CN108016027A - A kind of control method of BOPP bidirectional stretching systems - Google Patents
A kind of control method of BOPP bidirectional stretching systems Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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- B29C55/10—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial
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- B29K2023/10—Polymers of propylene
- B29K2023/12—PP, i.e. polypropylene
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Abstract
本发明提供了一种BOPP双向拉伸系统的控制方法,对于系统拉伸段内任意的三电机子系统:包括前置轴、第一张力辊、主驱轴、第二张力辊、后置轴,采用两个分布式控制器进行控制,其中,通过第一控制器控制前置轴电机和主驱轴电机,并通过第二控制器控制主驱轴电机和后置轴电机,同时,所述第一控制器和第二控制器通过叠加控制因子a和b共享一部分输出以控制所述主驱轴电机。本发明的方法中两个连续的控制器通过叠加控制因子共享一部分输入和输出,可以显著提高系统速度和张力的解耦能力,并据此将以上子系统扩展至双向拉伸过程的多电机卷绕系统中,同时还设计了薄膜纵向和横向厚度控制模型,以实现拉伸过程的速度、张力、厚度的同步精确控制。
The invention provides a control method of a BOPP bidirectional stretching system, for any three-motor subsystem in the stretching section of the system: including the front shaft, the first tension roller, the main drive shaft, the second tension roller, and the rear shaft , using two distributed controllers for control, wherein the front axle motor and the main drive axle motor are controlled by the first controller, and the main drive axle motor and the rear axle motor are controlled by the second controller. At the same time, the The first controller and the second controller share a part of output by superimposing control factors a and b to control the main drive shaft motor. In the method of the present invention, two continuous controllers share a part of the input and output by superimposing control factors, which can significantly improve the decoupling ability of the system speed and tension, and accordingly extend the above subsystem to the multi-motor roll of the biaxial stretching process In the winding system, the longitudinal and transverse thickness control models of the film are also designed to realize the synchronous and precise control of the speed, tension and thickness of the stretching process.
Description
技术领域technical field
本发明涉及控制技术领域,具体涉及一种BOPP双向拉伸系统的控制方法。The invention relates to the technical field of control, in particular to a control method for a BOPP biaxial stretching system.
背景技术Background technique
BOPP是“Biaxially Oriented Polypropylene”的缩写,BOPP薄膜即双向拉伸聚丙烯薄膜。BOPP薄膜的生产是将高分子聚丙烯的熔体首先通过狭长机头制成片材或厚膜,然后在专用的拉伸机内,在一定的温度和设定的速度下,同时或分步在垂直的两个方向(纵向、横向)上进行的拉伸,并经过适当的冷却或热处理或特殊的加工(如电晕、涂覆等)制成的薄膜。BOPP is the abbreviation of "Biaxially Oriented Polypropylene", and BOPP film is a biaxially oriented polypropylene film. The production of BOPP film is to first make the melt of high molecular weight polypropylene through a narrow and long die into a sheet or a thick film, and then in a special stretching machine, at a certain temperature and a set speed, simultaneously or step by step A film made by stretching in two vertical directions (longitudinal and transverse) and undergoing appropriate cooling or heat treatment or special processing (such as corona, coating, etc.).
在BOPP薄膜卷绕传输及拉伸系统中,主要控制目标是在卷径和设定值变化的扰动情况下,独立控制各个传动辊的速度和张力。然而,这些扰动因素和控制量往往相互作用且无法进行单独地描述。整个系统的铸片-纵拉-横拉-牵引-收卷生产过程中包括一系列执行机构(驱动电机),而采用一个全局的多变量控制器来实现多电机的控制是难以实现的。In the BOPP film winding transmission and stretching system, the main control objective is to independently control the speed and tension of each drive roller under the disturbance of the roll diameter and the change of the set value. However, these disturbance factors and control quantities often interact and cannot be described individually. The production process of casting sheet-longitudinal drawing-horizontal drawing-drawing-winding of the whole system includes a series of actuators (drive motors), and it is difficult to realize the control of multiple motors by using a global multi-variable controller.
发明内容Contents of the invention
本发明解决的技术问题在于提供一种BOPP双向拉伸系统的控制方法,以降低薄膜纵向厚度偏差。The technical problem solved by the present invention is to provide a control method of the BOPP biaxial stretching system to reduce the longitudinal thickness deviation of the film.
为了解决上述问题,本发明采用了如下技术方案:In order to solve the above problems, the present invention adopts the following technical solutions:
一种BOPP双向拉伸系统的控制方法,对于系统拉伸段内任意的三电机子系统:包括前置轴、第一张力辊、主驱轴、第二张力辊、后置轴,采用两个分布式控制器进行控制,其中,通过第一控制器控制前置轴电机和主驱轴电机,并通过第二控制器控制主驱轴电机和后置轴电机,同时,所述第一控制器和第二控制器通过叠加控制因子a和b共享一部分输出以控制所述主驱轴电机。A control method for a BOPP bidirectional stretching system. For any three-motor subsystem in the stretching section of the system: including the front shaft, the first tension roller, the main drive shaft, the second tension roller, and the rear shaft, two The distributed controller performs control, wherein, the front shaft motor and the main drive shaft motor are controlled by the first controller, and the main drive shaft motor and the rear shaft motor are controlled by the second controller. At the same time, the first controller Share a part of the output with the second controller by superimposing the control factors a and b to control the main drive shaft motor.
进一步的,所述第一控制器以前置轴处薄膜张力设定值Tu_ref和主驱轴处薄膜速度设定值Vref为输入,并根据第一张力辊处薄膜的实时张力Tu和主驱轴处薄膜的实时速度V,得到前置轴电机张力控制偏差值xu=Tu_ref-Tu和速度控制偏差值xv=Vref-V,进而根据如下公式得到前置轴转矩控制信号uu和主驱轴电机转矩控制信号uv1:Further, the first controller takes the film tension setting value T u_ref at the leading shaft and the film speed setting value V ref at the main drive shaft as inputs, and according to the real-time tension T u of the film at the first tension roller and the main The real-time velocity V of the film at the driving shaft is obtained from the tension control deviation value of the front shaft motor x u =T u_ref -T u and the speed control deviation value x v =V ref -V, and then the torque control of the front shaft is obtained according to the following formula Signal u u and main drive shaft motor torque control signal u v1 :
其中,Pu、Pv1为比例增益系数,Tiu、Tiv1为积分时间常数,iu、iv为前置轴电机和主驱轴电机的机械传动比,nu、nv为前置轴电机和主驱轴电机的电机转速;Among them, P u , P v1 are proportional gain coefficients, T iu , T iv1 are integral time constants, i u , iv are mechanical transmission ratios of front shaft motor and main drive shaft motor, nu u , n v are front shaft motors Motor speed of shaft motor and main drive shaft motor;
所述第二控制器以主驱轴处薄膜速度设定值Vref和后置轴处薄膜张力设定值Tw_ref为输入,并根据主驱轴处薄膜的实时速度V和第二张力辊处薄膜的实时张力Tw,得到后置轴电机张力控制偏差值xw=Tw_ref-Tw和速度控制偏差值xv=Vref-V,进而根据如下公式得到主驱轴电机转矩控制信号uv2和后置轴电机转矩控制信号uw:The second controller takes the film speed set value V ref at the main drive shaft and the film tension set value T w_ref at the rear shaft as inputs, and according to the real-time speed V of the film at the main drive shaft and the film tension at the second tension roller For the real-time tension T w of the film, the tension control deviation value of the rear shaft motor x w =T w_ref -T w and the speed control deviation value x v =V ref -V are obtained, and then the torque control signal of the main drive shaft motor is obtained according to the following formula u v2 and rear axle motor torque control signal u w :
其中,Pw、Pv2为比例增益系数,Tiw、Tiv2为积分时间常数,iw、iv为后置轴电机和主驱轴电机的机械传动比,nw、nv为后置轴电机和主驱轴电机的电机转速;Among them, P w , P v2 are proportional gain coefficients, T iw , T iv2 are integral time constants, i w , iv are the mechanical transmission ratios of the rear shaft motor and the main drive shaft motor, n w , n v are the rear Motor speed of shaft motor and main drive shaft motor;
之后,根据重叠控制因子a和b得到主驱轴电机控制信号uv=a·uv1+b·uv2。Afterwards, according to the overlapping control factors a and b, the main drive shaft motor control signal u v =a·u v1 +b·u v2 is obtained.
进一步的,所述第一张力辊处薄膜的实时张力T1为前置轴和第一张力辊之间薄膜的张力,T2为第一张力辊和主驱轴之间薄膜的张力Tu;所述第二张力辊处薄膜的实时张力T3为主驱轴和第二张力辊之间薄膜的张力,T4为第二张力辊和后置轴之间薄膜的张力;T1、T2、T3、T4和主驱轴处薄膜的实时速度V通过如下公式获得:Further, the real-time tension of the film at the first tension roller place T 1 is the tension of the film between the front shaft and the first tension roller, and T 2 is the tension Tu of the film between the first tension roller and the main drive shaft; the real-time tension of the film at the second tension roller place T 3 is the tension of the film between the driving shaft and the second tension roller, T 4 is the tension of the film between the second tension roller and the rear shaft; T 1 , T 2 , T 3 , T 4 and the main driving shaft The real-time velocity V of the film is obtained by the following formula:
其中,Ωk=Vk/Rk为第k辊的转速,Kk为电机转矩常数,Uk为电机转矩,Jk为转动惯量,Rk为卷径,Cf为摩擦转矩,V0为前置轴出口处薄膜的额定膜速度,Tk和Lk为第k-1辊与第k辊之间的张力和膜长,V0为薄膜理想速度,T0为薄膜理想张力,E为薄膜材料的杨氏弹性模量,S为薄膜截面积;主驱轴处薄膜的实时速度V=V3。Among them, Ω k = V k / R k is the rotational speed of the kth roller, K k is the motor torque constant, U k is the motor torque, J k is the moment of inertia, R k is the roll diameter, C f is the friction torque , V 0 is the rated film speed of the film at the exit of the front shaft, T k and L k are the tension and film length between the k-1 roller and the k roller, V 0 is the ideal film speed, T 0 is the ideal film speed Tension, E is the Young's modulus of elasticity of the film material, S is the cross-sectional area of the film; the real-time speed of the film at the main drive shaft V=V 3 .
进一步的,所述BOPP双向拉伸系统的铸片、纵拉、横拉、牵引及收卷五部分包括M1-M12共12台轴驱动电机,其中,电机M1驱动冷辊,电机M2、M3、M4驱动纵向拉伸区的三个拉伸辊,电机M5驱动横向拉伸区拉伸辊,M6、M7、M8、M9和M10驱动5组牵引导向辊,电机M11、M12驱动两个互为备用的收卷轴;Further, the five parts of the BOPP biaxial stretching system, including casting, longitudinal drawing, transverse drawing, traction and winding, include a total of 12 shaft drive motors from M1 to M12, wherein the motor M1 drives the cooling roll, and the motors M2, M3, M4 drives the three stretching rollers in the longitudinal stretching area, motor M5 drives the stretching rollers in the transverse stretching area, M6, M7, M8, M9 and M10 drive 5 sets of traction guide rollers, and motors M11 and M12 drive two sets of each other as spares the reel;
将上述12台轴驱动电机及其对应的12个轴分为5个子系统,每个子系统包括3台电机及对应的3根轴;将每个子系统中的3根轴分别抽象为所述前置轴、主驱轴、后置轴,通过2个PID控制器进行控制。The above 12 shaft drive motors and their corresponding 12 shafts are divided into 5 subsystems, each subsystem includes 3 motors and corresponding 3 shafts; the 3 shafts in each subsystem are respectively abstracted as the front shaft, main drive shaft and rear shaft are controlled by 2 PID controllers.
进一步的,本发明的方法还包括横向厚度偏差控制模型和纵向厚度偏差控制模型,其中横向厚度偏差控制模型包括如下步骤:Further, the method of the present invention also includes a lateral thickness deviation control model and a longitudinal thickness deviation control model, wherein the lateral thickness deviation control model includes the following steps:
S1、通过配置于牵引部分中的第一测厚仪,检测双向拉伸后的薄膜厚度;S1. Detect the thickness of the biaxially stretched film through the first thickness gauge configured in the traction part;
S2、将第一测厚仪检测到的厚度与厚度设定值比较,得到厚度差值;S2. Comparing the thickness detected by the first thickness gauge with the thickness setting value to obtain a thickness difference;
S3、铸片PID控制器根据所述厚度差值经计算得到修正值,并通过螺栓温控PID控制器调节,改变热敏模头螺栓温度,以使膜头唇口开口度发生变化,调节片材的厚度;其中,S3. The cast sheet PID controller calculates the correction value according to the thickness difference, and adjusts it through the bolt temperature control PID controller to change the temperature of the heat-sensitive die head bolts so that the opening degree of the lip of the membrane head changes, and the adjustment sheet The thickness of the material; among them,
膜头唇口开口度修正参数通过如下传递函数获得:The correction parameters of the lip opening of the membrane head are obtained through the following transfer function:
其中,W为膜头唇口开口度修正参数,Ky为膜头唇口开口度目标变化量,Kx为螺栓调节量,ma为变位比参数,Gp为膜头唇口截面形状放大系数,T0为厚度设定值,Tm为第一测厚仪检测的薄膜厚度值。Among them, W is the correction parameter of the mouth opening of the membrane head, Ky is the target change amount of the mouth opening of the membrane head, K x is the adjustment amount of the bolt, ma is the displacement ratio parameter, and G p is the enlargement of the cross-sectional shape of the mouth of the membrane head coefficient, T 0 is the thickness setting value, and T m is the film thickness value detected by the first thickness gauge.
进一步的,所述BOPP双向拉伸系统中配置32组热敏模头螺栓,分区调节BOPP原料聚合物熔体的挤出量,且每个热敏模头螺栓均采用独立的控制回路进行控制。Further, the BOPP biaxial stretching system is equipped with 32 sets of heat-sensitive die bolts to adjust the extrusion volume of the BOPP raw polymer melt in different regions, and each heat-sensitive die bolt is controlled by an independent control loop.
进一步的,所述纵向厚度偏差控制模型包括如下步骤:Further, the longitudinal thickness deviation control model includes the following steps:
S1、通过配置于铸片部分中的第二测厚仪,检测冷辊出口的成形厚片厚度;S1. Detect the thickness of the formed slab at the outlet of the chill roll through the second thickness gauge configured in the casting part;
S2、将第二测厚仪测得的薄膜厚度与设定值比较,得到误差信号;S2. Comparing the film thickness measured by the second thickness gauge with the set value to obtain an error signal;
S3、根据所述误差信号,通过冷辊PID调节器改变冷辊的线速度,以控制薄膜纵向厚度偏差。S3. According to the error signal, change the linear speed of the chill roll through the chill roll PID regulator, so as to control the longitudinal thickness deviation of the film.
本发明的BOPP双向拉伸系统的膜厚控制方法,整个系统张力能够较好的保持恒定,且提高了系统速度和张力的解耦能力,降低了薄膜纵向厚度偏差和横向厚度偏差。According to the film thickness control method of the BOPP biaxial stretching system of the present invention, the tension of the whole system can be kept constant, and the decoupling ability of the system speed and tension is improved, and the longitudinal thickness deviation and transverse thickness deviation of the film are reduced.
附图说明Description of drawings
图1为BOPP双向拉伸系统的组成示意图。Figure 1 is a schematic diagram of the composition of the BOPP biaxial stretching system.
图2为本发明的控制方法中三电机重叠控制模型示意图。Fig. 2 is a schematic diagram of a three-motor overlapping control model in the control method of the present invention.
图3为图2中三电机重叠控制模型的实验结果图。Fig. 3 is a diagram of the experimental results of the three-motor overlapping control model in Fig. 2 .
图4为本发明的控制方法中多电机半分散重叠控制模型示意图。Fig. 4 is a schematic diagram of a multi-motor semi-decentralized overlapping control model in the control method of the present invention.
图5为本发明的控制方法中纵向厚度偏差控制回路的组成示意图。Fig. 5 is a schematic diagram of the composition of the longitudinal thickness deviation control loop in the control method of the present invention.
图6本发明的控制方法中纵向和横向厚度偏差控制回路的组成示意图。Fig. 6 is a schematic composition diagram of the longitudinal and transverse thickness deviation control loops in the control method of the present invention.
图7为现有控制方法和本发明的控制方法中测厚仪检测的横向厚度偏差数据对比图。Fig. 7 is a comparison chart of lateral thickness deviation data detected by the thickness gauge in the existing control method and the control method of the present invention.
图8为现有控制方法和本发明的控制方法中测厚仪检测的纵向厚度偏差数据对比图。Fig. 8 is a comparison chart of longitudinal thickness deviation data detected by the thickness gauge in the existing control method and the control method of the present invention.
具体实施方式Detailed ways
为了进一步理解本发明,下面结合实施例对本发明优选实施方案进行描述,但是应当理解,这些描述只是为进一步说明本发明的特征和优点,而不是对本发明权利要求的限制。In order to further understand the present invention, the preferred embodiments of the present invention are described below in conjunction with examples, but it should be understood that these descriptions are only to further illustrate the features and advantages of the present invention, rather than limiting the claims of the present invention.
首先对BOPP双向拉伸系统进行说明。如图1所示,BOPP双向拉伸系统包括挤出、铸片、纵拉、横拉、牵引和收卷六个子系统。First, the BOPP biaxially stretched system will be described. As shown in Figure 1, the BOPP biaxial stretching system includes six subsystems: extrusion, casting, longitudinal stretching, transverse stretching, traction and winding.
其中,挤出系统主要由一级主挤、二级主挤、第一辅挤、第二辅挤及过滤器组成。具体的,一级主挤作用是使物料接受外部加热器传入的热量,在螺杆的剪切、压缩下达到半熔状态,定量向二级主挤供应物料。二级主挤主要由熔融物料压缩区与计量区组成,其作用是将聚合物充分熔融、塑化并通过高剪切作用,使物料均匀混合、计量挤出。物料从料斗进入一级主挤后,经过进料区、压缩区、计量区被塑化、压缩,然后送入二级主挤。一级主挤螺杆由两个电机驱动,二级主挤螺杆由一个电机驱动,调节螺杆转速可改变挤出机的出料压力以及控制物料的熔融温度。第一辅挤和第二辅挤由单螺轩挤出机驱动,其主要功能是对固态树脂实施连续的输送、熔融、混合、排气、加压等作用,将均匀塑化好的熔体定压定量地挤入成型模具。Among them, the extrusion system is mainly composed of primary extrusion, secondary extrusion, first auxiliary extrusion, second auxiliary extrusion and filter. Specifically, the function of the first-stage main extrusion is to make the material receive the heat from the external heater, and reach a semi-molten state under the shear and compression of the screw, and quantitatively supply the material to the second-stage main extrusion. The secondary main extrusion is mainly composed of a molten material compression zone and a metering zone. Its function is to fully melt and plasticize the polymer, and through high shearing, the materials are uniformly mixed and metered for extrusion. After the material enters the first-stage main extrusion from the hopper, it is plasticized and compressed through the feeding area, compression area, and metering area, and then sent to the second-level main extrusion. The first-stage main extrusion screw is driven by two motors, and the second-stage main extrusion screw is driven by one motor. Adjusting the screw speed can change the discharge pressure of the extruder and control the melting temperature of the material. The first auxiliary extrusion and the second auxiliary extrusion are driven by a single-screw extruder. Its main function is to continuously convey, melt, mix, exhaust, and pressurize the solid resin, and to uniformly plasticize the melt. Constant pressure and quantitative extrusion into the molding die.
铸片系统主要由膜头、加热螺栓、冷辊、1#测厚仪组成。“铸片”是指熔融塑料在压力的推动下,强行通过长形的口模,并在外力(静电、气流等)作用下,使熔融塑料地速贴附在冷鼓表面上,制成固态片材的过程。其中,膜头是流延铸片的关键装置,它直接决定铸片的外形和厚度的均匀性,模头开度通过若干个带有加热线圈的推拉式差动螺栓进行初调。1#测厚仪可对铸片进行自动测厚,并将铸片厚度值反馈给控制系统。加热螺栓:包括32组差动式加热螺栓,通过手动调节+自控调节方式进行挤出量和薄膜厚度偏差的调节控制。采用手动调节方式:手动旋转螺栓,螺栓每转一周,模唇开度便增加或减小[m1-m2](设差动螺栓的外螺纹螺距为m1,内螺纹纹螺距为m2)。控制器系统根据1#测厚仪检测的铸片厚度调节,实时调节模头加热螺栓温度,对模唇开度进行微调。冷辊用于将流出模头的BOPP熔体快速冷却到其玻璃化温度以下,形成玻璃态的厚度均匀的铸片。急冷的目的是使厚片成无定型结构,尽量减少其结晶,以免对下道拉伸工序产生不良影响。冷辊由电机M1驱动,控制系统根据拉伸厚度控制要求调节冷辊转速。冷辊内通30℃左右的冷却水,以保证铸片冷却至60℃以下。The casting system is mainly composed of membrane head, heating bolt, chill roll and 1# thickness gauge. "Cast sheet" means that the molten plastic is forced to pass through the long die under the pressure, and under the action of external force (static electricity, air flow, etc.), the molten plastic is quickly attached to the surface of the cold drum and made into a solid state. Sheet process. Among them, the film head is the key device of cast casting, which directly determines the uniformity of the shape and thickness of the casting, and the opening of the die is initially adjusted by several push-pull differential bolts with heating coils. The 1# thickness gauge can automatically measure the thickness of the cast slab, and feed back the thickness value of the cast slab to the control system. Heating bolts: including 32 sets of differential heating bolts, the extrusion volume and film thickness deviation can be adjusted and controlled by manual adjustment + automatic adjustment. Manual adjustment method: manually rotate the bolt, and the opening of the die lip will increase or decrease [m1-m2] every time the bolt rotates once (assuming that the pitch of the outer thread of the differential bolt is m1, and the pitch of the inner thread is m2). The controller system adjusts the thickness of the cast sheet detected by the 1# thickness gauge, adjusts the temperature of the heating bolt of the die head in real time, and fine-tunes the opening of the die lip. The cooling roll is used to quickly cool the BOPP melt flowing out of the die below its glass transition temperature, forming a glassy cast sheet with uniform thickness. The purpose of rapid cooling is to make the thick sheet form an amorphous structure and minimize its crystallization, so as to avoid adverse effects on the next stretching process. The cold roll is driven by the motor M1, and the control system adjusts the speed of the cold roll according to the requirements of stretching thickness control. Cooling water at about 30°C is passed through the cooling roll to ensure that the cast sheet is cooled to below 60°C.
纵拉系统用于将来自铸片机的厚片在加热状态下进行一定倍数的纵向拉伸。纵向拉伸系统分为:预热区、拉伸区、定型区和冷却区四个区,由预热辊、拉伸辊、冷却辊、橡胶压辊、温控系统、穿片系统等组成。其中温控系统于预热区采用低压蒸汽加热,拉伸区、定型区和冷却区则采用高温高压水加热。在拉伸区配置有三个拉伸辊,分别由电机M2、M3、M4驱动。The longitudinal stretching system is used to stretch the slab from the casting machine to a certain number of longitudinal stretches in a heated state. The longitudinal stretching system is divided into four zones: preheating zone, stretching zone, shaping zone and cooling zone, which is composed of preheating roller, stretching roller, cooling roller, rubber pressing roller, temperature control system, sheet feeding system, etc. Among them, the temperature control system uses low-pressure steam heating in the preheating zone, and high-temperature and high-pressure water heating in the stretching zone, shaping zone and cooling zone. There are three stretching rollers arranged in the stretching area, which are respectively driven by motors M2, M3, and M4.
横拉系统由烘箱、链夹和导轨、静压箱、链条张紧器、导轨宽度调节装置、开闭夹器、热风循环系统、润滑系统及EPC等组成。横拉机构由进膜、预热、拉幅、缓冲、定型和冷却等功能段组成,各段的加热温度均不高于190℃。横拉机的作用是将经过纵向拉伸的薄膜在横拉机内分别通过预热、拉幅、热定型和冷却而完成薄膜的横向拉伸。横向拉伸辊由电机M5驱动。The horizontal tension system is composed of oven, chain clamp and guide rail, static pressure box, chain tensioner, guide rail width adjustment device, opening and closing clamp, hot air circulation system, lubrication system and EPC. The horizontal stretching mechanism is composed of functional sections such as film feeding, preheating, tentering, buffering, shaping and cooling, and the heating temperature of each section is not higher than 190°C. The function of the horizontal stretching machine is to complete the transverse stretching of the film through preheating, tentering, heat setting and cooling in the horizontal stretching machine. The transverse stretching roller is driven by a motor M5.
牵引系统:由若干个牵引导向辊、冷却辊、展平辊、张力辊、跟踪辊、切边装置及边料粉碎系统、2#测厚仪和电晕处理机等组成。其中,2#测厚仪用于在线测量拉伸后的BOPP薄膜的横向厚度。电晕处理机通过在电极上施加高频高压电流,使电极产生电晕放电,气体电离产生高能离子,在强电场作用下冲击塑料薄膜表面,使薄膜表面活化,以增加薄膜的表面湿张力。牵引导向辊包括5组牵引导向辊,由电机M6、M7、M8、M9和M10驱动。Traction system: It is composed of several traction guide rollers, cooling rollers, flattening rollers, tension rollers, tracking rollers, edge trimming devices, edge material crushing systems, 2# thickness gauges, and corona treatment machines. Among them, the 2# thickness gauge is used to measure the transverse thickness of the stretched BOPP film online. The corona treater applies a high-frequency and high-voltage current to the electrode to cause the electrode to generate a corona discharge, and the gas ionizes to generate high-energy ions, which impact the surface of the plastic film under the action of a strong electric field to activate the surface of the film to increase the surface wet tension of the film. The traction guide rollers include 5 sets of traction guide rollers, which are driven by motors M6, M7, M8, M9 and M10.
收卷系统由触辊、1#收卷轴、2#收卷轴、转塔、自动斩膜刀组成。1#收卷轴、2#收卷轴互为备用,分别由M11和M12驱动,转塔由M13驱动。当1#收卷轴接近满套时,由转塔将1#收卷轴旋转到备用工位,斩膜刀将膜切断,收卷系统切换至2#收卷轴工作,操作人员则将1#收卷轴的成品膜吊装外运。The winding system is composed of touch roller, 1# winding shaft, 2# winding shaft, turret and automatic film cutting knife. 1# winding shaft and 2# winding shaft are spare for each other, driven by M11 and M12 respectively, and the turret is driven by M13. When the 1# winding shaft is close to the full set, the turret will rotate the 1# winding shaft to the spare station, the film cutter will cut off the film, the winding system will switch to the 2# winding shaft, and the operator will turn the 1# winding shaft The finished film is hoisted and shipped out.
上述BOPP双向拉伸系统采用双轴定向平膜分步拉伸法。纵拉系统有10个预热辊、4个拉伸辊、2个定型辊。横拉系统采用四区预热,三区拉伸,二区定型,一区冷却的方式。系统纵向拉伸采用小间隙单点拉伸,拉伸倍数由1:1到1:6之间任意设定和可调,横向拉伸倍数最大可达到1:11。冷鼓和纵拉慢速辊和横拉之间,以及纵拉快速辊和横拉之间采用张力传感器进行速度同步。从冷鼓开始至牵引机组的速度给定呈速度链关系,保证生产线的速度同步。为了实现上述系统的稳定控制,本发明提供了一种BOPP双向拉伸系统的控制方法。The above-mentioned BOPP biaxial stretching system adopts a biaxially oriented flat film stepwise stretching method. The longitudinal stretching system has 10 preheating rolls, 4 stretching rolls and 2 setting rolls. The horizontal stretching system adopts four-zone preheating, three-zone stretching, two-zone setting, and one-zone cooling. The longitudinal stretching of the system adopts single-point stretching with small gaps, and the stretching ratio can be set and adjusted arbitrarily from 1:1 to 1:6, and the maximum horizontal stretching ratio can reach 1:11. Tension sensors are used for speed synchronization between the cold drum and longitudinal stretching slow rolls and cross stretching, and between longitudinal stretching fast rolls and cross stretching. The speed setting from the cold drum to the traction unit is in a speed chain relationship to ensure that the speed of the production line is synchronized. In order to realize the stable control of the above system, the present invention provides a control method of the BOPP biaxial stretching system.
本发明的一个方面提供了一种拉伸控制方法。下面先从一种较为简单的模型说起。One aspect of the present invention provides a stretch control method. Let's start with a simpler model.
如图2所示,对于系统拉伸段内任意的三电机子系统:包括前置轴、第一张力辊、主驱轴、第二张力辊、后置轴,采用两个分布式控制器进行控制,其中,通过第一控制器控制前置轴电机和主驱轴电机,并通过第二控制器控制主驱轴电机和后置轴电机,同时,所述第一控制器和第二控制器通过叠加控制因子a和b共享一部分输出以控制所述主驱轴电机。As shown in Figure 2, for any three-motor subsystem in the stretching section of the system: including the front shaft, the first tension roller, the main drive shaft, the second tension roller, and the rear shaft, two distributed controllers are used to implement control, wherein the front shaft motor and the main drive shaft motor are controlled by the first controller, and the main drive shaft motor and the rear shaft motor are controlled by the second controller, and at the same time, the first controller and the second controller A part of the output is shared by superimposing the control factors a and b to control the main drive shaft motor.
具体的,第一控制器以前置轴处薄膜张力设定值Tu_ref和主驱轴处薄膜速度设定值Vref为输入,并根据第一张力辊处薄膜的实时张力Tu和主驱轴处薄膜的实时速度V,得到前置轴电机张力控制偏差值xu=Tu_ref-Tu和速度控制偏差值xv=Vref-V,进而根据如下公式得到前置轴转矩控制信号uu和主驱轴电机转矩控制信号uv1:Specifically, the first controller takes the film tension set value T u_ref at the front shaft and the film speed set value V ref at the main drive shaft as inputs, and according to the real-time tension Tu_ref of the film at the first tension roller and the main drive shaft The real-time speed V of the film at the position, the tension control deviation value of the front shaft motor x u = T u_ref -T u and the speed control deviation value x v = V ref -V are obtained, and then the torque control signal u of the front shaft is obtained according to the following formula u and main drive shaft motor torque control signal u v1 :
其中,Pu、Pv1为比例增益系数,Tiu、Tiv1为积分时间常数,iu、iv为前置轴电机和主驱轴电机的机械传动比,nu、nv为前置轴电机和主驱轴电机的电机转速;Among them, P u , P v1 are proportional gain coefficients, T iu , T iv1 are integral time constants, i u , iv are mechanical transmission ratios of front shaft motor and main drive shaft motor, nu u , n v are front shaft motors Motor speed of shaft motor and main drive shaft motor;
第二控制器以主驱轴处薄膜速度设定值Vref和后置轴处薄膜张力设定值Tw_ref为输入,并根据主驱轴处薄膜的实时速度V和第二张力辊处薄膜的实时张力Tw,得到后置轴电机张力控制偏差值xw=Tw_ref-Tw和速度控制偏差值xv=Vref-V,进而根据如下公式得到主驱轴电机转矩控制信号uv2和后置轴电机转矩控制信号uw:The second controller takes the film speed set value V ref at the main drive shaft and the film tension set value T w_ref at the rear shaft as inputs, and according to the real-time speed V of the film at the main drive shaft and the film at the second tension roller Real-time tension T w , obtain the tension control deviation value of the rear shaft motor x w = T w_ref -T w and the speed control deviation value x v = V ref -V, and then obtain the torque control signal u v2 of the main drive shaft motor according to the following formula And the rear axle motor torque control signal u w :
其中,Pw、Pv2为比例增益系数,Tiw、Tiv2为积分时间常数,iw、iv为后置轴电机和主驱轴电机的机械传动比,nw、nv为后置轴电机和主驱轴电机的电机转速;Among them, P w , P v2 are proportional gain coefficients, T iw , T iv2 are integral time constants, i w , iv are the mechanical transmission ratios of the rear shaft motor and the main drive shaft motor, n w , n v are the rear Motor speed of shaft motor and main drive shaft motor;
之后,根据重叠控制因子a和b得到主驱轴电机控制信号uv=a·uv1+b·uv2。Afterwards, according to the overlapping control factors a and b, the main drive shaft motor control signal u v =a·u v1 +b·u v2 is obtained.
在上述计算中,第一张力辊处薄膜的实时张力T1为前置轴和第一张力辊之间薄膜的张力,T2为第一张力辊和主驱轴之间薄膜的张力Tu;所述第二张力辊处薄膜的实时张力T3为主驱轴和第二张力辊之间薄膜的张力,T4为第二张力辊和后置轴之间薄膜的张力;T1、T2、T3、T4和主驱轴处薄膜的实时速度V通过如下公式获得:In the above calculation, the real-time tension of the film at the first tension roller T 1 is the tension of the film between the front shaft and the first tension roller, and T 2 is the tension Tu of the film between the first tension roller and the main drive shaft; the real-time tension of the film at the second tension roller place T 3 is the tension of the film between the driving shaft and the second tension roller, T 4 is the tension of the film between the second tension roller and the rear shaft; T 1 , T 2 , T 3 , T 4 and the main driving shaft The real-time velocity V of the film is obtained by the following formula:
其中,Ωk=Vk/Rk为第k辊的转速,Kk为电机转矩常数,Uk为电机转矩,Jk为转动惯量,Rk为卷径,Cf为摩擦转矩,V0为前置轴出口处薄膜的额定膜速度,Tk和Lk为第k-1辊与第k辊之间的张力和膜长,V0为薄膜理想速度,T0为薄膜理想张力,E为薄膜材料的杨氏弹性模量,S为薄膜截面积;主驱轴处薄膜的实时速度V=V3。Among them, Ω k = V k / R k is the rotational speed of the kth roller, K k is the motor torque constant, U k is the motor torque, J k is the moment of inertia, R k is the roll diameter, C f is the friction torque , V 0 is the rated film speed of the film at the exit of the front shaft, T k and L k are the tension and film length between the k-1 roller and the k roller, V 0 is the ideal film speed, T 0 is the ideal film speed Tension, E is the Young's modulus of elasticity of the film material, S is the cross-sectional area of the film; the real-time speed of the film at the main drive shaft V=V 3 .
如图3所示,为采用上述控制模型后的实验结果图,可以看出,无论是开卷张力和收卷张力,还是主驱轴速度均具有良好的稳定性。As shown in Figure 3, it is the experimental result graph after using the above control model. It can be seen that both the unwinding tension and winding tension, and the speed of the main drive shaft have good stability.
下面,将上述控制模型应用到整个BOPP双向拉伸系统中。如图4所示,整个BOPP双向拉伸系统的铸片、纵拉、横拉、牵引及收卷五部分包括M1-M12共12台轴驱动电机,其中,电机M1驱动冷辊,电机M2、M3、M4驱动纵向拉伸区的三个拉伸辊,电机M5驱动横向拉伸区的拉伸辊,电机M6、M7、M8、M9和M10驱动5组牵引导向辊,电机M11、M12电机驱动两个互为备用的收卷轴;将上述12台轴驱动电机及其对应的12个轴分为5个子系统,每个子系统包括3台电机及对应的3根轴;将每个子系统中的3根轴分别抽象为所述前置轴、主驱轴、后置轴,通过2个PID控制器进行控制。其中,两个收卷机轴仅在工作状态下作为最后一个单元的后置轴。Next, the above control model is applied to the entire BOPP biaxial stretching system. As shown in Figure 4, the five parts of the entire BOPP biaxial stretching system, including casting, longitudinal drawing, transverse drawing, traction and winding, include a total of 12 shaft drive motors from M1 to M12. Among them, the motor M1 drives the cooling roll, and the motor M2, M3 and M4 drive the three stretching rollers in the longitudinal stretching zone, motor M5 drives the stretching rollers in the transverse stretching zone, motors M6, M7, M8, M9 and M10 drive 5 sets of traction guide rollers, and motors M11 and M12 drive Two mutually spare rewinding shafts; the above 12 shaft drive motors and their corresponding 12 shafts are divided into 5 subsystems, each subsystem includes 3 motors and corresponding 3 shafts; 3 in each subsystem The root shafts are respectively abstracted into the front shaft, the main drive shaft, and the rear shaft, and are controlled by two PID controllers. Among them, the two winder shafts are only used as the rear shafts of the last unit in the working state.
另一方面,在拉伸过程中,结晶与定向是否均匀,程度大小是否适当,关键在于材料温度均匀和稳定。为了保证温度场的控制精度,系统设计采用PID温度控制方式。系统厚度控制技术采用两台测厚仪分别检测厚片、薄膜产品的厚度,将测得的数据反馈给控制系统,计算出纵向和横向的厚度偏差,根据薄膜纵向厚度偏差来控制挤出机螺杆转速修正量,同时根据薄膜横向厚度偏差来控制挤出机机头相应部位螺栓的温度来实现厚片、薄膜厚度的自动控制。On the other hand, in the stretching process, whether the crystallization and orientation are uniform and whether the degree is appropriate depends on the uniformity and stability of the material temperature. In order to ensure the control accuracy of the temperature field, the system design adopts the PID temperature control method. The thickness control technology of the system uses two thickness gauges to detect the thickness of thick sheet and film products respectively, and feeds the measured data back to the control system to calculate the longitudinal and transverse thickness deviation, and control the extruder screw according to the longitudinal thickness deviation of the film Speed correction amount, and at the same time control the temperature of the bolts at the corresponding parts of the extruder head according to the film transverse thickness deviation to realize the automatic control of thick sheet and film thickness.
基于此,本发明的另一个方面还提供了一种膜厚控制方法。具体的,本发明的膜厚控制方法采用了包括横向厚度偏差控制模型和纵向厚度偏差控制模型的如下方案:Based on this, another aspect of the present invention also provides a film thickness control method. Specifically, the film thickness control method of the present invention adopts the following scheme including a lateral thickness deviation control model and a longitudinal thickness deviation control model:
其中,如图5所示,本发明的膜厚控制方法中纵向厚度偏差控制模型包括如下步骤:Wherein, as shown in Figure 5, the longitudinal thickness deviation control model in the film thickness control method of the present invention comprises the following steps:
首先通过配置于铸片系统中的第二测厚仪,检测冷辊出口的成形厚片厚度;First, through the second thickness gauge configured in the casting system, the thickness of the formed slab at the exit of the chill roll is detected;
之后将第二测厚仪测得的薄膜厚度与设定值比较,得到误差信号;Then compare the film thickness measured by the second thickness gauge with the set value to obtain an error signal;
然后根据所述误差信号,通过冷辊PID调节器改变冷辊的线速度,以控制薄膜纵向厚度偏差。Then, according to the error signal, the linear speed of the chilled roll is changed through the chilled roll PID regulator to control the longitudinal thickness deviation of the film.
同时,如图6所示,本发明的膜厚控制方法中进一步包括横向厚度偏差控制模型,具体包括如下步骤:At the same time, as shown in Figure 6, the film thickness control method of the present invention further includes a lateral thickness deviation control model, which specifically includes the following steps:
首先通过配置于牵引系统中的第一测厚仪,检测双向拉伸后的薄膜厚度;First, through the first thickness gauge configured in the traction system, the thickness of the film after biaxial stretching is detected;
之后将第一测厚仪检测到的厚度与厚度设定值比较,得到厚度差值;Then compare the thickness detected by the first thickness gauge with the thickness setting value to obtain the thickness difference;
然后铸片PID控制器根据所述厚度差值经计算得到修正值,并通过螺栓温控PID控制器调节,改变热敏模头螺栓温度,利用控制挤出机膜头的热敏螺栓的温度变化,使螺栓发生热伸缩,引起膜头唇口开口度发生变化,调节片材的厚度;其中,Then the cast sheet PID controller calculates the correction value according to the thickness difference, and adjusts it through the bolt temperature control PID controller to change the temperature of the heat-sensitive die head bolt, and use the temperature change of the heat-sensitive bolt to control the extruder film head , causing the bolts to thermally expand and contract, causing the opening of the membrane head lip to change, and adjusting the thickness of the sheet; among them,
膜头唇口开口度修正参数通过如下传递函数获得:The correction parameters of the lip opening of the membrane head are obtained through the following transfer function:
其中,Ky为膜头唇口开口度目标变化量,Kx为螺栓调节量,ma为变位比参数,Gp为膜头唇口截面形状放大系数,T0为厚度设定值,Tm为第一测厚仪检测的薄膜厚度值。Among them, Ky is the target variation of the opening degree of the membrane head lip, K x is the bolt adjustment amount, ma is the displacement ratio parameter, G p is the magnification factor of the membrane head lip section shape, T 0 is the thickness setting value, T m is the film thickness value detected by the first thickness gauge.
上述过程中,机头螺栓温度的控制采用直接反馈式,控制系统按一定周期进行实时计算,间隙式地调节机头螺栓的电压和通电率,达到调整螺栓温度—改变膜头唇口开口度—调节挤出量的过程。In the above process, the temperature control of the machine head bolt adopts the direct feedback method, and the control system performs real-time calculation according to a certain period, and adjusts the voltage and energization rate of the machine head bolt intermittently, so as to adjust the bolt temperature—change the opening degree of the membrane head lip— The process of adjusting the amount of extrusion.
优选的,上述的BOPP双向拉伸系统中配置32组热敏模头螺栓,分区调节BOPP原料聚合物熔体的挤出量,且每个热敏模头螺栓均采用独立的控制回路进行控制。Preferably, 32 sets of heat-sensitive die head bolts are configured in the above-mentioned BOPP biaxial stretching system to adjust the extrusion volume of BOPP raw polymer melt in different regions, and each heat-sensitive die head bolt is controlled by an independent control loop.
上述的本发明的膜厚控制方法的的实施效果如附图7-8所示。其中:图7(a)为采用现有控制方法时,测厚仪检测的某一时间点BOPP薄膜的横向厚度偏差值,从中可以看出,薄膜的横向厚度偏差波动比较大,有多处的横向厚度偏差值超过了上下限阈值。图7(b)为采用本发明的控制方法,测厚仪检测的某一时间点BOPP薄膜的横向厚度偏差值,从中可以看出,薄膜的横向厚度偏差波动比现有控制方法要小很多,厚度偏差也只是在薄膜的边部超过了上下限阈值,厚度平均值也更接近设定值3.22μm。通过控制机头螺栓温度来调节薄膜横向厚度偏差的控制方法起到了显著的控制效果。The implementation effects of the above-mentioned film thickness control method of the present invention are shown in FIGS. 7-8 . Among them: Figure 7(a) shows the lateral thickness deviation value of the BOPP film at a certain time point detected by the thickness gauge when the existing control method is adopted. It can be seen from this that the lateral thickness deviation of the film fluctuates relatively large, and there are many The lateral thickness deviation value exceeds the upper and lower thresholds. Fig. 7 (b) adopts the control method of the present invention, the lateral thickness deviation value of the BOPP film at a certain time point detected by the thickness gauge, as can be seen from it, the lateral thickness deviation fluctuation of the film is much smaller than the existing control method, The thickness deviation only exceeds the upper and lower limit thresholds at the edge of the film, and the average thickness is closer to the set value of 3.22 μm. The control method of adjusting the lateral thickness deviation of the film by controlling the temperature of the head bolts has achieved a significant control effect.
图8(a)为采用现有的控制方法时,测厚仪检测的BOPP薄膜的纵向厚度偏差值,其中,每一列代表薄膜某一纵向位置的厚度最大值(最高红色点)、最小值(最低红色点)和平均值(黑色点)。从中可以看出,薄膜的纵向厚度偏差波动比较大,有多处的纵向厚度偏差值超过了上下限阈值。图8(b)为采用本发明的控制方法,测厚仪检测的BOPP薄膜的纵向厚度偏差值,从中可以看出,薄膜的纵向厚度的最大值、最小值和平均值波动比改造之前要小很多。通过控制挤出机螺杆转速来调节薄膜纵向厚度偏差的方法起到了显著的控制效果。Figure 8(a) shows the longitudinal thickness deviation value of the BOPP film detected by the thickness gauge when using the existing control method, where each column represents the maximum value (highest red point) and minimum value ( lowest red point) and average (black point). It can be seen that the longitudinal thickness deviation of the film fluctuates relatively large, and the longitudinal thickness deviation values in many places exceed the upper and lower limit thresholds. Fig. 8 (b) adopts the control method of the present invention, the vertical thickness deviation value of the BOPP film that the thickness gauge detects, can find out from it, the maximum value, the minimum value and the average value fluctuation of the longitudinal thickness of the film are smaller than before transformation a lot of. The method of adjusting the longitudinal thickness deviation of the film by controlling the screw speed of the extruder has a significant control effect.
以上实施例的说明只是用于帮助理解本发明的方法及其核心思想。应当指出,对于本技术领域的普通技术人员来说,在不脱离本发明原理的前提下,还可以对本发明进行若干改进和修饰,这些改进和修饰也落入本发明权利要求的保护范围内。The descriptions of the above embodiments are only used to help understand the method and core idea of the present invention. It should be pointed out that for those skilled in the art, without departing from the principle of the present invention, some improvements and modifications can be made to the present invention, and these improvements and modifications also fall within the protection scope of the claims of the present invention.
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Application publication date: 20180511 Assignee: Hairuixing (Wuhan) Technology Co.,Ltd. Assignor: WUHAN University OF SCIENCE AND TECHNOLOGY Contract record no.: X2024980022297 Denomination of invention: A control method for BOPP biaxial stretching system Granted publication date: 20191203 License type: Common License Record date: 20241106 |