WO2019113873A1 - 一种智能温控流延膜机 - Google Patents

一种智能温控流延膜机 Download PDF

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Publication number
WO2019113873A1
WO2019113873A1 PCT/CN2017/116101 CN2017116101W WO2019113873A1 WO 2019113873 A1 WO2019113873 A1 WO 2019113873A1 CN 2017116101 W CN2017116101 W CN 2017116101W WO 2019113873 A1 WO2019113873 A1 WO 2019113873A1
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Prior art keywords
module
temperature
extruder
integrated controller
film machine
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PCT/CN2017/116101
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English (en)
French (fr)
Inventor
徐惠良
胡超飞
周作银
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昌龙兴科技（深圳）有限公司
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Priority to PCT/CN2017/116101 priority Critical patent/WO2019113873A1/zh
Publication of WO2019113873A1 publication Critical patent/WO2019113873A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D7/00—Producing flat articles, e.g. films or sheets
    • B29D7/01—Films or sheets
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
    • G05D23/00—Control of temperature

Definitions

  • the invention relates to the field of cast film machines.
  • the casting film machine is a molding device capable of preparing a melt into a film having a uniform thickness and a certain width, and is suitable for the experiment and production of film forming.
  • each temperature zone corresponds to a temperature control table.
  • each control table needs to be separately set to set the heating temperature of the casting film machine, which is not only troublesome to set the temperature. And it is not convenient to adjust and control the temperature.
  • the heating zone with fast heating will reach the set temperature first, and the temperature zone to be heated slowly can reach the set temperature before starting the mixing. It will cause the material in the heated heating zone to degrade or age under the condition of long-time heating, which affects the performance of the product.
  • each temperature zone is separately connected to the temperature control meter and the ammeter, each control meter and ammeter must be wired, resulting in a large number of lines, which not only has safety hazards but is not conducive to maintenance. Moreover, the existing cast film machine cannot alarm and prompt the fault in real time when the heater fails.
  • the invention provides an intelligent temperature-controlled cast film machine, which can set the temperature with one button, the temperature control is more precise, the wiring is reduced, the real-time alarm can be realized, and the operation is simple.
  • the invention provides an intelligent temperature-controlled cast film machine, comprising a temperature control system, the temperature control system comprising an integrated controller, a remote I/O and a field bus module, the remote I/O comprising a functional module and an analog module And a digital module, the function module, the analog module, the digital module and the integrated controller are respectively connected to the field bus module; the function module collects temperature data of each temperature zone and collects Data is transmitted to the integrated controller via the fieldbus module; the analog module collects current data of each temperature zone and transmits the collected current data to the integrated controller via the field bus module; The digital module collects the switching signal of the intelligent temperature-controlled cast film machine and transmits the collected signal to the integrated controller through the field bus module; the integrated controller performs the received data or signal Processing and outputting a control instruction according to the processing result, where the control instruction is transmitted to the function module and the analog module via the field bus module Or the digital module, each module performs function adjustment according to the received control instruction.
  • the integrated controller includes a PLC and a touch screen, and the PLC respectively connects the field bus module and the touch screen, the PLC processes data and outputs a control instruction, and the touch screen is used for displaying The data received by the PLC and setting parameters of each temperature zone.
  • the intelligent temperature-controlled cast film machine comprises an extruder, a casting cooling device, a swing device and a fully automatic winding device, and the material is plastically extruded through the extruder to the casting cooling device. And forming a film by cooling and cooling on the casting cooling device, and the formed plastic film is drawn from the casting cooling device to the swing device, the swing device adjusts the tension of the plastic film, and pulls the plastic film to The automatic winding device, the automatic winding device winds the plastic film to the paper tube and cuts the unloading material.
  • the extruder includes an electric heater and a cooling fan, and the electric heater and the cooling fan are respectively connected to the function module, and the function module selects to open according to a control instruction of the integrated controller.
  • An electric heater or the cooling fan when the function module detects that the temperature of the extruder is higher than a set temperature, the integrated controller outputs a start command to the cooling fan, and the cooling fan operates Cooling the extruder, when the function module detects that the temperature of the extruder drops to a set temperature, the integrated controller outputs a shutdown command to the cooling fan, and the cooling fan stops operating;
  • the functional module detects that the temperature of the extruder is lower than a set temperature
  • the integrated controller outputs a start command to the electric heater, and the electric heater operates to heat the extruder
  • the integrated controller outputs a control command to the electric heater, the electric heater reduces heating power or Stop heating.
  • the analog module collects current data of the extruder and rotational speed data of the extruder, and transmits the collected data to the integrated controller, and the integrated controller will receive the received data. After the data is calculated and analyzed, a current control command and a speed control command are respectively output to the analog module, and the analog module respectively adjusts the current of the extruder and the squeeze according to the received current control command and the speed control command. The speed of the machine.
  • the digital quantity module collects the switching quantity signal of the extruder, and transmits the collected signal to the integrated controller, and when the integrated controller determines the extrusion according to the received data When the machine fails, the integrated controller outputs a shutdown command to the digital module, and the digital module controls shutting down the extruder.
  • the intelligent temperature-controlled cast film machine includes a thickness gauge, the thickness gauge is disposed between the casting cooling device and the swing device, and the formed plastic film is from the casting cooling device. Traction to the thickness gauge, the thickness gauge measures the thickness of the plastic film in real time.
  • the extruder comprises a melt metering pump, a barrel and a die, one end of the barrel is provided with an outlet, the die is connected to the casting cooling device, and the melt metering pump is arranged at the The outlet and the die are connected to the outlet and the die, and the melt metering pump is used to meter control and stabilize the extruded material.
  • the casting machine further includes a double chamber vacuuming device fixedly mounted on the die, the double cavity vacuuming device for removing the casting cooling device and the flow The air between the membranes.
  • the extruder includes a pulverizing material discharging device
  • the pulverizing material discharging device includes a hopper
  • the feeding hopper is provided with a conveying mechanism. After the material is put into the hopper, the conveying mechanism rotates. Feeding, the conveying mechanism is used to uniformly feed the extruder and prevent material clogging.
  • the intelligent temperature-controlled cast film machine provided by the invention adopts an integrated controller to set and adjust the temperature of the casting film machine, and can realize one-button setting temperature, and it is no need to separately set the temperature of each control table, and the operation is simpler and faster;
  • the present invention provides a novel casting temperature control system, which collects different functional data by setting different modules and transmits them to the integrated controller for processing, thereby reducing the use of the temperature control table and the ammeter, and reducing the use. Wiring is beneficial to reduce the cost of the casting film machine;
  • the temperature control system of the casting machine provided by the invention can collect the temperature data of each temperature zone in real time and adjust in time, the temperature control is more precise, and the temperature inconsistency of each temperature zone is avoided to affect the performance of the material;
  • the intelligent temperature-controlled cast film machine of the invention can also monitor the abnormal working state of the casting film machine by setting the digital module and alarm and prompt the fault in real time.
  • Figure 1 is a schematic view of a temperature control system of the present invention
  • FIG. 2 is a circuit diagram of a functional module of a temperature control system of the present invention
  • FIG. 3 is a circuit diagram of an analog module of the temperature control system of the present invention.
  • FIG. 4 is a circuit diagram of a digital module and a field bus module of the temperature control system of the present invention
  • Figure 5 is a front elevational view of the intelligent temperature-controlled cast film machine of the present invention.
  • Figure 6 is a top plan view of the intelligent temperature controlled cast film machine of the present invention.
  • the present invention provides a temperature control system 20 for a cast film machine 10, the temperature control system 20 including an integrated controller 21, a remote I/O 23, and a fieldbus module 22, the remote I /O23 includes a function module 231, an analog module 232, and a digital module 233, the function module 231, the analog module 232, the digital module 233, and the integrated controller 21 respectively and the field bus module 22, the function module 231 collects temperature data of each temperature zone and transmits the collected data to the integrated controller 21 via the field bus module 22; the analog quantity module 232 collects current data of each temperature zone and The collected current data is transmitted to the integrated controller 21 via the field bus module 22; the digital quantity module 233 collects the switching quantity signal of the intelligent temperature control casting film machine 10 and passes the collected signal through the The field bus module 22 is transmitted to the integrated controller 21; the integrated controller 21 processes the received data or signal and outputs a control command according to the processing result, and the control command passes through the present Module transmission bus 22 to the functional module 231, the analog
  • the intelligent temperature-controlled cast film machine 10 adopts the integrated controller 21 to set and adjust the temperature of the casting film machine 10, and can realize one-button setting temperature, without separately setting the temperature of each control table, not only reducing the temperature.
  • the use of control tables and ammeters reduces wiring and makes operation quicker and easier.
  • the temperature control system 20 of the present invention collects the temperature data of each temperature zone in real time and adjusts it in time, the temperature control is more precise, and the temperature inconsistency of each temperature zone is avoided to affect the performance of the material.
  • the temperature control system 20 of the present invention monitors the abnormal working state of the cast film machine 10 by setting the digital quantity module 233 and alarms and prompts the fault in real time.
  • the present invention provides an intelligent temperature-controlled cast film machine 10 including a temperature control system 20 , an extruder 30 , a casting cooling device 50 , a dual chamber vacuuming device 40 , and a swing device 70 . , Thickness Gauge 60 and fully automatic winding system.
  • the temperature control system 20 monitors and regulates the temperature of each temperature zone of the extruder 30, and the material is plastically extruded through the extruder 30 to the casting cooling device 50, and the dual chamber vacuuming device 40 Removing the gas flow layer on the casting roll, the material is cooled and cooled on the casting cooling device 50 to form a film, and the formed plastic film is drawn from the casting cooling device 50 to the thickness gauge 60.
  • the thickness gauge 60 measures the thickness of the plastic film in real time, and then the plastic film is drawn to the swinging device 70, which adjusts the tension of the plastic film and draws the plastic film to the fully automatic winding device 80, The fully automatic winding device 80 winds the plastic film to the paper tube and cuts the unloading.
  • the head of the extruder 30 is provided with a blanking device for adding material to the extruder 30.
  • the conventional unloading device is only a simple hopper 341, and the material is added due to different material thicknesses. In the process, the port of the hopper 341 is easily blocked, and the density of the mixture is different, which may cause uneven mixing during the feeding process, which seriously affects the quality and performance of the product.
  • the extruder 30 of the present invention employs a pulverizing material blanking device 34 including a hopper 341 for adding and storing materials, the lower end of the hopper 341 communicating with the barrel 32 of the extruder 30, and the hopper 341 A conveying mechanism for rotating feed is provided, the conveying mechanism comprising a screw disposed at a junction of the hopper 341 and the barrel 32.
  • the conveying mechanism comprising a screw disposed at a junction of the hopper 341 and the barrel 32.
  • the material is more uniformly mixed, and under the action of the screw, the material is continuously delivered to the barrel 32 without clogging, and the material added by the pulverizing material discharging device 34 does not block the port of the hopper 341 and the material.
  • the mixing is more uniform and effectively guarantees the quality of the product.
  • the extruder 30 of the present invention can be selected from a single screw extruder 30, a twin screw extruder 30 or other screw extruder 30.
  • the extruder 30 has a screw in the barrel 32, which enables the material to be fully plasticized and Mix evenly.
  • the single-screw extruder 30 as an example, after the material is conveyed to the barrel 32 of the extruder 30 via the blanking device, first enters the conveying section of the screw, the material starts to be heated and is compacted by pressing, and the material is not plasticized yet.
  • the material Under the rotation of the screw, the material is transported to the compression section of the screw, at which time the temperature of the material is heated to the plasticizing temperature, the material is plasticized, fully plasticized and uniformly mixed under the action of the screw, and then, the completely plasticized material
  • the metering section of the screw is included and extruded from the outlet of the barrel 32.
  • An electric heater is provided in the extruder 30 for heating the extruder 30.
  • the extruder 30 is provided with a plurality of temperature zones, and thermocouples are provided in these temperature zones, and the functions of the thermocouples connected to the intelligent temperature system are provided.
  • Module 231 when the extruder 30 is running, the function module 231 collects the temperature data of each temperature zone in real time and transmits the data to the integrated controller 21 of the intelligent temperature system via the field bus module 22, and the PLC 211 of the integrated controller 21 processes the data and The received temperature data is displayed on the touch screen 212.
  • the operator can monitor the temperature and the working state of each temperature zone of the extruder 30 in real time through the touch screen 212, and can also set or adjust the temperature of each temperature zone on the touch screen 212.
  • the control command is issued to the function module 231 through the PLC 211, and the function module 231 controls the electric heaters in the respective temperature zones to perform heating or stop heating according to the instructions.
  • the extruder 30 is further provided with a cooling fan.
  • the integrated controller 21 determines that the temperature of the extruder 30 is higher than the set temperature according to the temperature data collected by the function module 231, the integrated controller 21 outputs a start command to the function module 231.
  • the function module 231 turns on the cooling fan according to the instruction, and the cooling fan runs to cool the extruder 30.
  • the integrated controller 21 When the temperature of the extruder 30 drops to the set temperature, the integrated controller 21 outputs a shutdown command to the function module 231, and the function module 231 Turn off the cooling fan according to the instructions.
  • the casting film machine 10 of the present invention can set and adjust the temperature of the extruder 30 through the integrated controller 21, and can realize one-button setting temperature, and it is no longer necessary to separately set the temperature of each control table, and the operation is simpler and faster; and the function module 231
  • the temperature data of each temperature zone can be collected in real time and adjusted in time, and the temperature control is more precise, which avoids the inconsistency of temperature in each temperature zone and affects the performance of materials.
  • the intelligent temperature control system 20 of the present invention further includes an analog module 232 and a digital module 233, which are respectively connected to the integrated controller 21 via the fieldbus module 22.
  • the analog module 232 collects the current data of each temperature zone of the extruder 30 and transmits the collected current data to the integrated controller 21 via the field bus module 22.
  • the current data is mainly the current data of the electric heater, and the integrated controller 21 pairs
  • the received current data is analyzed, the current of each electric heater in the temperature zone is adjusted in time, thereby controlling the heating rate of the electric heater, ensuring smooth and uniform heating in each temperature zone, and by collecting current data, the integrated controller 21 can monitor the electricity in real time. The working state of the heater and timely detection of abnormal working conditions or faults.
  • the analog module 232 also collects the rotational speed of the screw of the extruder 30, and collects the rotation rate of the screw in real time through the sensor connected to the screw and transmits it to the integrated controller 21, and can also control the adjustment according to the instruction of the integrated controller 21.
  • the screw speed of the machine 30 is convenient to adjust the screw speed according to actual needs, which is not only convenient to operate but also beneficial to ensure the quality of the product.
  • the digital module 233 is mainly used to collect the switching signal of the casting film machine 10, and the collected signal is transmitted to the integrated controller 21 through the field bus module 22.
  • the integrated controller 21 receives data and signals from the function module 231, the analog module 232 and the digital module 233, and performs analysis and adjustment.
  • the integrated controller 21 leads the work of each part. Through the real-time monitoring of the working status of each part and timely adjustment, the casting film machine 10 is guaranteed to operate normally.
  • the integrated controller 21 determines that a certain portion of the extruder 30 has failed based on the received data and signals, the integrated controller 21 outputs a shutdown command to the digital module 233, and the digital module 233 controls the shutdown based on the received command.
  • the machine 30, the digital module 233 and the integrated controller 21 cooperate with the branch line automatic control, which not only has a fast response speed, can detect faults in time and shut down the running machine, can reduce the damage of the machine to the greatest extent, and the process is automated. Processing is safer.
  • the outlet of the barrel 32 of the extruder 30 is connected to a melt metering pump.
  • the material is plasticized and mixed by the extruder 30 and then extruded from the outlet of the barrel 32 into the melt metering pump.
  • the melt metering pump can be metered and controlled. The material can be adjusted according to the actual demand. At the same time, the melt metering pump can also stabilize the extruded material. During the extrusion process of the material, uneven material feeding, temperature fluctuation, pulsation of the screw speed, etc., tend to cause uneven extrusion of the material, affecting the precision and quality of the product.
  • the use of the melt metering pump can eliminate the feeding error of the feeding system and reduce the fluctuation of the upstream process transfer, make the state of the material more stable, improve the dimensional accuracy of the extruded product, and effectively reduce the scrap rate.
  • the melt metering pump is connected to a die 33, and the other end of the die 33 is connected to a casting roll of the casting cooling device 50, and the plasticized material is transferred to the casting roll through the die 33, and the casting roller is driven by the motor. Under the rotation, the melt cools down on the surface of the casting roll and rapidly solidifies into a film.
  • the casting roller used in the invention has a double-layer bidirectional spiral flow channel, and the inside of the casting roller adopts a double-layer structure, which can effectively reduce the weight of the cooling water in the casting roller, reduce the power of the casting roller driving motor, and is energy-saving and environmentally friendly, and The built-in bi-directional spiral flow path can make the roll surface cooling temperature more uniform and the formed film is more flat.
  • the casting film machine 10 of the present invention is further provided with a double chamber vacuuming device 40 which is mounted on the die 33 and connected to the die 33.
  • a double chamber vacuuming device 40 which is mounted on the die 33 and connected to the die 33.
  • the airflow layer on the surface of the casting roller can be effectively removed, so that the melt-forming and the casting roller can be completely bonded without generating bubbles, and the thickness of the formed plastic film is more uniform.
  • the device can also effectively clean the surface of the casting roll to remove dust scattered on the surface of the casting roll, thereby ensuring the quality of the product and reducing the scrap rate.
  • the formed plastic film is pulled out from the casting roll, and a thickness gauge 60 is placed in front of the casting roll to pass the plastic film through the thickness gauge 60.
  • the thickness gauge 60 can measure the thickness of the plastic film in real time, and the thickness of the plastic film can be further
  • the specific conditions of the pre-processing process of the reactive plastic film can be adjusted according to the thickness of the previous processing process to obtain the plastic film of the required thickness, or whether the previous processing technology has a fault or a parameter to be adjusted according to whether the thickness of the plastic film is uniform.
  • the thickness gauge 60 can directly reflect the quality of the final product on the one hand, and can adjust the parameters of the extruder 30 or the casting cooling device 50 and the respective components according to the data of the thickness gauge 60, thereby obtaining a product of the highest quality.
  • the obtained plastic film is thickness measured by the thickness gauge 60, and then pulled to the automatic winding device 80 for winding, between the automatic winding device 80 and the thickness gauge 60.
  • a swinging device 70 is provided. After the plastic film is pulled out of the thickness gauge 60, it is bypassed by the swinging device 70 and then pulled to the fully automatic winding device 80.
  • the swinging device 70 is mainly used to adjust the tension of the plastic film. After the plastic film is pulled out from the thickness gauge 60, if it enters the automatic winding device 80 directly, since the automatic winding device 80 and the thickness gauge 60 have a certain distance, the plastic film is pulled to the automatic winding.
  • the device 80 will sag due to the action of gravity, so that the plastic film is in a slack state, which may cause the automatic winding device 80 to wrinkle and not flatten when the plastic film is wound, which affects the appearance and quality of the product.
  • the present invention provides an oscillating device 70 in front of the automatic winding device 80.
  • the plastic film first bypasses the oscillating device 70.
  • the oscillating device 70 applies a reverse pulling force to the plastic film to be transferred to the fully automatic winding device 80.
  • the plastic film is tight, and the plastic film is conveyed more smoothly during the operation of the automatic winding device 80, which is convenient for large-diameter winding, and can ensure that the product does not wrinkle and effectively improve the quality of the product.
  • the unit of the invention adopts a fully automatic paper-feeding and unwinding device to replace the traditional manual paper-feeding tube, which not only greatly improves the production efficiency, reduces the labor cost, but also effectively improves the safety of the operation of the equipment.

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  • Physics & Mathematics (AREA)
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  • Mechanical Engineering (AREA)
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Abstract

一种智能温控流延膜机(10)，包括一种温度控制系统(20)，温度控制系统包括集成控制器(21)以及通过现场总线模块(22)与集成控制器连接的功能模块(231)、模拟量模块(232)和数字量模块(233)；功能模块采集各温区的温度数据，模拟量模块采集各温区的电流数据，数字量模块采集流延膜机的开关量信号，各模块采集的数据与信号均通过现场总线模块传输给集成控制器；集成控制器对接收到的数据和信号进行处理并根据处理结果分别输出控制指令，控制指令经由现场总线模块传输给功能模块、模拟量模块或数字量模块，各模块根据接收到的控制指令进行功能调节。流延膜机可一键设置温度，温度控制更加精确，减少了温度控制表及电流表的使用，操作更简便。

Description

一种智能温控流延膜机 技术领域
本发明涉及流延膜机技术领域。
背景技术
流延膜机是可以把熔体制备成均匀厚度，一定宽度的片状薄膜的成型设备，适用于薄膜成型的实验和生产中。
目前常见流延膜机的加热一般是由温度控制表来控制，采用电流表来监测电流。由于流延机的混料段具有多个温区，每个温区都对应一个温度控制表，在使用时，需要单独设置每个控制表以设置流延膜机的加热温度，不仅设置温度麻烦，且不便于对温度进行调节与控制。在流延机的混料过程中，由于每个温区的加热时间不一样，加热快的温区会先到达设定温度，待加热慢的温区达到设定温度后才能开始混料，这样会造成加热快的温区的物料在长时间加热的情况下发生降解或老化，影响制品的性能。再者，由于每个温区都单独连接温度控制表及电流表，每一个控制表及电流表都要接线，造成线路繁多，不仅存在安全隐患且不利于检修。且现有的流延膜机在加热器出现故障时，不能实时报警及提示故障。
发明内容
为了解决上述问题，本发明提出一种智能温控流延膜机，可以一键设置温度，温度控制更加精确，减少了接线，可实时报警，且操作简便。
本发明通过以下技术方案实现：
本发明提出一种智能温控流延膜机，包括温度控制系统，所述温度控制系统包括集成控制器、远程I/O和现场总线模块，所述远程I/O包括功能模块、模拟量模块和数字量模块，所述功能模块、所述模拟量模块、所述数字量模块和 所述集成控制器分别与所述现场总线模块连接；所述功能模块采集各个温区的温度数据并将采集的数据经由所述现场总线模块传输给所述集成控制器；所述模拟量模块采集各个温区的电流数据并将采集的电流数据经由所述现场总线模块传输给所述集成控制器；所述数字量模块采集所述智能温控流延膜机的开关量信号并将采集到的信号通过所述现场总线模块传输给所述集成控制器；所述集成控制器对接收到的数据或信号进行处理并根据处理结果输出控制指令，控制指令经由所述现场总线模块传输给所述功能模块、所述模拟量模块或所述数字量模块，各模块根据接收到的控制指令进行功能调节。
进一步的，所述集成控制器包括PLC和触控屏，所述PLC分别连接所述现场总线模块与所述触控屏，所述PLC处理数据并输出控制指令，所述触控屏用于显示所述PLC接收到的数据并设定各个温区的参数。
进一步的，所述智能温控流延膜机包括挤出机、流延冷却装置、摆动装置和全自动收卷装置，物料经由所述挤出机塑炼挤出至所述流延冷却装置，并在所述流延冷却装置上经冷却降温成膜，成型的塑料薄膜从所述流延冷却装置上牵引至所述摆动装置，所述摆动装置调节塑料薄膜的张力，并将塑料薄膜牵引至所述全自动收卷装置，所述全自动收卷装置将塑料薄膜收卷至纸筒并裁剪卸料。
进一步的，所述挤出机包括电加热器和冷却风扇，所述电加热器与所述冷却风扇分别连接所述功能模块，所述功能模块根据所述集成控制器的控制指令选择开启所述电加热器或所述冷却风扇；当所述功能模块检测到所述挤出机的温度高于设定的温度时，所述集成控制器输出启动指令给所述冷却风扇，所述冷却风扇运行给所述挤出机降温，当所述功能模块检测到所述挤出机的温度降至设定温度时，所述集成控制器输出关闭指令给所述冷却风扇，所述冷却风扇 停止运转；当所述功能模块检测到所述挤出机的温度低于设定的温度时，所述集成控制器输出启动指令给所述电加热器，所述电加热器运行给所述挤出机加热，当所述功能模块检测到所述挤出机的温度升高至设定温度时，所述集成控制器输出控制指令给所述电加热器，所述电加热器降低加热功率或停止加热。
进一步的，所述模拟量模块采集所述挤出机的电流数据及所述挤出机的转速数据，并将采集到的数据传输给所述集成控制器，所述集成控制器将接收到的数据进行计算分析后分别输出电流控制指令和转速控制指令给所述模拟量模块，所述模拟量模块根据接收到的电流控制指令和转速控制指令分别调节所述挤出机的电流以及所述挤出机的转速。
进一步的，所述数字量模块采集所述挤出机的开关量信号，并将采集到的信号传输给所述集成控制器，当所述集成控制器根据接收到的数据判断出所述挤出机出现故障时，所述集成控制器输出关闭指令给所述数字量模块，所述数字量模块控制关闭所述挤出机。
进一步的，所述智能温控流延膜机包括测厚仪，所述测厚仪设于所述流延冷却装置与所述摆动装置之间，成型的塑料薄膜从所述流延冷却装置上牵引至所述测厚仪，所述测厚仪实时测量塑料薄膜的厚度。
进一步的，所述挤出机包括熔体计量泵、料筒和模头，所述料筒一端设有出口，所述模头连接所述流延冷却装置，所述熔体计量泵设于所述出口与所述模头之间并连通所述出口与所述模头，所述熔体计量泵用于计量控制并稳定挤出的物料。
进一步的，所述流延机还包括双腔抽真空装置，所述双腔抽真空装置固定安装于所述模头上，所述双腔抽真空装置用于去除所述流延冷却装置与流延膜之间的空气。
进一步的，所述挤出机包括粉碎料下料装置，所述粉碎料下料装置包括加料斗，所述加料斗内设有输送机构，物料投入到所述加料斗后，所述输送机构旋转送料，所述输送机构用来给挤出机均匀送料并防止物料堵塞。
本发明的有益效果：
1.本发明提供的智能温控流延膜机采用集成控制器设置并调节流延膜机的温度，可以实现一键设置温度，无需再单独设置每个控制表的温度，操作更加简单快捷；
2.本发明提供了一种新型的流延机温度控制系统，通过设置不同的模块分别采集不同的功能数据，再传输给集成控制器处理，减少了温度控制表及电流表的使用，同时减少了接线，有利于降低流延膜机的成本；
3.本发明的提供的流延机温度控制系统可以实时采集各个温区的温度数据并及时进行调节，温度控制更加精确，且避免了各个温区温度不一致影响物料的性能；
4.本发明的智能温控流延膜机还通过设置数字量模块可以监测流延膜机的异常工作状态并实时报警及提示故障。
附图说明
图1为本发明的温度控制系统的示意图；
图2为本发明的温度控制系统的功能模块的电路示意图；
图3为本发明的温度控制系统的模拟量模块的电路示意图；
图4为本发明的温度控制系统的数字量模块与现场总线模块的电路示意图；
图5为本发明的智能温控流延膜机的主视图；
图6为本发明的智能温控流延膜机的俯视图。
具体实施方式
为了更加清楚、完整的说明本发明的技术方案，下面结合附图对本发明作进一步说明。
请参考图1～图4，本发明提出一种流延膜机10的温度控制系统20，所述温度控制系统20包括集成控制器21、远程I/O23和现场总线模块22，所述远程I/O23包括功能模块231、模拟量模块232和数字量模块233，所述功能模块231、所述模拟量模块232、所述数字量模块233和所述集成控制器21分别与所述现场总线模块22连接；所述功能模块231采集各个温区的温度数据并将采集的数据经由所述现场总线模块22传输给所述集成控制器21；所述模拟量模块232采集各个温区的电流数据并将采集的电流数据经由所述现场总线模块22传输给所述集成控制器21；所述数字量模块233采集所述智能温控流延膜机10的开关量信号并将采集到的信号通过所述现场总线模块22传输给所述集成控制器21；所述集成控制器21对接收到的数据或信号进行处理并根据处理结果输出控制指令，控制指令经由所述现场总线模块22传输给所述功能模块231、所述模拟量模块232或所述数字量模块233，各模块根据接收到的控制指令进行功能调节。本发明提供的智能温控流延膜机10采用集成控制器21设置并调节流延膜机10的温度，可以实现一键设置温度，无需再单独设置每个控制表的温度，不仅减少了温度控制表及电流表的使用，同时减少了接线，且操作更加简单快捷。本发明的温度控制系统20通过实时采集各个温区的温度数据并及时进行调节，温度控制更加精确，且避免了各个温区温度不一致影响物料的性能。此外，本发明的温度控制系统20还通过设置数字量模块233监测流延膜机10的异常工作状态并实时报警及提示故障。
请参考图5和图6，本发明提供了一种智能温控流延膜机10，包括温度控制系统20、挤出机30、流延冷却装置50、双腔抽真空装置40、摆动装置70、 测厚仪60以及全自动收卷系统。所述温度控制系统20监测并调节所述挤出机30各个温区的温度，物料经由所述挤出机30塑炼挤出至所述流延冷却装置50，所述双腔抽真空装置40除去流延辊上的气流层，物料在所述流延冷却装置50上经冷却降温成膜，成型的塑料薄膜从所述流延冷却装置50上牵引至所述测厚仪60，所述测厚仪60实时测量塑料薄膜的厚度，随后塑料薄膜被牵引至所述摆动装置70，所述摆动装置70调节塑料薄膜的张力，并将塑料薄膜牵引至所述全自动收卷装置80，所述全自动收卷装置80将塑料薄膜收卷至纸筒并裁剪卸料。
具体的，挤出机30的首部设有下料装置，下料装置用于给挤出机30添加物料，传统的下料装置只是一个简单的加料斗341，由于物料粗细不一，在添加物料的过程中极易导致加料斗341的端口堵塞，且混合料的密度不一样，在加料过程中还会导致混合不均匀，严重影响制品的质量及性能。本发明的挤出机30采用一种粉碎料下料装置34，其包括加料斗341，用于添加并存储物料，加料斗341的下端连通挤出机30的料筒32，加料斗341内还设有一旋转送料的输送机构，该输送机构包括一个螺杆，螺杆设置在加料斗341与料筒32的连接处。当往加料斗341里面添加物料时，螺杆在传动机构的作用下旋转，并将物料传送至挤出机30的料筒32内，螺杆有很好的搅拌作用，可以将传送至料筒32的物料混合的更加均匀，且在螺杆的作用下，物料源源不断的被输送至料筒32而不会堵塞，通过这种粉碎料下料装置34添加物料不仅不会堵塞加料斗341的端口且物料混合更加均匀，有效地保证了产品的质量。
本发明的挤出机30可选用单螺杆挤出机30、双螺杆挤出机30或其他螺杆挤出机30，挤出机30料筒32内有螺杆，能使得物料可以充分进行塑化以及均匀混合。以单螺杆挤出机30为例，物料经由下料装置输送至挤出机30的料筒32后，首先进入螺杆的输送段，物料开始加热并被挤压压实，此时物料尚未塑 化，在螺杆的旋转下，物料被输送至螺杆的压缩段，此时物料的温度加热到塑化温度，物料塑化，在螺杆的作用下充分塑化并混合均匀，随后，完全塑化的物料计入螺杆的计量段，再从料筒32的出口挤出。
挤出机30内设有电加热器，用作给挤出机30加热，挤出机30上设有多个温区，这些温区内设有热电偶，这些热电偶连接智能温度系统的功能模块231，在挤出机30运行时，功能模块231实时采集各个温区的温度数据并将数据经由现场总线模块22传输给智能温度系统的集成控制器21，集成控制器21的PLC211处理数据并在触摸屏212上显示接收到的温度数据，此时，操作者可通过触摸屏212实时监测挤出机30各个温区的温度以及工作状态，也可在触摸屏212上设置或调整各个温区的温度，通过PLC211发出控制指令给功能模块231，功能模块231根据指令控制各个温区的电加热器进行加热或停止加热。挤出机30还设有冷却风扇，当集成控制器21根据功能模块231采集的温度数据判断出挤出机30的温度高于设定的温度时，集成控制器21输出启动指令给功能模块231，功能模块231根据指令开启冷却风扇，冷却风扇运行给所述挤出机30降温，当挤出机30的温度降至设定温度时，集成控制器21输出关闭指令给功能模块231，功能模块231根据指令关闭冷却风扇。本发明的流延膜机10通过集成控制器21设置并调节挤出机30的温度，可以实现一键设置温度，无需再单独设置每个控制表的温度，操作更加简单快捷；且功能模块231可以实时采集各个温区的温度数据并及时进行调节，温度控制更加精确，避免了各个温区温度不一致影响物料的性能。
本发明的智能温度控制系统20还包括模拟量模块232和数字量模块233，分别通过现场总线模块22与集成控制器21连接。模拟量模块232采集上述挤出机30各温区的电流数据并将采集的电流数据经由现场总线模块22传输给集 成控制器21，电流数据主要是电加热器的电流数据，集成控制器21对接收到的电流数据进行分析，及时调整各温区电加热器的电流，从而控制电加热器的加热速率，保证各个温区加热平稳均匀，且通过采集电流数据，集成控制器21可以实时监测电加热器的工作状态并及时发现异常工作状态或故障。此外，模拟量模块232还采集挤出机30的螺杆的转速，通过与螺杆连接的传感器，实时采集螺杆的旋转速率并传输给集成控制器21，也可以根据集成控制器21的指令控制调整挤出机30的螺杆转速，便于根据实际需求调整螺杆转速，不仅操作便捷且有利于保证产品的质量。数字量模块233主要用于采集流延膜机10的开关量信号，采集到的信号通过现场总线模块22传输给集成控制器21。集成控制器21接收来自功能模块231、模拟量模块232与数字量模块233的数据及信号，并进行分析及调整，在流延膜机10的使用过程中，集成控制器21主导各个部分的工作，通过实时监测各个部分的工作状态并及时进行调整，保证流延膜机10正常运转。当集成控制器21根据接收到的数据及信号判断出挤出机30某一部分出现故障时，集成控制器21输出关闭指令给数字量模块233，数字量模块233根据接收到的指令控制关闭挤出机30，数字量模块233与集成控制器21配合支线自动控制，这种方式不仅响应速度快，可以及时发现故障并关闭运行的机器，能最大其程度的降低机器的损坏，且其过程实现自动化处理，更加安全。
挤出机30料筒32的出口连接一个熔体计量泵，物料经挤出机30的塑化混合后再从料筒32的出口挤出进入熔体计量泵，熔体计量泵可以计量控制挤出的物料，可根据实际需求调整单位时间内挤出的物料的量。同时，熔体计量泵还可以稳定挤出的物料，在物料的挤出过程中，物料加料不均匀、温度波动、螺杆转速的脉动等易造成物料挤出不均匀，影响制品的精度及质量，使用熔体计量泵可消除加料系统的加料误差并减弱上游工艺传递的波动，使物料的状态更 加稳定，提高挤出制品的尺寸精度，有效地降低废品率。
熔体计量泵连接一个模头33，模头33的另一端连接流延冷却装置50的流延辊，塑化后的物料通过模头33传送至流延辊上，流延辊在马达的驱动下旋转，熔体在流延辊表面冷却降温并迅速固化成膜。本发明采用的流延辊内置双层双向螺旋流道，流延辊内部采用双层结构，可以有效地减少流延辊内冷却水的重量，降低流延辊驱动马达的功率，节能环保，且内置双向螺旋流道，可以使辊面冷却温度更加均匀，成型的薄膜更加平整。本发明的流延膜机10还设置有双腔抽真空装置40，该装置安装在模头33上，与模头33连接。在流延机使用时，熔体从熔体计量泵输送至流延辊上，由于模头33与流延辊之间存在一定的间隙，随着流延辊的旋转，在流延辊周围形成以气流层，易导致熔体冷却时与流延辊之间形成气泡，导致薄膜无法与流延辊贴合，使得成型的薄膜不平整且冷却不均匀，严重影响产品的质量。本发明通过采用双腔抽真空装置40，可以有效地除去流延辊表面的气流层，使得熔体成型时与流延辊之间完整贴合而不产生气泡，成型的塑料薄膜厚度也更加均匀，该装置还可以有效地清洁流延辊表面，除去流延辊表面散落的灰尘，从而保证制品的质量，降低废品率。
成型的塑料薄膜从流延辊上牵引出来，流延辊前方放置一个测厚仪60，使塑料薄膜经过测厚仪60，测厚仪60可以实时测量塑料薄膜的厚度，通过塑料薄膜厚度可以进一步反应塑料薄膜的前期加工工艺的具体情况，可以根据厚度调整前期的加工工艺以获取所需厚度的塑料薄膜，或根据塑料薄膜的厚度是否均匀判断前期的加工工艺是否存在故障或需调整的参数。测厚仪60可以在一方面直接反应最终的产品的质量，根据测厚仪60的数据可以调整挤出机30或流延冷却装置50以及各个零部件的参数，从而得到质量最优的产品。
根据上述一系列加工工序及调整之后，得到的塑料薄膜经过测厚仪60测量 厚度，然后牵引至全自动收卷装置80进行收卷，在全自动收卷装置80与测厚仪60之间还设置有摆动装置70，塑料薄膜从测厚仪60被牵引出来后先绕过摆动装置70，再牵引至全自动收卷装置80。摆动装置70主要用于调节塑料薄膜的张力。在塑料薄膜从测厚仪60牵引出来后，若直接进入全自动收卷装置80，由于全自动收卷装置80与测厚仪60之间存在一定的距离，塑料薄膜在牵引至全自动收卷装置80由于重力的作用会产生下垂，使得塑料薄膜处于松弛的状态，易导致全自动收卷装置80在卷收塑料薄膜时出现褶皱而不平整，影响产品的美观及质量。本发明在全自动收卷装置80前设置一个摆动装置70，塑料薄膜先绕过摆动装置70，此时，摆动装置70施加给塑料薄膜一个反向的拉力，使得传送至全自动收卷装置80的塑料薄膜紧绷，在全自动收卷装置80运转时塑料薄膜的传送更加平稳，便于实现大卷径收卷，且能保证产品不产生褶皱，有效地提高产品的质量。本发明的机组采用全自动穿纸及退卷装置以代替传统的手工穿纸管，不仅大大提高了生产效率，降低人工成本，且有效地提高了设备操作的安全性。
当然，本发明还可有其它多种实施方式，基于本实施方式，本领域的普通技术人员在没有做出任何创造性劳动的前提下所获得其他实施方式，都属于本发明所保护的范围。

Claims (10)

  1. 一种智能温控流延膜机，其特征在于，所述智能温控流延膜机包括温度控制系统，所述温度控制系统包括集成控制器、远程I/O和现场总线模块，所述远程I/O包括功能模块、模拟量模块和数字量模块，所述功能模块、所述模拟量模块、所述数字量模块和所述集成控制器分别与所述现场总线模块连接；所述功能模块采集各个温区的温度数据并将采集的数据经由所述现场总线模块传输给所述集成控制器；所述模拟量模块采集各个温区的电流数据并将采集的电流数据经由所述现场总线模块传输给所述集成控制器；所述数字量模块采集所述智能温控流延膜机的开关量信号并将采集到的信号通过所述现场总线模块传输给所述集成控制器；所述集成控制器对接收到的数据或信号进行处理并根据处理结果输出控制指令，控制指令经由所述现场总线模块传输给所述功能模块、所述模拟量模块或所述数字量模块，各模块根据接收到的控制指令进行功能调节。
  2. 根据权利要求1所述的智能温控流延膜机，其特征在于，所述集成控制器包括PLC和触控屏，所述PLC分别连接所述现场总线模块与所述触控屏，所述PLC处理数据并输出控制指令，所述触控屏用于显示所述PLC接收到的数据并设定各个温区的参数。
  3. 根据权利要求1所述的智能温控流延膜机，其特征在于，所述智能温控流延膜机包括挤出机、流延冷却装置、摆动装置和全自动收卷装置，物料经由所述挤出机塑炼挤出至所述流延冷却装置，并在所述流延冷却装置上经冷却降温成膜，成型的塑料薄膜从所述流延冷却装置上牵引至所述摆动装置，所述摆动装置调节塑料薄膜的张力，并将塑料薄膜牵引至所述全自动收卷装置，所述全自动收卷装置将塑料薄膜收卷至纸筒并裁剪卸料。
  4. 根据权利要求3所述的智能温控流延膜机，其特征在于，所述挤出机包括电加热器和冷却风扇，所述电加热器与所述冷却风扇分别连接所述功能模块， 所述功能模块根据所述集成控制器的控制指令选择开启所述电加热器或所述冷却风扇；当所述功能模块检测到所述挤出机的温度高于设定的温度时，所述集成控制器输出启动指令给所述冷却风扇，所述冷却风扇运行给所述挤出机降温，当所述功能模块检测到所述挤出机的温度降至设定温度时，所述集成控制器输出关闭指令给所述冷却风扇，所述冷却风扇停止运转；当所述功能模块检测到所述挤出机的温度低于设定的温度时，所述集成控制器输出启动指令给所述电加热器，所述电加热器运行给所述挤出机加热，当所述功能模块检测到所述挤出机的温度升高至设定温度时，所述集成控制器输出控制指令给所述电加热器，所述电加热器降低加热功率或停止加热。
  5. 根据权利要求3所述的智能温控流延膜机，其特征在于，所述模拟量模块采集所述挤出机的电流数据及所述挤出机的转速数据，并将采集到的数据传输给所述集成控制器，所述集成控制器将接收到的数据进行计算分析后分别输出电流控制指令和转速控制指令给所述模拟量模块，所述模拟量模块根据接收到的电流控制指令和转速控制指令分别调节所述挤出机的电流以及所述挤出机的转速。
  6. 根据权利要求3所述的智能温控流延膜机，其特征在于，所述数字量模块采集所述挤出机的开关量信号，并将采集到的信号传输给所述集成控制器，当所述集成控制器根据接收到的数据判断出所述挤出机出现故障时，所述集成控制器输出关闭指令给所述数字量模块，所述数字量模块控制关闭所述挤出机。
  7. 根据权利要求3所述的智能温控流延膜机，其特征在于，所述智能温控流延膜机包括测厚仪，所述测厚仪设于所述流延冷却装置与所述摆动装置之间，成型的塑料薄膜从所述流延冷却装置上牵引至所述测厚仪，所述测厚仪实时测量塑料薄膜的厚度。
  8. 根据权利要求3所述的智能温控流延膜机，其特征在于，所述挤出机包括熔体计量泵、料筒和模头，所述料筒一端设有出口，所述模头连接所述流延冷却装置，所述熔体计量泵设于所述出口与所述模头之间并连通所述出口与所述模头，所述熔体计量泵用于计量控制并稳定挤出的物料。
  9. 根据权利要求8所述的智能温控流延膜机，其特征在于，所述流延机还包括双腔抽真空装置，所述双腔抽真空装置固定安装于所述模头上，所述双腔抽真空装置用于去除所述流延冷却装置与流延膜之间的空气。
  10. 根据权利要求3所述的智能温控流延膜机，其特征在于，所述挤出机包括粉碎料下料装置，所述粉碎料下料装置包括加料斗，所述加料斗内设有输送机构，物料投入到所述加料斗后，所述输送机构旋转送料，所述输送机构用来给挤出机均匀送料并防止物料堵塞。
PCT/CN2017/116101 2017-12-14 2017-12-14 一种智能温控流延膜机 WO2019113873A1 (zh)

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