Explain the manufacturer's operating procedures for pre-stressed plastic corrugated pipe equipment
Explain the manufacturer's operating procedures for pre-stressed plastic corrugated pipe equipment1. Purpose and scope
1.1 Purpose
Standardize production operations, strengthen product quality monitoring, and prevent safety and quality accidents.
1.2 Scope
This system is applicable to all operators in the production department.
2 operating specifications
2.1 Preparation before starting
2.1.1 The electrician on duty inspects the electrical appliances and electrical components of the entire production line, and turns on the power after it meets the power-on requirements.
2.1.2 Set the production temperature, pressure, speed, expansion, length, etc. according to the regulations of the process card, and start heating. Heat each zone of the machine head for about 5 hours, then turn on the enlightenment 1# and 2# extruder to heat up (at the same time turn on the cooling water in the feeding section), after reaching the set temperature, keep warm for about 2.5 hours (about 8 hours in total) , It is strictly prohibited to start production in advance.
2.1.3 Change the molding die, die head or die head according to production requirements.
(1) Install the machine head as a whole;
A. Turn on: Turn on the heating section of the machine head 1-7, set the temperature to 220 degrees, and the heating time for 5-6 hours before ejecting the machine head.
B. During the production process:
The heating section of zone 1-7 will continue to heat, and the heating section of zone 8-22 will stop heating. The machine head can be ejected after about 3 hours.
(2) Changing the die head:
A. Turn on the heating section in the 18-22 zone of the machine head, set the temperature to 220 degrees, and the heating time for 4-5 hours before disassembly and assembly.
B. When replacing the inner and outer die heads, the gap size must be adjusted according to the standard. After heating up for 6 hours, tighten the fixing screws again, and then rotate the inner and outer die respectively, and observe the die along the wire. Whether the direction moves freely to prevent the fixing screws from being tightened too tightly.
(3) Change mold:
A. Turn on the heating section in the 18-22 zone of the machine head, set the temperature to 220 degrees, and the heating time for 4-5 hours before disassembly and assembly.
B. When replacing the inner and outer die heads, the gap size must be adjusted according to the standard. After heating up for 6 hours, tighten the fixing screws again, and then rotate the inner and outer die respectively to observe the die along the wire mouth Whether the direction moves freely to prevent the fixing screws from being tightened too tightly.
(3) Change mold:
A. Check whether the hydraulic system is operating normally, whether all limit switches are in place and can be turned on and off freely;
B. When changing molds, three people must operate at the same time.
C. After the reloading is complete, turn on the molding machine and run it for 20 minutes. In this process, check the tightness of the positioning pins one by one to prevent the pins from falling off during the production process; check whether the sealing strips are intact one by one.
2.4 Adjust the center of the machine head and molding machine: After changing the machine head and mold, move the molding machine to the production position, open the upper and lower molds, and adjust the gap with a feeler gauge and a vernier caliper.
2.5 Installation of the sizing water jacket: After the temperature reaches the requirements, tighten the screws fixed everywhere again before installing the sizing water jacket. And use a feeler gauge to adjust the gap between the water jacket and the machine head to ensure levelness.
2.1.6 Replace the supporting guide plates and gaskets at both ends of the sink, and adjust their centers on the same straight line. According to the specifications of the pipe, adjust the position of the roller to hold the pipe level.
2.1.7 Adjust the front and rear clamping devices of the pipe cutting machine to adapt to the cutting of the corresponding pipe.
2.1.8 Check whether the cooling table, cutting machine, and stacker are operating normally.
2.1.9 Check whether the safety cover of each transmission part is firm.
2.1.10 Check whether there is debris in the hopper and whether the feeding equipment is normal.
2.1.11 Check whether each lubrication part is in good condition, observe the oil level in the lubricating oil tank, and replenish it if it is insufficient.
2.1.12 Check whether the cooling water pipeline is unblocked, check whether the compressed air pipeline and vacuum pipeline are unblocked; whether the switching is normal. Check and clean the vacuum pump, spray water tank and the scale in the pipeline to ensure that the pipeline is unblocked.
Prestressed plastic corrugated pipe equipment
Production operation
1. Feeding: Use a vacuum feeder to put the materials into the hopper, and start the dryer to dry the materials. The drying temperature depends on the specific conditions, but should not exceed 80 degrees.
2. Open the cooling water in the reducer of the extruder, and turn the ball valve at the outlet to an appropriate size to cool the lubricating oil.
3. After checking that the heating and holding time have been reached, tighten the connecting screws again. (When tightening the screws, all heaters should be powered off, and the operator should wear gloves and other protective equipment).
4. Start the drive motor of the extruder, make the screw run at a low speed (lt20r/min), slightly open the hopper insert, and feed slowly. Adjust the temperature, screw speed and feed rate of each zone according to the plasticization state of the material failure and the melt pressure displayed when the standby head discharges the material.
Observe the raw material supply of the extruder at any time during the production process to avoid material breakage.
5. When the die mouth of the machine head starts to discharge, please observe carefully. If the wall thickness of the tube blank is not uniform, adjust it so that the inner and outer tube blanks are uniformly squeezed.
6. After uniformly unloading, remove excess material from the mold. Install the sizing sleeve, connect the pipe and check for leaks. Remove the zone 18-22 heater from the mold section.
7. Press the "forward" button of the jog molding machine to bring the molding machine to the preset position, pay attention to the gap between the module and the molding kit, and adjust whether there is any interference.
8. After the molding machine is adjusted in place, start the vacuum pump and open a vacuum. Start the operation module of the molding machine. Normal inflation started and it expanded rapidly.
9. Start the #1 extruder, stop the rapid inflation after a period of time, and start the #2 extruder after the outer wall has formed, the vacuum has formed pressure, and the internal vacuum.
10. After the normal production of the pipeline, each component begins to cool. Observe the changes in gauge pressure, temperature and speed of pressure gauges at all levels at any time, and make corresponding records.
11. The pipeline passes through the spray cooling tank to start the pump motor, so that the pipeline sprays cooling water evenly to further cool the pipeline. Start the drying device to remove water from the outer surface of the pipe.
12. Start the cutting machine and the palletizer respectively to cut and palletize.
Shutdown operation
1. Stop heating
2. First close the hopper board, stop feeding, gradually reduce the screw speed, and stop extrusion.
3. Stop the compressed air and vacuum, and exit the molding machine backwards. After the pipe is separated from the molding module, press the "Stop" button of the molding machine to stop the molding module.
4. Stop cooling each part.
5. Cut off the power, water and compressed air of each device.
6. Clean up the scene.
Downtime processing
1. In case of unsatisfactory pipe forming, adjustment is required. It is necessary to stop the extruder first, and then the forming machine will exit to the correct position.
The forming module continues to run until the pipe is separated from the forming module.
2. In an emergency, press the emergency stop button, and immediately cut off the main power supply when a major accident occurs during the operation of the equipment.
Operation precautions
1. It is strictly forbidden to mix metal blocks and other hard sundries into the material.
2. The surface temperature of the charging stand should not be too high. When it exceeds 50, the cooling water supply should be increased appropriately.
3. It is strictly forbidden to open the lid of the barrel without cutting off the heating power supply.
4. It is strictly forbidden to operate electrical switches with wet hands.
5. It is strictly forbidden to drive in advance without sufficient heating.
6. In the production process, start the molding machine first, then start the extruder, and adjust the rotation speed of the extruder screw according to the pipeline condition. When the machine stops, the situation is just the opposite.
7. The lubrication system of the molding machine should be filled with oil in time. It is strictly forbidden to run without oil. The lubricating oil circuit should be checked regularly and not blocked.
8. Keep the module clean, and clean the dust and oil stains in the cracks in time to keep it clean.
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