As the central equipment in chemical fiber production, the operation status of wet spinning machine directly affects product quality and production efficiency. A scientific maintenance system needs to run through three dimensions: daily inspections, periodic maintenance, and targeted repairs. The following will elaborate on the key links.
1、 Daily basic maintenance
1. Purification of slurry circulating system: after the end of each shift, the residual slurry in the storage tank must be drained, the attachments on the inner wall of the pipeline shall be washed with hot water, and the gel particles on the surface of the filter element shall be cleaned. It is recommended to disassemble the static mixer for ultrasonic cleaning every week to prevent impurities from accumulating and affecting the dispersion effect.
2. Precision care of spray nozzle components: During shutdown, use specialized needle tools to clear the spray nozzle holes and check the consistency of the aperture with a microscope. Replace the gemstone material guide wire once a month to avoid surface scratches causing single wire breakage. The disassembly and assembly of the spinneret must strictly follow the torque specifications, and a pneumatic sealing test must be conducted after installation.
3. Dynamic balance of coagulation bath: Daily monitoring of bath concentration and temperature fluctuations, controlling the temperature difference within ± 0.5 ℃. Real time monitoring of concentration changes using an online refractometer and timely replenishment of fresh solvents. Clean the crystal deposits on the inner wall of the tank every month and replace the mechanical seals of the circulation pump.
2、 Periodic deep maintenance
1. Transmission system calibration: Calibrate the parallelism of the stretching rollers every quarter, use a laser alignment instrument to ensure that the axis deviation of each roller is ≤ 0.1mm. Adjust the tension of the synchronous belt according to the parameters in the manual, and replace the severely worn synchronous belt in a timely manner. The gearbox lubricating oil should be replaced every six months, using high-temperature resistant food grade grease.
2. Optimization of temperature control module: Pressure testing of heating/cooling pipelines is conducted annually, and aged aluminum silicate insulation cotton is replaced. The temperature sensor is calibrated with a standard platinum resistor to ensure that the temperature gradient in each area is accurately controlled within the process window. The response time of steam valves needs to be regularly tested to ensure rapid shut-off under emergency stop conditions.
3. Fluid system upgrade: Implement a preventive replacement system for the diaphragm of the metering pump, and force replacement after 800 hours of operation. The clearance adjustment of the gear pump requires precise measurement with a feeler gauge. If the leakage at the shaft seal exceeds 3 drops per minute, it needs to be repaired. The pipeline joints are reinforced with double clamps to prevent loosening caused by vibration.
3、 Key points of special protection
1. Anti corrosion management: Components that come into contact with acidic baths are made of Hastelloy alloy material, and the flange connection surface is coated with polytetrafluoroethylene sealant. If the shutdown exceeds 4 hours, the pipeline must be emptied to prevent electrochemical corrosion.
2. Static elimination system: The wire guide is equipped with an ion air rod, and the grounding resistance is kept below 4 Ω. Operators should wear anti-static work clothes, and the humidity in the workshop should be controlled above 60% RH.
3. Emergency response plan: Configure a backup power module to cope with sudden power outages, and the nitrogen protection device can maintain positive pressure for 15 minutes after a gas outage. The inventory cycle of key spare parts (such as spinnerets and metering pumps) shall not exceed 6 months.
The maintenance of wet spinning machines requires the establishment of a "prevention oriented, data-driven" management mechanism, which combines standardized operating procedures (SOP), equipment health records, and predictive maintenance systems to achieve a transition from passive maintenance to active control. Daily inspection records should be included in the MES system, and big data analysis should be used to predict the lifespan of vulnerable parts, ultimately achieving the core goal of reducing unplanned downtime and improving the rate of high-quality products.