The following is a systematic maintenance plan for the melt composite spinning machine, which combines equipment characteristics and production needs to ensure stable operation and product quality from multiple dimensions:
1、 Daily basic maintenance
Cleaning Management
After daily shutdown, it is necessary to immediately clean the residual polymer inside and outside the machine body, with a focus on removing the coking material on the surface of the spinneret, distribution plate, and bundle to prevent solidification blockage from affecting the uniformity of the fiber network; Use a dedicated copper brush combined with a neutral solvent (such as acetone) to wipe the screw feed section to avoid local overheating caused by the accumulation of raw material degradation products.
Temperature control system monitoring: Record the temperature curves of each zone every hour, and compare them with the set value. The deviation should be<± 2 ℃. If the heating coil turns red abnormally or the temperature control module alarms, the machine should be stopped immediately to check for poor thermocouple contact or cooling fan failure.
2、 Periodic deep maintenance
Mechanical transmission system
Dismantle the side cover of the gearbox every week, check the lubricating oil level and impurity content, and replace the fully synthetic gear oil (ISO VG68) every quarter; Adjust the tension of the synchronous belt to a pressing depth of 10-15mm. If the tooth profile of the severely worn synchronous belt deviates by more than 2mm, it must be replaced.
Screw component maintenance: Disassemble the screw every month for ultrasonic cleaning, check the wear of the screw edges (if it exceeds 15% of the original thickness, chrome plating repair is required), and strictly tighten the flange bolts according to the torque manual during assembly to prevent material leakage.
Renewal of filtration system
Dynamically adjust the filter replacement cycle based on the impurity content of raw materials (transparent PA raw materials can be extended to 72 hours, and recycled polyester is recommended to be replaced within 48 hours); When replacing, use nitrogen back blowing to remove residual carbon black particles. Before installing the new filter element, apply silicone oil to the sealing ring to enhance air tightness.
3、 Specialized care for core components
Maintenance of spinneret
Establish a "preventive replacement" mechanism, and immediately replace the spare spinneret when the fluctuation of single hole wire output exceeds 5%; The old board undergoes alkaline boiling, ultrasonic cleaning, and mirror polishing treatment. Qualified products are screened and returned to the warehouse using a laser micro hole detector.
Optimization of hot runner insulation: Install ceramic fiber insulation cover on the distribution plate to reduce the difference in melt viscosity caused by radiation heat dissipation; Regularly verify the power of the heating coil to ensure that the temperature difference between each zone is less than 3 ℃.
Static mixer calibration
Disassemble the mixing components every half month, measure the gap between the spiral blades (standard value is 0.15 ± 0.02mm), and use laser cladding repair when exceeding the tolerance; When testing the mixing efficiency, the standard deviation of component distribution for upstream and downstream sampling analysis should be less than 0.8%.
4、 Lubrication and anti-corrosion system
Establish a "five fixed" lubrication system: mark all lubrication points at designated locations (37 in total), add oil in a quantitative manner (for bearings, the amount of oil added each time is 1/3 of the grease capacity), use high-temperature lithium based grease for quality control (drip point>180 ℃), execute on a regular basis (daily oil injection for main motor bearings), and assign personnel to be responsible.
Rust prevention treatment: Exposed metal parts are sprayed with rust inhibitor containing molybdenum disulfide, and the hydraulic rod piston rod is coated with a hard chromium layer with a thickness of ≥ 0.05mm. The inner wall of the material receiving groove is treated with PTFE coating.
5、 Data based operation and maintenance management
Real time monitoring of key parameters through DCS system: screw speed fluctuation value<± 1rpm, melt pressure standard deviation<0.2MPa, and stretching roller speed ratio error<0.3%; Use a vibration analyzer to measure the effective value of bearing vibration velocity (RMS ≤ 4.5mm/s) on a monthly basis.
Archive management: Establish equipment health records, record spare part numbers, fault codes, and solutions for each maintenance and replacement, and use big data analysis to predict the life cycle of vulnerable parts.