament molding is improved. Acquire the line graph of box internal melt pressure through pressure sensor, real-time supervision melt pressure changes, can help the site personnel to know the state and the situation of change of PEEK fuse-element, and in time adjust or change the raw materials, improve product production's efficiency and quality, acquire each spinning position subassembly pressure through pressure sensor, and the pressure line graph of real-time update subassembly pressure, be used for the subassembly pressure condition of accurate control each spinning position, the melt pressure fluctuation suddenly of a certain spinning position is great or exceed the threshold value, report to the police and remind operating personnel, in time and the accurate subassembly of changing, with the stability of guarantee spinning quality.
The invention is further configured to: the parameter monitoring module still includes measuring pump monitoring unit, measuring pump monitoring unit includes a plurality of hall sensor and flow sensor, hall sensor is used for acquireing the rotational speed balance degree of measuring pump, hall sensor is through monitoring unstable rotational speed fluctuation, reports to the police in real time, flow sensor is used for acquireing the fuse-element flow of measuring pump in the unit interval, flow sensor passes through the controller and is connected with the actuating mechanism of measuring pump to the frequency of motion of modulation measuring pump.
Through adopting above-mentioned technical scheme, the rotational speed equilibrium degree to the measuring pump is detected with hall sensor's mode, detect the melt flow of measuring pump simultaneously, when melt flow tends to the stability, can improve the fashioned uniformity of fibre monofilament, and flow sensor passes through the actuating mechanism of controller and measuring pump and is connected, when the melt flow changes in the measuring pump, can finely tune the rotational speed of system measuring pump, when the melt volume changes and leads to the melt resistance to change, through the automatically regulated of measuring pump, and then maintain the stability of melt flow, improve the uniformity of fibre monofilament, improve the anti broken silk ability of fibre monofilament.
The invention is further configured to: parameter monitoring module still includes finish pump monitoring unit, finish pump monitoring unit includes level sensor and unusual alarm device of electric current, level sensor floats on the finish liquid level, and the real-time supervision liquid level condition, finish inslot still are carved with minimum liquid position point simultaneously, and when actual liquid level was less than this position, then report to the police and remind the staff, unusual alarm device of electric current is used for monitoring the current signal of finish pump frequency conversion output, appears when unusual when the electric current, in time reports to the police.
Through adopting above-mentioned technical scheme, through the liquid level condition of finish in level sensor monitoring finish groove, detect the electric current output condition of measuring pump simultaneously through unusual alarm device of electric current, and can obtain finish surplus live time according to liquid level and finish pump actual setting frequency conversion, help the staff to master the finish live condition, and the minimum liquid position point that is carved with also can in time remind the staff to add the finish, guarantee the normal clear of spinning, avoid the product to lead to the emergence of quality problems because of the oiliness is unusual.
The invention is further configured to: the parameter monitoring module further comprises a hot roller drafting system monitoring unit, the hot roller drafting system monitoring unit comprises a rotation speed sensor and a temperature sensor IV, the rotation speed sensor is located on the rear side of the hot roller and used for monitoring the rotating speed of the hot roller and ensuring that the drafting multiple accords with a set value, the temperature sensor IV is located on the front side of the hot roller, and the temperature sensor IV is used for acquiring real-time temperature.
By adopting the technical scheme, the rotating speed and the temperature of each pair of hot rollers are monitored in real time through the rotating speed sensor and the temperature sensor, so that the working personnel can know the running condition of the hot rollers conveniently, and the drafting multiple of the fibers can be reflected directly.
The invention is further configured to: the parameter monitoring module still includes the coiling monitoring unit, the coiling monitoring unit includes speedtransmitter, time recorder, a plurality of digital camera and disconnected silk sensor, speedtransmitter is used for acquireing real-time winding speed, time recorder records real-time coiling time, when the time reachs and sets for full-lap time and accomplishes the switching, notes moment and number of times when the full-lap, disconnected silk sensor electric connection has the count module, digital camera is connected with digital display screen, digital camera is used for acquireing picture image to the digital display screen of winder when disconnected silk sensor triggers.
By adopting the technical scheme, the speed sensor in the winding monitoring unit acquires the speed of the winding machine in real time, the time recording device records the real-time winding time, and when the time reaches the set full-winding time and the switching is completed, the time and the times of the full-winding are recorded, so that the winding condition can be mastered by a worker. And digital camera can monitor the operating condition of winder, and disconnected silk sensor is as monitoring components and parts and trigger signal's source simultaneously, can be when fibre monofilament draft, coiling, and the people of being convenient for know the situation of fibre monofilament to when the disconnected silk condition appears, through the digital display screen of being connected with digital camera, switch the picture to disconnected silk department, the operating personnel of being convenient for and maintenance personal are quick overhauls disconnected silk department.
The invention is further configured to: the production line simulation model comprises a winding machine simulation model, a digital display unit corresponding to the time recording device is arranged on the winding machine simulation model and used for displaying real-time winding time, and the time and the frequency of the full winding, the digital display unit corresponding to the broken wire sensors and located at each winding node is further sequentially arranged on the winding machine simulation model, and the digital display unit is connected with the broken wire sensors through a counting module so as to display the frequency of the broken wires at each winding node.
By adopting the technical scheme, the digital display unit corresponding to the time recording device is arranged on the simulation model of the winding machine and used for displaying real-time winding time, counting the time when the winding machine is fully wound and the number of times of the full winding, helping a worker to master the winding condition, carrying out process adjustment on the spinning position with abnormal number of times of the full winding, or enabling a maintenance worker to overhaul equipment to eliminate problems, so that the spinning efficiency is improved. The digital display unit is arranged at each winding node and corresponds to the broken wire sensor, and the number of broken wires at the winding node can be counted, so that maintenance personnel can know the running condition of the equipment through the number of broken wires at the broken wire position when the equipment runs for a long time, the equipment is maintained and repaired regularly, and the service life of the equipment is prolonged.
The invention is further configured to: the historical data module comprises computer equipment and an MES system, the computer equipment acquires and records real-time parameters of all production processes through the controller to form a historical database and a curve graph corresponding to all the production processes, and the real-time parameters are marked on the curve graph at equal intervals by taking time as an axis.
By adopting the technical scheme, the computer equipment acquires the real-time parameters of each production process through the controller and displays the parameters on the computer, so that the staff is helped to master each link in the production in real time, and the stable production of products is facilitated. The historical data is collected and stored in stages when the real-time parameters are received by combining computer equipment with an MES (manufacturing execution system), and is expressed in a graph mode, so that managers can conveniently learn the change condition of the parameters, the production state of the fiber monofilaments can be judged according to experience, and the equipment can be overhauled before major faults occur to the equipment. Meanwhile, each process condition can be continuously optimized by establishing a historical database, a set of production process which is most suitable for preparing the PEEK filaments is mastered, the PEEK filaments can be prepared more quickly and stably in subsequent production, the cost of time, raw materials, manpower and the like is effectively reduced, real-time parameters are marked at equal intervals by taking the time as an axis, the graph recognition is facilitated, operators and maintenance personnel can conveniently learn the time period of fault generation, and the quality of the produced fiber filaments in the time period is tracked in time.
In conclusion, the invention has the following beneficial effects:
the production environment and the actual parameters of each production process are monitored in real time through a parameter monitoring module, the control parameters are collected as digital signals or analog signals, in the actual production process, the control parameters are checked through finished products and compared with the actual parameters, when the quality of the finished products and the corresponding actual parameters are in a stable state, parameter data are collected and stored to serve as standard threshold values, meanwhile, a database is built for the collected control parameters, abnormal changes of the control parameters can be recorded, operators can conveniently review changes of equipment in the whole process, fault analysis is conducted, meanwhile, when the real-time parameters exceed the standard threshold values, an automatic early warning signal is output through the parameter monitoring module, the operators can be reminded, therefore, in the fiber production process, frequent inspection by the operators is not needed, labor intensity of the operators is reduced, and the maintenance personnel can be helped to know the running state of the equipment through the recorded parameter changes when the operators are absent, and regular maintenance and adjustment can be conducted.
Drawings
FIG. 1 is a block diagram of the system of the present invention;
FIG. 2 is a schematic diagram of a first structure of a modeling module for simulating a PEEK material drying process;
FIG. 3 is a schematic structural diagram of a second model building module for simulating a process of extruding, molding and winding a fiber monofilament in the present invention;
FIG. 4 is a schematic structural diagram III of a model building module according to the present invention for simulating the operation of a unit in the fiber filament side-blowing cooling process.
Detailed Description
The invention is described in detail below with reference to the figures and examples.
As shown in fig. 1 to 4, a full-flow intelligent control system for preparing a peek filament includes:
as shown in fig. 1, the parameter monitoring module obtains environmental parameters and real-time parameters of each production process to output control parameters as digital signals or analog signals, wherein the production process includes: the system comprises a fluidized bed, a drying tower, a screw extruder, a filter, a spinning box, a metering pump, a spinning assembly, an oil pump, a hot roller and a winding machine, wherein real-time parameters comprise a material level parameter, a temperature parameter, a pressure parameter and a speed parameter, in the embodiment, PEEK raw materials are stirred, mixed and conveyed into the fluidized bed through vacuum material suction equipment for stirring and crystallization, crystallization treatment is carried out for set time at set temperature and dry air flow, the real-time parameters comprise crystallization temperature, dry air flow and crystallization time in the fluidized bed, the crystallized materials are conveyed into the drying tower for circulation drying treatment, the real-time parameters comprise drying temperature, drying time, dry air dew point, dry air flow and material level in the drying tower, the dried materials are conveyed into the screw extruder through a hopper and are extruded into the filter through multi-zone melting stirring, the real-time parameters comprise temperatures of various zones of the screw, extrusion pressure of the screw, pipeline temperature, pressure before filtering, pressure after filtering, box temperature and melt temperature after filtering are conveyed into the metering pump, filaments are extruded into a plurality of primary filaments after extrusion by the PEEK and spinning assembly, then are subjected to side draft, and are subjected to cooling, and are processed into a finished product, a wind speed sensor, and a wind speed sensor is set, and a corresponding control parameter is set, and a wind speed sensor is set.
Specifically, the parameter monitoring module comprises a drying monitoring unit, a screw monitoring unit, a spinning box monitoring unit, a metering pump monitoring unit, an oil pump monitoring unit, a hot roller drafting unit monitoring unit and a winding monitoring unit, wherein the drying monitoring unit comprises a first temperature sensor, a dew point sensor, an air flow sensor and a material level sensor which are arranged in a drying tower, the dew point sensor and the air flow sensor are electrically connected with an air inlet valve through a controller to adjust the dew point condition in the drying tower, the parameter model comprises a material level model, a temperature model and a pressure model when the material level parameter, the temperature parameter and the pressure parameter are in a stable state, and the parameter monitoring module responds to the fact that the real-time parameter exceeds a standard threshold value to output an automatic early warning signal; the screw monitoring unit comprises a plurality of temperature sensors II and pressure sensors, the temperature sensors II are arranged in all sections of the screw extruder and used for acquiring temperature line graphs and melt temperatures of all the sections, the pressure sensors are respectively arranged at the outlet end of the screw extruder, the inlet of the filter and the outlet of the filter and used for acquiring screw extrusion pressure, pre-filtering pressure and post-filtering pressure, the pressure sensors are coupled through a controller, the controller receives the extrusion pressure, the pre-filtering pressure and the post-filtering pressure, and a filtering pressure warning signal is output in response to the fact that the difference value of the pre-filtering pressure and the post-filtering pressure is larger than a set standard pressure reference; the spinning manifold monitoring unit comprises a temperature sensor III and a pressure sensor, the temperature sensor is used for acquiring the temperature of a heat-conducting medium of the manifold and ensuring that the temperature of the melt is within a specified temperature range, the pressure sensor is used for acquiring the pressure of the melt at each spinning position in the manifold, acquiring a pressure line diagram of the manifold, updating the pressure line diagram of the assembly in real time and responding to the fact that real-time parameters exceed a standard threshold value so as to output an automatic early warning signal; the metering pump monitoring unit comprises a plurality of Hall sensors and a flow sensor, the Hall sensors are used for acquiring the rotating speed balance degree of the metering pump and responding to the unstable fluctuation of the rotating speed of the metering pump to output a filtering pressure warning signal, the flow sensor is used for acquiring the melt flow of the metering pump in unit time period, and the flow sensor is connected with a driving mechanism of the metering pump through a controller to modulate the movement frequency of the metering pump; the oil pump monitoring unit comprises a liquid level sensor and a current abnormity alarm device, the liquid level sensor monitors the liquid level condition of the oil in the oil tank, the current output condition of the metering pump is detected through the current abnormity alarm device, the residual service time of the oil can be obtained through conversion according to the liquid level and the actual set frequency of the oil pump, and an automatic early warning signal is output in response to the fact that the actual liquid level of the oil is lower than the lowest liquid level point or the current of the metering pump is abnormal; the monitoring unit of the hot roller drafting system comprises a rotation speed sensor and a temperature sensor IV, wherein the rotation speed sensor is positioned at the rear side of the hot roller and used for monitoring the rotation speed of the hot roller and ensuring that the drafting multiple accords with a set value, and the temperature sensor IV is positioned at the front side of the hot roller and used for acquiring real-time temperature; winding monitoring unit, including speed sensor, time recorder, a plurality of digital cameras and disconnected silk sensor, speed sensor acquires the speed of winder in real time, time recorder records real-time coiling time, when the time reachs and sets for full roll time and accomplishes the switching, moment and number of times when noting full roll, disconnected silk sensor electric connection has a count module, digital cameras is connected with digital display screen, digital cameras is used for acquireing picture image to digital display screen of winder when disconnected silk sensor triggers.
As shown in fig. 2 to 4, a model module is established, is in data connection with the parameter monitoring module, receives the control parameters to establish a data module, and the data module comprises a production line simulation model and a parameter model matched with the production line simulation model, and is used for drawing up a standard threshold value of an environmental parameter and a real-time parameter, wherein the production line simulation model comprises a winder simulation model, a digital display unit corresponding to a time recording device is arranged on the winder simulation model and is used for displaying real-time winding time, time and times during full winding, digital display units corresponding to a broken wire sensor are sequentially arranged at each winding node, and the digital display units are connected with the broken wire sensor through a counting module to display the broken wire times at each winding node.
The historical data module is communicated with the parameter monitoring module, receives the control parameters in real time, responds to the fact that the control parameters are suddenly changed from standard threshold values to store the current control parameters to the database, and concretely comprises computer equipment and an MES system, the computer equipment obtains and records the real-time parameters of all production processes through the controller to form the historical database and a curve graph corresponding to all the production processes, the real-time parameters are marked on the curve graph at equal intervals by taking time as an axis, the historical data module further comprises mobile intelligent equipment such as an intelligent mobile phone and a tablet personal computer, communication with the computer equipment and the controller is achieved through the internet or a local area network, and the historical data of PEEK filament production are obtained through APP matched with the MES system.
The drying monitoring unit is arranged, when the PEEK raw material enters a crystallization and drying state after being stirred and mixed, the drying state of the PEEK raw material and the dew point condition in the drying tower are fed back, when the dew point changes, the air inlet valve is controlled by the controller through the change of the collection parameters of the dew point sensor, the automatic control of the dew point can be realized, thereby the drying degree of the PEEK raw material is adjusted, the quality of the subsequent fiber monofilaments is improved, the temperature of each heating section of the screw extruder is detected by the screw monitoring unit through the temperature sensor I, the temperature of each section is accurately measured and recorded in real time, the real-time temperature of the whole screw extruder and the temperature change of each section taking time as a cross shaft are drawn into curves, the accurate control of the temperature of the PEEK raw material in each stage process is realized, and the finished product characteristics of the PEEK fiber are improved, and the pressure sensor is coupled with the controller, the working state of the filter can be judged according to the pressure difference between the pre-filtering pressure and the post-filtering pressure, when the difference between the pre-filtering pressure and the post-filtering pressure is abnormally increased to be greater than a standard pressure reference, a filtering pressure warning signal is output to warn operators, the operators can be reminded actively, the operators and maintenance personnel can know the condition of the filter in advance, so that the filter can be cleaned according to the blockage condition of the filter, the frequency of cleaning the filter by the maintenance personnel is reduced, the labor intensity is reduced, the production running time is prolonged, the productivity is improved, the temperature and the pressure of a melt are monitored by the spinning box monitoring unit, and the temperature sensor is used for the temperature of a box heat-conducting medium, when the difference value of about 1 ℃ with the set temperature, the heating is adjusted in time, the melt temperature is guaranteed to be within the specified temperature range, the fluctuation is small, the stability of monofilament forming is improved, the pressure sensor is used for acquiring a line graph of the melt pressure in the box body, the melt pressure change is monitored in real time, the state and the change condition of the PEEK melt can be known by field personnel, the raw materials are adjusted or replaced in time, and the efficiency and the quality of product production are improved.
In PEEK fuse-element is through measuring pump extrusion moulding process, detect the rotational speed equilibrium degree of measuring pump with hall sensor's mode, detect the melt flow of measuring pump simultaneously, when melt flow tends to the stability, can improve the fashioned uniformity of fibre monofilament, and flow sensor passes through the controller and is connected with the actuating mechanism of measuring pump, when the melt flow changes in the measuring pump, can finely tune the reciprocating motion frequency of system measuring pump, and then maintain the melt volume change and when leading to the melt resistance change, through the automatically regulated of measuring pump, and then maintain the stability of melt flow, improve the uniformity of fibre monofilament, improve the anti broken silk ability of fibre monofilament. And the pressure of each spinning component is monitored through the pressure sensor, the pressure line graph of the component pressure is updated in real time, when the component pressure suddenly fluctuates greatly or exceeds a threshold value, an alarm is given to remind an operator, and the components are replaced timely and accurately, so that the stability of the spinning quality is guaranteed.
Then when the refrigerated filament passes through the finish pump and oils, level sensor monitors the liquid level condition of finish in the finish groove among the finish pump monitoring unit, detect the current output condition of measuring pump through unusual alarm device of current simultaneously, and can obtain finish surplus live time according to liquid level and finish pump actual setting frequency conversion, help the staff to master the finish live condition, and the minimum liquid position point that is carved with also can in time remind the staff to add the finish, guarantee the normal clear of spinning, avoid the product to lead to the emergence of quality problems because of the oiliness is unusual.
After oiling, drafting is carried out through a hot roller drafting system, the rotating speed and the temperature of each pair of hot rollers are monitored in real time by a rotating speed sensor and a temperature sensor in a monitoring unit, so that a worker can know the running condition of the hot rollers conveniently, and the drafting multiple of fibers can be reflected directly.
When the drafted yarn is wound by the winding machine, the speed sensor in the winding monitoring unit acquires the speed of the winding machine in real time, the time recording device records the real-time winding time, and when the time reaches the set full-winding time and the switching is completed, the time and the frequency of the full-winding time are recorded, so that the winding condition can be mastered by a worker. The digital camera can monitor the working state of the winding machine, meanwhile, the broken filament sensor serves as a source of monitoring components and trigger signals, the fiber monofilaments can be drafted and wound, people can know the conditions of the fiber monofilaments conveniently, when the broken filament condition occurs, the picture is switched to the broken filament position through the digital display screen connected with the digital camera, a digital display unit corresponding to the time recording device is arranged on a simulation model of the winding machine and used for displaying real-time winding time, the time and the full-winding times during full winding are counted, the winding condition is mastered by workers, the spinning position with the abnormal full-winding times is subjected to process adjustment, or maintenance personnel are allowed to overhaul the equipment to eliminate the problems, and the spinning efficiency is improved. The digital display unit is arranged at each winding node and corresponds to the broken wire sensor, the number of times of broken wires at the winding nodes can be counted, and therefore when the digital display unit is operated for a long time, maintenance personnel can know the operation condition of the equipment through the number of times of broken wires at the broken wire position, management personnel can acquire the specific production condition of a production line through computer equipment and mobile intelligent equipment, maintenance personnel and operation personnel are scheduled in time to overhaul the broken wire position, and production efficiency and productivity are improved.
The computer equipment acquires the real-time parameters of each production process through the controller and displays the parameters on the computer, so that the computer equipment helps workers to master each link in the production in real time, and the stable production of products is facilitated. The historical data is collected and stored in stages when the real-time parameters are received by combining computer equipment with an MES (manufacturing execution system), and is expressed in a graph mode, so that managers can conveniently learn the change condition of the parameters, the production state of the fiber monofilaments can be judged according to experience, and the equipment can be overhauled before major faults occur to the equipment. Meanwhile, the historical database is established, so that each process condition can be continuously optimized, a set of most suitable production process for preparing the PEEK filaments is mastered, the PEEK filaments can be rapidly and stably prepared in subsequent production, and the time, raw materials, labor and other costs are effectively reduced.
The production environment and the actual parameters of each production process are monitored in real time through the parameter monitoring module, the control parameters are collected as digital signals or analog signals, in the actual production process, the parameter data are collected and stored as standard threshold values when the quality of finished products and the corresponding actual parameters are in a stable state through finished product inspection and actual parameter comparison, meanwhile, a database is established for the collected control parameters, abnormal changes of the control parameters can be recorded, operators can conveniently review and check changes of equipment in the whole process to carry out fault analysis, meanwhile, when the real-time parameters exceed the standard threshold values, the parameter monitoring module outputs automatic early warning signals to remind the operators, therefore, in the fiber production process, frequent inspection by the operators is not needed, the labor intensity of the operators is reduced, and the recorded parameter changes can help maintenance personnel to know the running state of the equipment so as to carry out regular maintenance and adjustment.
The above description is only a preferred embodiment of the present invention, and the protection scope of the present invention is not limited to the above embodiments, and all technical solutions belonging to the idea of the present invention belong to the protection scope of the present invention. It should be noted that modifications and adaptations to those skilled in the art without departing from the principles of the present invention should also be considered as within the scope of the present invention.
Claims (10)
1. A full-flow intelligent control system for preparing a polyether-ether-ketone filament is characterized in that: the method comprises the following steps:
the parameter monitoring module is used for acquiring environmental parameters and real-time parameters of each production process so as to output control parameters which are digital signals or analog signals;
the model building module is in data connection with the parameter monitoring module and receives the control parameters to build a data module, and the data module comprises a production line simulation model and a parameter model matched with the production line simulation model and is used for drawing up standard threshold values of environmental parameters and real-time parameters;
the historical data module is communicated with the parameter monitoring module, receives the control parameters in real time and responds to the abrupt change of the control parameters to be different from the standard threshold value so as to store the current control parameters to the database;
the production process comprises the following steps: the device comprises a fluidized bed, a drying tower, a screw extruder, a filter, a spinning box body, a metering pump, a spinning assembly, an oil pump, a hot roller and a winding machine, wherein the real-time parameters comprise a material level parameter, a temperature parameter, a pressure parameter and a speed parameter.
The parameter model comprises a material level model, a temperature model, a pressure model and a speed model when the material level parameter, the temperature parameter, the pressure parameter and the speed parameter are in a stable state, and the parameter monitoring module responds to the fact that the real-time parameter exceeds a standard threshold value to output an automatic early warning signal.
2. The full-process intelligent control system for preparing a polyetheretherketone filament according to claim 1, wherein: the parameter monitoring module comprises a drying monitoring unit, the drying monitoring unit comprises a first temperature sensor, a dew point sensor, an air flow sensor and a material level sensor which are arranged in the drying tower, and the dew point sensor and the air flow sensor are electrically connected with an air inlet valve through a controller to adjust the dew point condition in the drying tower.
3. The system of claim 1, wherein the system comprises: the parameter monitoring module further comprises a screw monitoring unit, the screw monitoring unit comprises a plurality of temperature sensors II and pressure sensors, the temperature sensors II are arranged in all sections of the screw extruder and are used for acquiring temperature line graphs and melt temperatures of all the sections, and the pressure sensors are respectively arranged at the outlet end of the screw extruder, the inlet of the filter and the outlet of the filter and are used for acquiring screw extrusion pressure, pre-filtering pressure and post-filtering pressure;
the pressure sensors are coupled through a controller, the controller receives the extrusion pressure, the pre-filtering pressure and the post-filtering pressure, and outputs a filtering pressure warning signal in response to the difference value between the pre-filtering pressure and the post-filtering pressure being greater than a set standard pressure reference.
4. The system of claim 1, wherein the system comprises: the parameter monitoring module further comprises a spinning box monitoring unit, the spinning box monitoring unit comprises a third temperature sensor and a pressure sensor, the third temperature sensor is used for acquiring the temperature of a box heat-conducting medium, the third temperature sensor monitors the temperature of the heat-conducting medium to ensure that the temperature of a melt is within a specified temperature range, the pressure sensor is used for acquiring the melt pressure of each spinning position in the box, a pressure line graph of the assembly pressure is updated in real time, and when the assembly pressure suddenly fluctuates greatly or exceeds a threshold value, an alarm is given in time.
5. The full-process intelligent control system for preparing a polyetheretherketone filament according to claim 1, wherein: the parameter monitoring module still includes measuring pump monitoring unit, measuring pump monitoring unit includes a plurality of hall sensor and flow sensor, hall sensor is used for acquireing the rotational speed balance degree of measuring pump, hall sensor is through monitoring unstable rotational speed fluctuation, reports to the police in real time, flow sensor is used for acquireing the fuse-element flow of measuring pump in the unit interval, flow sensor passes through the controller and is connected with the actuating mechanism of measuring pump to the frequency of motion of modulation measuring pump.
6. The system of claim 1, wherein the system comprises: parameter monitoring module still includes finish pump monitoring unit, finish pump monitoring unit includes level sensor and unusual alarm device of electric current, level sensor floats on the finish liquid level, and the real-time supervision liquid level condition still is carved with minimum liquid position point in the finish inslot simultaneously, when actual liquid level is less than this position, then reports to the police and reminds the staff, unusual alarm device of electric current is used for monitoring the current signal of finish pump frequency conversion output, when the current appears unusually, in time reports to the police.
7. The system of claim 1, wherein the system comprises: the parameter monitoring module further comprises a hot roller drafting system monitoring unit, the hot roller drafting system monitoring unit comprises a rotation speed sensor and a temperature sensor IV, the rotation speed sensor is located on the rear side of the hot roller and used for monitoring the rotating speed of the hot roller and ensuring that the drafting multiple accords with a set value, the temperature sensor IV is located on the front side of the hot roller, and the temperature sensor IV is used for acquiring real-time temperature.
8. The system of claim 1, wherein the system comprises: the parameter monitoring module still includes the coiling monitoring unit, the coiling monitoring unit includes speedtransmitter, time recorder, a plurality of digital camera and disconnected silk sensor, speedtransmitter is used for acquireing real-time winding speed, time recorder records real-time coiling time, when the time reachs and sets for full-lap time and accomplishes the switching, notes moment and number of times when the full-lap, disconnected silk sensor electric connection has the count module, digital camera is connected with digital display screen, digital camera is used for acquireing picture image to the digital display screen of winder when disconnected silk sensor triggers.
9. The system of claim 1, wherein the system comprises: the production line simulation model comprises a winding machine simulation model, a digital display unit corresponding to the time recording device is arranged on the winding machine simulation model and used for displaying real-time winding time, time and times during full winding, the digital display unit corresponding to the broken wire sensor and located at each winding node is further sequentially arranged on the winding machine simulation model and connected with the broken wire sensor through a counting module so as to display the times of broken wires at each winding node.
10. The system of claim 1, wherein the system comprises: the historical data module comprises computer equipment and an MES system, the computer equipment acquires and records real-time parameters of all production processes through the controller to form a historical database and a curve graph corresponding to all the production processes, and the real-time parameters are marked on the curve graph at equal intervals by taking time as an axis.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN116736817A (en) * | 2023-08-11 | 2023-09-12 | 西安启银致远企业管理有限公司 | Intelligent control method for hydrophilic silver fiber dressing production and processing |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116736817A (en) * | 2023-08-11 | 2023-09-12 | 西安启银致远企业管理有限公司 | Intelligent control method for hydrophilic silver fiber dressing production and processing |
| CN116736817B (en) * | 2023-08-11 | 2023-11-03 | 西安启银致远企业管理有限公司 | Intelligent control method for hydrophilic silver fiber dressing production and processing |
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