Samar da inganci da ingancin fim ɗin ɓarna na PVC kai tsaye yana ƙayyade ƙarfin samar da kamfani, farashi, da ƙimar kasuwa. Ƙananan aiki yana haifar da ɓarnawar iya aiki da jinkirin bayarwa, yayin da lahani mai inganci (kamar raguwar rashin daidaituwa da rashin gaskiya) yana haifar da gunaguni da dawowar abokin ciniki. Don cimma nasarar ci gaba biyu na "babban inganci + babban inganci," ana buƙatar ƙoƙari na yau da kullun a cikin maɓalli huɗu masu mahimmanci: sarrafa albarkatun ƙasa, haɓaka kayan aiki, gyare-gyaren tsari, dubawa mai inganci. A ƙasa akwai takamaiman mafita masu aiki:
Ikon Madogararsa: Zaɓi Abubuwan Raw Dama don Rage Haɗin Bayan-Sake Haɗari
Raw kayan su ne tushen inganci da abin da ake bukata don dacewa. Ƙananan ko rashin daidaiton albarkatun ƙasa suna haifar da dakatarwar samarwa akai-akai don gyare-gyare (misali, share toshewa, sarrafa sharar gida), rage aiki kai tsaye. Mai da hankali kan ainihin nau'ikan albarkatun ƙasa guda uku:
1.Gudun PVC: Ba da fifiko ga "Maɗaukakin Tsabta + Nau'ikan Aikace-aikace"
• Daidaita Samfura:Zaɓi guduro tare da ƙimar K-madaidaicin dangane da kauri na fim ɗin raguwa. Don fina-finai na bakin ciki (0.01-0.03 mm, misali, marufi na abinci), zaɓi guduro tare da ƙimar K-55-60 (mai kyau ruwa don saurin extrusion). Don fina-finai masu kauri (0.05 mm+, misali, fakitin pallet), zaɓi guduro tare da ƙimar K-60-65 (ƙarfi da juriya mai tsage). Wannan yana guje wa kaurin fim ɗin da ba daidai ba wanda ya haifar da ƙarancin guduro ruwa.
• Sarrafa Tsafta:Ana buƙatar masu samar da kayayyaki don samar da rahotannin tsarkakewar guduro, tabbatar da ragowar vinyl chloride monomer (VCM) abun ciki shine <1 ppm da ƙazanta (misali, ƙura, ƙananan ƙwayoyin polymers) abun ciki shine <0.1%. Najasa na iya toshe extrusion mutu kuma ya haifar da raƙuman ruwa, yana buƙatar ƙarin lokacin hutu don tsaftacewa da tasiri yadda ya dace.
2.Additives: Mayar da hankali kan "Ƙarfafa Ƙwarewa, Ƙarfafawa, da Biyayya"
• Masu kwantar da hankali:Maye gurbin tsofaffin matakan gishirin gubar (mai guba da mai saurin rawaya) dacalcium-zinc (Ca-Zn)composite stabilizers. Wadannan ba wai kawai suna bin ka'idoji irin su EU REACH da shirin shekaru biyar na kasar Sin karo na 14 ba, har ma suna inganta yanayin zafi. A zafin jiki na extrusion na 170-200 ° C, suna rage lalata PVC (hana yellowing da brittleness) da rage yawan sharar gida da fiye da 30%. Ga samfuran Ca-Zn tare da "ginayen man shafawa," suna kuma rage rikicewar mutuwa kuma suna haɓaka saurin extrusion da 10-15%.
• Filastik:Ba da fifiko ga DOTP (dioctyl terephthalate) akan DOP na gargajiya (dioctyl phthalate). DOTP yana da mafi kyawun dacewa tare da resin PVC, yana rage "exudates" a kan fuskar fim ( guje wa mannewa da kuma inganta nuna gaskiya) yayin da ke haɓaka daidaituwa (za'a iya sarrafa saurin raguwa a cikin ± 3%).
• kayan kwalliya)• Abubuwan Haɓaka Aiki:Don fina-finan da ke buƙatar nuna gaskiya (misali, marufi na kwaskwarima), ƙara 0.5-1 phr na mai bayyanawa (misali, sodium benzoate). Don fina-finai masu amfani da waje (misali, marufi na kwaskwarima), marufi na kayan aikin lambu), ƙara 0.3-0.5 phr na abin sha na UV don hana launin rawaya da wuri da rage tarkacen samfurin da aka gama.
3.Kayayyakin Taimako: Guji “Asara Boye”
• Yi amfani da maɗaukaki masu tsafta (misali, xylene) tare da abun cikin danshi <0.1%. Danshi yana haifar da kumfa mai iska a lokacin extrusion, yana buƙatar lokacin raguwa don zubar da ruwa (ɓata 10-15 minti a kowane abin da ya faru).
• Lokacin sake amfani da datsa gefen, tabbatar da abun ciki na ƙazanta a cikin kayan da aka sake fa'ida shine <0.5% (wanda ake iya tacewa ta hanyar allon raga 100) kuma adadin kayan da aka sake fa'ida bai wuce 20% ba. Abubuwan da aka sake sarrafa su da yawa suna rage ƙarfin fim da bayyana gaskiya.
Inganta Kayan Aiki: Rage “Downtime” da Inganta “Madaidaicin Aiki”
Babban mahimmancin samar da kayan aiki shine "kuɗin aiki mai tasiri na kayan aiki". Ana buƙatar kulawar rigakafi da haɓakawa ta atomatik don rage raguwa, yayin da inganta ingantaccen kayan aiki yana tabbatar da inganci.
1.Extruder: Madaidaicin Kula da Zazzabi + Tsabtace Mutuwa na yau da kullun don Guji "Tsarowa da Rawaya"
• Sarrafa Yanayin Zazzabi:Dangane da halaye na narkewa na resin PVC, raba ganga mai extruder zuwa yankunan zafin jiki na 3-4: yankin abinci (140-160 ° C, resin preheating), yankin matsawa (170-180 ° C, guduro mai narkewa), yankin metering (180-200 ° C, daidaitawa da narke), kuma ya mutu kai (175-195 ° C). Yi amfani da tsarin sarrafa zafin jiki mai hankali (misali, PLC + thermocouple) don kiyaye canjin zafin jiki tsakanin ± 2°C. Yawan zafin jiki yana haifar da launin rawaya na PVC, yayin da rashin isasshen zafin jiki yana haifar da narkewar guduro marar cika da lahani na "ido-kifi" (yana buƙatar raguwa don daidaitawa).
• Tsabtace Mutuwa na yau da kullun:Tsaftace ragowar kayan carbonized (kayayyakin lalata PVC) daga kan mutun kowane sa'o'i 8-12 (ko yayin canjin kayan) ta amfani da goga mai kwazo (don guje wa zazzage leɓen mutuwa). Don wuraren da suka mutu, yi amfani da mai tsabtace ultrasonic (minti 30 a kowane zagaye). Carbonized abu yana haifar da baƙar fata a kan fim ɗin, yana buƙatar rarrabuwar sharar gida da kuma rage inganci.
2.Tsarin sanyaya: Yin sanyaya Uniform don Tabbatar da "Kwantar da Fim + Tsayawa Daidaita"
• Gyaran Rubutun Sanyaya:Ƙirƙirar daidaiton juzu'in sanyaya uku kowane wata ta amfani da matakin Laser (haƙuri <0.1 mm). A lokaci guda, yi amfani da ma'aunin zafi da sanyio na infrared don saka idanu akan yanayin jujjuyawa (ana sarrafa shi a 20-25 ° C, bambancin zafin jiki <1 ° C). Yanayin zafin jiki mara daidaituwa yana haifar da ƙimar sanyaya fim ɗin da ba daidai ba, yana haifar da bambance-bambancen raguwa (misali, 50% raguwa a gefe ɗaya da 60% a ɗayan) kuma yana buƙatar sake yin aikin samfuran da aka gama.
• Inganta Zoben Iska:Don aikin fim ɗin da aka busa (amfani da wasu fina-finai na ɓacin rai), daidaita daidaiton iska na zoben iska. Yi amfani da na'urar anemometer don tabbatar da bambancin gudun iskar a cikin madaidaicin inda zoben iska ya kasance <0.5m/s. Gudun iska mara daidaituwa yana lalata kumfa na fim, yana haifar da "karɓar kauri" da haɓaka sharar gida.
3.Winding da Gyara Gyara Maimaituwa: Aiki Automation yana Rage "Shigar da Manual"
• Winder ta atomatik:Canja zuwa winder tare da "kullun madauki da tashin hankali". Daidaita tashin hankali a cikin ainihin lokacin (saitin ya dogara da kauri na fim: 5-8 N don fina-finai na bakin ciki, 10-15 N don fina-finai masu kauri) don guje wa "sako da iska" (buƙatar juyawa ta hannu) ko "tatsin iska" (wanda ke haifar da shimfidar fim da nakasar). Ana haɓaka haɓakar iska da kashi 20%.
• Sake yin amfani da ƙorafe-ƙorafe a kan-Gidan:Shigar da tsarin haɗaɗɗen tsarin “tsatsa mai murƙushewa” kusa da injin slitting. Nan da nan murkushe gefuna (5-10 mm fadi) da aka samar a lokacin tsagawa da kuma ciyar da shi zuwa ga extruder hopper ta bututun (gauraye da sabon abu a 1: 4 rabo). Matsakaicin sake amfani da ƙwanƙwasa yana ƙaruwa daga kashi 60% zuwa 90%, yana rage sharar ɗanyen abu da kawar da asarar lokaci daga tarkace da hannu.
Tsari Tsari: Tace "Ikon Tsari" don Guji "Lalacewar Bature"
Ƙananan bambance-bambance a cikin sigogi na tsari na iya haifar da bambance-bambancen ingancin inganci, har ma da kayan aiki iri ɗaya da albarkatun ƙasa. Ƙirƙirar "tebur alamar ma'auni" don mahimman matakai guda uku-extrusion, sanyaya, da slitting-da saka idanu gyare-gyare a ainihin lokaci.
1.Tsarin Extrusion: Sarrafa "Matsi na narkewa + Saurin Extrusion"
• Matsanancin Narke: Yi amfani da firikwensin matsa lamba don saka idanu da matsa lamba na narkewa a mashigar mutuwa (an sarrafa a 15-25 MPa). Matsi mai yawa (30 MPa) yana haifar da zubar da jini kuma yana buƙatar lokaci don kulawa; rashin isasshen matsa lamba (10 MPa) yana haifar da ƙarancin narkewar ruwa da kauri mara daidaituwa.
• Saurin Extrusion: Saita dangane da kauri na fim-20-25 m / min don fina-finai na bakin ciki (0.02 mm) da 12-15 m / min don fina-finai masu kauri (0.05 mm). Guji "ɗaukakin miƙewa" (rage ƙarfin fim) wanda ya haifar da babban gudun ko "sharar da aka yi" daga ƙananan gudu.
2.Tsarin sanyaya: Daidaita "Lokacin sanyaya + Yanayin iska"
• Lokacin sanyaya: Sarrafa lokacin zama na fim ɗin akan jujjuyawar sanyaya a 0.5-1 sakan (wanda aka samu ta hanyar daidaita saurin juzu'i) bayan fitarwa daga mutu. Rashin isasshen lokacin zama (<0.3 seconds) yana haifar da sanyayawar fim ɗin da ba ta cika ba a lokacin iska; lokacin zama mai wuce kima (> 1.5 seconds) yana haifar da "tabobin ruwa" akan fuskar fim (rage nuna gaskiya).
• Zazzabi na zoben iska: Don aikin fim ɗin da aka hura, saita zafin zoben iska 5-10°C sama da yanayin zafi (misali, 30-35°C don yanayin 25°C). Ka guje wa "sanyi kwatsam" (yana haifar da matsanancin damuwa na ciki da sauƙi mai tsagewa yayin raguwa) daga iska mai sanyi ta busa kai tsaye a kan kumfa na fim.
3.Tsari Tsagewa: Madaidaicin "Saitin Nisa + Sarrafa tashin hankali"
• Nisa Tsagewa: Yi amfani da tsarin jagorar gefen gani don sarrafa daidaitattun tsagawa, tabbatar da juriya mai faɗi <± 0.5 mm (misali, 499.5-500.5 mm don buƙatun abokin ciniki na nisa na 500 mm). Guji dawowar abokin ciniki sakamakon karkacewar faɗin.
• Tashin hankali: Daidaita bisa kaurin fim-3-5 N don fina-finai na bakin ciki da 8-10 N don fina-finai masu kauri. Matsanancin tashin hankali yana haifar da shimfidar fim da lalacewa (rage raguwar raguwa); rashin isasshen tashin hankali yana haifar da sakin fina-finai mara kyau (mai saurin lalacewa yayin sufuri).
Ingancin Ingancin: "Sabbin Saƙon Kan Layi na Ainihin + Tabbacin Samfuran Wajen Layi" don Kawar da "Batched Abubuwan da ba daidai ba"
Gano ingantattun lahani kawai a matakin samfurin da aka gama yana haifar da juzu'i mai cikakken tsari (rasa duka inganci da farashi). Ƙirƙiri "tsarin duba cikakken tsari":
1.Duban Kan layi: Tsallake "Labaran Nan da nan" a cikin Ainihin Lokaci
• Duban Kauri:Sanya ma'aunin kauri na Laser bayan mirginawar sanyaya don auna kaurin fim kowane sakan 0.5. Saita “ƙofa ƙararrawa” (misali, ± 0.002 mm). Idan an wuce iyakar, tsarin ta atomatik yana daidaita saurin extrusion ko tazarar mutuwa don gujewa ci gaba da samar da samfuran da ba su dace ba.
• Duban Bayyanar:Yi amfani da tsarin hangen nesa na na'ura don duba fuskar fim, gano lahani kamar "black spots, pinholes, and creases" (daidaicin 0.1 mm). Tsarin yana yin alama ta atomatik wuraren lahani da ƙararrawa, ƙyale masu aiki su daina samarwa da sauri (misali, tsaftacewar mutu, daidaita zoben iska) da rage sharar gida.
2.Duban Wajen Layi: Tabbatar da "Ayyukan Maɓalli"
Misalin mirgina daya gama kowane awa 2 kuma gwada manyan alamomi guda uku:
• Yawan Ragewa:Yanke samfuran 10 cm × 10 cm, zafi su a cikin tanda 150 ° C na tsawon daƙiƙa 30, kuma auna raguwa a cikin injin injin (MD) da madaidaiciyar hanya (TD). Ana buƙatar raguwar 50-70% a cikin MD da 40-60% a cikin TD. Daidaita rabon filastik ko zafin zafin jiki idan sabawa ya wuce ± 5%.
• Fassara:Gwaji da mitar haze, ana buƙatar hazo <5% (don fina-finai na gaskiya). Idan hazo ya zarce ma'auni, duba tsaftar guduro ko tarwatsawar stabilizer.
• Ƙarfin Ƙarfafawa:Gwaji tare da na'ura mai gwadawa, yana buƙatar ƙarfin juzu'i na tsayi ≥20 MPa da ƙarfin juzu'i ≥18 MPa. Idan ƙarfin bai isa ba, daidaita ƙimar K-resin ko ƙara antioxidants.
The "Synergistic Logic" na inganci da inganci
Inganta ingantaccen aikin samar da fina-finai na PVC na raguwa yana mai da hankali kan "rage raguwa da ɓata lokaci," wanda aka samu ta hanyar daidaitawar albarkatun ƙasa, haɓaka kayan aiki, da haɓakawa ta atomatik. Haɓaka cibiyoyi masu inganci akan "sarrafa sauye-sauye da lahani," wanda ke goyan bayan gyare-gyaren tsari da cikakken bincike. Biyu ba sa cin karo da juna: misali, zabar inganci mai inganciCa-Zn stabilizersyana rage lalata PVC (inganta inganci) kuma yana haɓaka saurin extrusion (ƙarfafa haɓakawa); Tsarin dubawa na kan layi yana katse lahani (tabbatar da inganci) da kuma guje wa ɓarke (rage asarar inganci).
Kamfanoni suna buƙatar matsawa daga “inganta maki ɗaya” zuwa “haɓakawa na tsari,” haɗa albarkatun ƙasa, kayan aiki, matakai, da ma’aikata cikin rufaffiyar madauki. Wannan yana ba da damar cimma nasarar burin kamar "20% mafi girman ƙarfin samarwa, 30% ƙarancin sharar gida, da <1% ƙimar dawowar abokin ciniki," kafa gasa a cikin kasuwar fina-finai ta PVC ta raguwa.
Lokacin aikawa: Nuwamba-05-2025