Pamoja na maendeleo ya haraka ya ukuaji wa viwanda duniani, mahitaji ya vifaa vya juu vya utendaji katika magari, umeme na elektroniki, ujenzi, matibabu na nyanja zingine zinaongezeka siku baada ya siku. Plastiki za uhandisi, kama nyenzo muhimu ya utendaji wa juu, hatua kwa hatua zimebadilisha vifaa vya jadi vya chuma na plastiki ya jumla katika hali nyingi za utumiaji wa msingi kwa sababu ya mali zao bora za kiufundi., upinzani wa joto, upinzani wa kutu, utulivu wa dimensional na usindikaji. Teknolojia ya extrusion ya screw-pacha ni teknolojia ya usindikaji ya msingi ya misombo ya plastiki ya uhandisi, na utendaji wa vifaa vya extrusion huamua moja kwa moja ubora, ufanisi wa uzalishaji na athari ya matumizi ya bidhaa za plastiki za uhandisi.
We are committed to providing professional twin-screw extrusion solutions for engineering plastics processing, relying on our independently developed and manufactured HTS series extruders with high-torque gearboxes, which are specially designed for the processing characteristics and application needs of engineering plastics. This article will comprehensively elaborate on the performance characteristics, uainishaji, processing difficulties of engineering plastics, the core role of twin-screw extrusion technology in engineering plastics processing, the advantages of our HTS series extruders and their targeted adaptation to engineering plastics, pamoja na nyanja maalum za maombi, processing techniques and common problems and solutions. By supplementing detailed technical parameters, processing details and industry application cases, the article will be enriched to 3000-4000 maneno, providing comprehensive and professional reference for engineering plastics processing enterprises, technicians and relevant practitioners.
1. Overview of Engineering Plastics Industry and Core Performance Characteristics
1.1 Current Situation and Development Trend of Engineering Plastics Industry
Engineering plastics refer to a class of plastic materials that can be used as structural materials and bear mechanical loads in a wide temperature range. Compared with general plastics (such as polyethylene PE, polypropylene PP, polyvinyl chloride PVC), engineering plastics have more excellent comprehensive performance, and can meet the harsh use requirements in industrial production and high-end product manufacturing. Katika miaka ya hivi karibuni, driven by the upgrading of downstream industries such as automotive lightweight, electrical and electronic intelligence, na kifaa cha matibabu cha hali ya juu, soko la plastiki la uhandisi la kimataifa limeonyesha mwelekeo thabiti na wa haraka wa ukuaji.
Kulingana na data ya tasnia husika, ukubwa wa soko la plastiki za uhandisi duniani umezidi 100 bilioni dola za kimarekani, na inatarajiwa kudumisha kiwango cha ukuaji cha kila mwaka cha 7%-10% katika miaka mitano ijayo. Miongoni mwao, Asia-Pacific ndio soko kubwa zaidi la uzalishaji na matumizi ya plastiki ya uhandisi ulimwenguni, uhasibu kwa zaidi ya 55% ya hisa ya soko la kimataifa, hasa kutokana na maendeleo ya haraka ya magari, viwanda vya umeme na elektroniki nchini China, India na nchi zingine, pamoja na uboreshaji endelevu wa uwezo wa kusaidia viwanda na kiwango cha uvumbuzi wa kiteknolojia. China, kama mtumiaji na mzalishaji mkubwa zaidi wa uhandisi wa plastiki duniani, ina mahitaji makubwa ya soko, na pato la kila mwaka na matumizi yanaongezeka kwa kiwango cha tarakimu mbili, hasa katika nyanja za magari ya nishati mpya, 5G communications, and medical devices, the demand for high-performance engineering plastics is showing an explosive growth trend.
The development trend of the engineering plastics industry is mainly reflected in five aspects: kwanza, utendaji wa juu na utendaji kazi. With the continuous improvement of use requirements in downstream fields, engineering plastics are developing towards higher heat resistance, higher strength, better wear resistance and special functions (such as flame retardancy, antistatic, antibacterial, radiation resistance), to adapt to the harsh working environment of high temperature, high pressure, corrosion and radiation; pili, lightweight and integration. In the automotive, aerospace and other fields, in order to achieve energy saving and emission reduction goals, engineering plastics are increasingly used to replace metal materials, na ujumuishaji wa muundo wa bidhaa unakuwa wa juu zaidi, ambayo inaweza kupunguza idadi ya sehemu, kurahisisha mchakato wa uzalishaji na kupunguza gharama; tatu, ulinzi wa mazingira na recyclability. Pamoja na uimarishaji wa sera za kimataifa za ulinzi wa mazingira na uboreshaji wa ufahamu wa ulinzi wa mazingira, maendeleo na matumizi ya plastiki za uhandisi zinazoweza kutumika tena, plastiki za uhandisi zinazoweza kuharibika na teknolojia za usindikaji rafiki wa mazingira zimekuwa lengo la tasnia, kupunguza uchafuzi wa mazingira unaosababishwa na taka za plastiki; nne, akili na usahihi wa vifaa vya usindikaji. Plastiki za uhandisi zina ugumu wa usindikaji wa juu na mahitaji madhubuti ya ubora, ambayo inaweka mahitaji ya juu zaidi kwenye vifaa vya usindikaji. Mwenye akili, extruders pacha-screw sahihi na bora na mistari ya uzalishaji otomatiki imekuwa njia kuu ya tasnia, kutambua ufuatiliaji wa wakati halisi, automatic parameter adjustment and predictive maintenance of the processing process; fifth, diversification of application fields. Engineering plastics are gradually expanding from traditional automotive, electrical and electronic fields to new energy, matibabu, anga, construction and other emerging fields, opening up new market space.
Kinyume na msingi huu, twin-screw extrusion technology, as the core processing technology of engineering plastic compounds, has become the key to improving the competitiveness of engineering plastics enterprises. Engineering plastics are sensitive to overheating and hydrolytic degradation, and have high requirements on processing temperature, shear force, residence time and temperature control precision. Our HTS series extruders are specially designed for the processing characteristics of engineering plastics, with high torque, high speed, precise temperature control and excellent dispersibility, which can effectively solve the processing difficulties of engineering plastics and help enterprises achieve high-quality, efficient and stable production.
1.2 Core Performance Characteristics of Engineering Plastics
Compared with general plastics and metal materials, engineering plastics have unique comprehensive performance, which determines their wide application in various industrial fields. The core performance characteristics of engineering plastics are mainly reflected in the following five aspects, which also put forward special requirements for their processing technology and equipment:
1.2.1 Excellent Heat Resistance and Cold Resistance
Engineering plastics have a wide temperature adaptation range, which can maintain good mechanical properties (nguvu, ukakamavu, ugumu) in both high and low temperature environments. Compared with general plastics, which usually lose their mechanical properties at 80-120℃, most engineering plastics can work stably at 100-250℃, and some special engineering plastics (such as PEEK, PI) can even work at temperatures above 300℃. Wakati huo huo, engineering plastics also have good cold resistance, which can maintain good toughness at low temperatures (below -40℃), and are not easy to brittle fracture. This performance makes engineering plastics suitable for use in harsh temperature environments, such as automotive engine parts (high temperature) and outdoor electrical equipment (low temperature).
The excellent heat resistance of engineering plastics is mainly due to their special molecular structure (such as aromatic rings, heterocyclic rings) and strong intermolecular forces, which makes them not easy to melt and decompose at high temperatures. Hata hivyo, hii pia huleta matatizo fulani katika usindikaji: joto la juu la usindikaji linahitajika ili kuwafanya kuyeyuka na kutengeneza plastiki, na udhibiti sahihi wa halijoto unahitajika ili kuepuka mtengano wa joto.
1.2.2 Ustahimilivu mzuri wa kutu na Uimara
Plastiki za uhandisi zina utulivu bora wa kemikali na upinzani wa kutu, na si rahisi kuharibiwa na asidi, alkali, chumvi, vimumunyisho vya kikaboni na kemikali zingine. Ikilinganishwa na vifaa vya chuma, ambayo ni rahisi kutu na kutu, plastiki za uhandisi zina maisha marefu ya huduma katika mazingira magumu ya kemikali. Kwa mfano, polyamide (PA) plastiki za uhandisi ni sugu kwa vimumunyisho vingi vya kikaboni na asidi dhaifu na alkali; polycarbonate (Kompyuta) plastiki za uhandisi ni sugu kwa kutu na asidi zisizo oxidizing na chumvi; sulfidi ya polyphenylene (PPS) engineering plastics are resistant to corrosion by almost all chemicals except strong oxidizing acids.
Aidha, engineering plastics have good weather resistance and aging resistance, and are not easy to degrade and age under the action of sunlight, rain, oxygen and other environmental factors, which ensures their long-term stable use in outdoor and harsh environments. This performance makes engineering plastics widely used in chemical equipment, outdoor electrical equipment, automotive exterior parts and other fields.
1.2.3 Easy Processing and High Production Efficiency
Ikilinganishwa na vifaa vya chuma, engineering plastics have the advantages of easy processing, simple production process and high production efficiency. Metal materials usually need complex processing procedures such as forging, casting, mashine, which have high energy consumption, low efficiency and high cost; wakati plastiki za uhandisi zinaweza kusindika kwa extrusion, ukingo wa sindano, ukingo wa pigo na njia zingine, ambayo inaweza kutambua uzalishaji wa wingi, kurahisisha mchakato wa uzalishaji, kupunguza matumizi ya nishati na gharama ya uzalishaji. Kwa mfano, mzunguko wa usindikaji wa sehemu ya magari ya uhandisi ya plastiki kwa ukingo wa sindano ni sekunde chache hadi makumi ya sekunde., wakati mzunguko wa usindikaji wa sehemu hiyo ya chuma inaweza kuchukua saa kadhaa hadi siku kadhaa.
Hata hivyo, plastiki za uhandisi pia zina shida fulani za usindikaji: wao ni nyeti kwa overheating na uharibifu wa hidrolitiki, na ni rahisi kuoza ikiwa halijoto ya usindikaji ni ya juu sana au muda wa kukaa ni mrefu sana; wakati huo huo, baadhi ya plastiki za uhandisi (kama vile PA) kuwa na ufyonzaji mwingi wa maji, ambayo huathiri athari ya usindikaji na ubora wa bidhaa. Kwa hiyo, it is necessary to use professional processing equipment and scientific processing techniques to ensure the processing quality.
1.2.4 Excellent Dimensional Stability and Electrical Insulation
Engineering plastics have good dimensional stability, and the shrinkage rate is small (usually 0.3%-1.5%) during processing and use, which can ensure the dimensional accuracy of products and avoid deformation. This performance is particularly important for high-precision parts, such as electrical connectors, automotive precision components, vifaa vya matibabu, nk. The good dimensional stability of engineering plastics is mainly due to their high crystallinity, low water absorption (except for some varieties such as PA) and strong intermolecular forces.
Aidha, most engineering plastics have excellent electrical insulation performance, which can maintain good insulation performance in a wide temperature range and frequency range, na si rahisi kuendesha umeme na arc. Hii inafanya plastiki za uhandisi kutumika sana katika nyanja za umeme na elektroniki, kama vile bodi za waya, mahusiano ya cable, viunganishi, reli, motors na vipengele vingine vya umeme.
1.2.5 Uzito mwepesi na Nguvu Maalum ya Juu, Upinzani Bora wa Kuvaa
Plastiki za uhandisi zina sifa za uzani mwepesi (msongamano ni 1/3-1/5 ya vifaa vya chuma) na nguvu maalum ya juu (nguvu kwa kila kitengo cha uzito ni sawa na au hata juu kuliko ile ya vifaa vya chuma). Kwa mfano, nguvu maalum ya fiber kioo kraftigare polyamide (PA66+GF30) ni ya juu kuliko ile ya chuma cha kawaida cha kaboni, ambayo inaweza kupunguza uzito wa bidhaa kwa ufanisi wakati wa kuhakikisha utendaji wa mitambo. Utendaji huu ni muhimu hasa katika magari, anga na nyanja zingine zinazofuata uzani mwepesi na kuokoa nishati, which can reduce fuel consumption and carbon emissions.
Wakati huo huo, engineering plastics also have outstanding wear resistance and friction resistance, and the friction coefficient is small, which can be used in the production of wear-resistant parts (such as gears, bearings, sliding blocks) without additional lubrication or with less lubrication, reducing the maintenance cost of products. Kwa mfano, polyoxymethylene (POM) engineering plastics have excellent wear resistance and are known as “plastic steel”, which is widely used in the production of automotive gears, electrical components and other wear-resistant parts.
1.3 Common Classification of Engineering Plastics
Engineering plastics can be divided into different types according to their chemical structure, performance level and application field. The common classification methods are as follows, which helps to better understand the processing characteristics and application scenarios of different engineering plastics, and select appropriate extrusion equipment and processing techniques:
1.3.1 Classification by Performance Level
According to the performance level, engineering plastics can be divided into general engineering plastics and special engineering plastics.
- General Engineering Plastics: They are the most widely used engineering plastics, with relatively mature production technology, moderate price and good comprehensive performance. The main varieties include polyamide (PA), polycarbonate (Kompyuta), polyoxymethylene (POM), terephthalate ya polyethilini (PET), polybutylene terephthalate (PBT), nk. General engineering plastics are mainly used in automotive, umeme na elektroniki, home appliances and other fields, such as automotive parts, electrical connectors, makombora ya vifaa vya nyumbani, nk.
- Special Engineering Plastics: They have more excellent performance (such as higher heat resistance, upinzani wa kutu, mechanical properties) than general engineering plastics, but the production technology is complex and the price is high. The main varieties include polyphenylene sulfide (PPS), polyether ether ketone (PEEK), polyimide (PI), polysulfone (PSU), polyethersulfone (PES), nk. Special engineering plastics are mainly used in high-end fields such as aerospace, vifaa vya matibabu, new energy, and chemical equipment, such as aerospace components, medical implants, high-temperature resistant electrical components, nk.
1.3.2 Classification by Chemical Structure
According to the chemical structure of the molecular chain, engineering plastics can be divided into polyamide (PA), polycarbonate (Kompyuta), polyoxymethylene (POM), polyester (PET, PBT), sulfidi ya polyphenylene (PPS), polyether ether ketone (PEEK), nk. Each type of engineering plastic has its own unique performance characteristics and processing requirements:
- Polyamide (PA): Also known as nylon, it has excellent mechanical strength, wear resistance, toughness and chemical resistance, but has high water absorption, which affects the dimensional stability. Aina za kawaida ni pamoja na PA6, PA66, PA11, PA12, nk. Inatumika sana katika sehemu za magari (gia, bearings, ulaji mwingi), electrical connectors, nyuzi za nguo, nk.
- Polycarbonate (Kompyuta): Ina uwazi bora, nguvu ya athari, upinzani wa joto na insulation ya umeme, lakini ina upinzani duni wa kuvaa na ni rahisi kukwaruza. Inatumika sana katika nyanja za umeme na elektroniki (bodi za wiring, vifuniko vya taa), mashamba ya magari (lensi za taa, paneli za vyombo), nyanja za matibabu (vyombo vya matibabu), nk.
- Polyoxymethylene (POM): Ina upinzani bora wa kuvaa, upinzani wa msuguano, utulivu wa dimensional na nguvu za mitambo, na si rahisi kunyonya maji. Inajulikana kama “plastic steel” na hutumika sana katika sehemu za magari (gia, sliding blocks), vipengele vya umeme (swichi, bearings), sehemu za mitambo, nk.
- Polyester (PET, PBT): PET ina uwazi bora, upinzani wa joto na nguvu za mitambo, na hutumiwa hasa katika nyuzi, filamu, chupa na mashamba mengine; PBT ina upinzani bora wa kemikali, insulation ya umeme na fluidity usindikaji, na hutumika sana katika nyanja za umeme na elektroniki (viunganishi, reli), sehemu za magari, nk.
- Sulfidi ya polyphenylene (PPS): Ina upinzani bora wa joto (joto la matumizi ya muda mrefu hadi 200-220 ℃), upinzani wa kutu, upungufu wa moto na insulation ya umeme, lakini ina ugumu duni. Inatumika sana katika vipengele vya umeme vinavyostahimili joto la juu, sehemu za injini ya magari, vifaa vya kemikali, nk.
- Polyether Ether Ketone (PEEK): Ina utendaji bora wa kina, joto la matumizi ya muda mrefu hadi 250-300 ℃, upinzani mzuri wa kutu, nguvu ya mitambo na utangamano wa kibayolojia. Inatumika sana katika nyanja za hali ya juu kama vile anga, medical implants, na vipengele vya umeme vinavyohimili joto la juu.
1.3.3 Uainishaji kwa Sehemu ya Maombi
Kulingana na uwanja wa maombi, plastiki za uhandisi zinaweza kugawanywa katika plastiki za uhandisi za daraja la magari, plastiki za uhandisi wa daraja la umeme, plastiki za uhandisi za daraja la matibabu, plastiki za uhandisi za kiwango cha anga, nk. Different application fields have different requirements on the performance of engineering plastics. Kwa mfano, automotive-grade engineering plastics require good heat resistance, impact strength and weather resistance; electrical-grade engineering plastics require good electrical insulation and flame retardancy; medical-grade engineering plastics require good biocompatibility and sterility; aerospace-grade engineering plastics require good high-temperature resistance, low weight and high strength.
2. Core Processing Technology of Engineering Plastics: Twin-Screw Extrusion Technology
Engineering plastics processing mainly includes extrusion, ukingo wa sindano, ukingo wa pigo, molding and other methods, among which twin-screw extrusion technology is the core technology for the production of engineering plastic compounds (such as modified engineering plastics, reinforced engineering plastics) and semi-finished products (such as pipes, karatasi, fibers). Compared with single-screw extrusion technology, twin-screw extrusion technology has the advantages of strong shearing force, good mixing effect, precise temperature control, short residence time and strong adaptability to raw materials, which can effectively solve the processing difficulties of engineering plastics (such as sensitivity to overheating and hydrolytic degradation, poor mixing effect, low processing efficiency) and ensure the quality of engineering plastic products.
2.1 Processing Difficulties of Engineering Plastics and Requirements for Extrusion Equipment
As mentioned earlier, engineering plastics have excellent comprehensive performance, but their processing difficulty is also higher than that of general plastics, mainly due to their special molecular structure and performance characteristics. The main processing difficulties of engineering plastics and the corresponding requirements for extrusion equipment are as follows:
2.1.1 Sensitivity to Overheating and Hydrolytic Degradation
Most engineering plastics (kama vile PA, PBT, PPS) are sensitive to overheating and hydrolytic degradation. If the processing temperature is too high or the residence time in the extruder is too long, the molecular chain of the engineering plastic will break, resulting in thermal decomposition, which will reduce the mechanical properties, heat resistance and other performance of the product, and even cause discoloration, carbonization and other defects. Aidha, baadhi ya plastiki za uhandisi (kama vile PA) kuwa na ufyonzaji mwingi wa maji, and the moisture in the material will cause hydrolytic degradation during the high-temperature processing process, affecting the product quality.
This puts forward two key requirements for extrusion equipment: kwanza, uwezo sahihi wa kudhibiti joto, ambayo inaweza kudhibiti kwa ukali joto la usindikaji ndani ya safu bora ya plastiki ya uhandisi, kuepuka overheating mitaa, na usahihi wa udhibiti wa halijoto unapaswa kufikia ±1℃; pili, muda mfupi wa makazi, ambayo inaweza kupunguza muda ambao nyenzo hukaa kwenye pipa la extruder, kuepuka mtengano wa joto na uharibifu wa hidrolitiki. Extruders Twin-screw ina faida za muda mfupi wa makazi (usually 1-5 dakika) na udhibiti sahihi wa joto, ambayo yanafaa zaidi kwa usindikaji wa plastiki ya uhandisi kuliko extruders ya screw moja (muda wa kuishi 5-10 dakika).
2.1.2 Mahitaji ya Juu juu ya Mchanganyiko na Athari ya Kusambaza
Katika usindikaji wa plastiki ya uhandisi, mara nyingi ni muhimu kuongeza marekebisho (kama vile nyuzi za glasi, fiber kaboni, ulanga, wazuia moto, viwianishi) ili kuboresha utendaji wa bidhaa (kama vile kuimarisha, kukaza, kizuia moto). Kwa mfano, adding glass fiber to PA can improve its strength and dimensional stability; adding flame retardants to PBT can improve its flame retardancy. The uniform mixing and dispersion of modifiers in the engineering plastic matrix is crucial to the performance of the final product. If the mixing and dispersing effect is poor, the modifiers will agglomerate, resulting in uneven performance of the product, and even reduce the mechanical properties of the product.
This requires the extrusion equipment to have strong shearing force and mixing capacity. Twin-screw extruders adopt intermeshing co-rotating or counter-rotating twin-screw structure, and the relative movement between the screws can generate strong shear force and kneading force, which can fully break the agglomerates of modifiers, fanya virekebishaji kutawanywa kwa usawa katika matrix ya plastiki ya uhandisi, na hakikisha athari ya kuchanganya na kutawanya. Aidha, muundo wa msimu wa screw-pacha unaweza kuchanganya kwa uhuru vipengele tofauti vya screw (kama vile kusambaza vipengele, kuchanganya vipengele, vipengele vya kunyoa) kulingana na aina ya uhandisi plastiki na modifier, kuboresha zaidi athari ya kuchanganya na kutawanya.
2.1.3 Mahitaji ya Juu juu ya Upinzani wa Uvaaji wa Kifaa
Katika usindikaji wa plastiki za uhandisi zilizoimarishwa (kama vile nyuzi za glasi iliyoimarishwa PA, fiber kaboni iliyoimarishwa PPS), fiber ya kioo iliyoongezwa, fiber kaboni na modifiers nyingine zina ugumu wa juu, ambayo itasababisha uchakavu mkubwa kwa screw na pipa ya extruder wakati wa mchakato wa extrusion. Ikiwa screw na pipa vina upinzani duni wa kuvaa, zitavaliwa haraka, kusababisha kupunguzwa kwa nguvu ya kukata manyoya na uwezo wa kuchanganya wa extruder, kuathiri ubora wa bidhaa na kupunguza maisha ya huduma ya vifaa.
Hili linahitaji skrubu na pipa la extruder litengenezwe kwa nyenzo za hali ya juu zinazostahimili kuvaa na kuchakatwa na teknolojia ya hali ya juu ya utengenezaji.. Vyombo vyetu vya kutolea nje vya mfululizo wa HTS hupitisha chuma cha aloi kinachostahimili uchakavu kutoka nje kwa skrubu na pipa, na upate matibabu ya mchanganyiko wa bimetallic au matibabu ya kufunika kwa laser, ambayo inaboresha sana upinzani wa kuvaa na upinzani wa kutu wa screw na pipa, na inaweza kukabiliana na usindikaji wa plastiki za uhandisi zilizoimarishwa na marekebisho ya ugumu wa juu.
2.1.4 Mahitaji ya Juu juu ya Usindikaji wa Umeme na Udhibiti wa Shinikizo
Baadhi ya plastiki za uhandisi (kama vile PPS, PEEK) kuwa na mnato wa juu na unyevu duni wa usindikaji, which require the extruder to have strong conveying capacity and pressure control capacity to ensure the smooth progress of extrusion. If the conveying capacity is insufficient or the pressure control is unstable, it will cause uneven extrusion speed, unstable product size, and even equipment blockage.
Twin-screw extruders have strong conveying capacity and stable pressure control capacity. The intermeshing of the twin screws can generate strong pumping force, which can effectively convey high-viscosity engineering plastic materials; wakati huo huo, the extruder is equipped with a high-precision pressure sensor, which can monitor the extrusion pressure in real time and adjust the screw speed and feeding speed automatically to ensure the stability of the extrusion pressure and the smooth progress of processing.
2.2 Working Principle and Process Flow of Engineering Plastics Twin-Screw Extrusion
The twin-screw extrusion process of engineering plastics is a complex physical and chemical process, ambayo inahusisha mwingiliano wa mambo mbalimbali kama vile joto, shinikizo, shear nguvu na wakati. The core purpose is to melt and plasticize the engineering plastic raw materials and modifiers, mix them uniformly, and then extrude them into the required shape (such as particles, mabomba, karatasi, fibers) through the die head. Kanuni maalum ya kazi na mtiririko wa mchakato ni kama ifuatavyo:
2.2.1 Raw Material Pretreatment
Raw material pretreatment is the foundation of engineering plastics extrusion processing, which directly affects the processing effect and product quality. The raw materials of engineering plastics mainly include engineering plastic resin (kama vile PA, Kompyuta, POM), modifiers (kama vile nyuzi za glasi, fiber kaboni, ulanga, wazuia moto), viwianishi, lubricants and other additives. The pretreatment steps are as follows:
- Drying Treatment: Most engineering plastics (kama vile PA, PBT, PPS) kuwa na ufyonzaji mwingi wa maji, and the moisture in the raw materials will cause hydrolytic degradation during high-temperature processing, resulting in product defects (such as bubbles, cracks, reduced mechanical properties). Kwa hiyo, the raw materials must be dried before processing. The drying temperature and time are determined according to the type of engineering plastic: kwa mfano, PA6 is dried at 80-100℃ for 4-6 masaa, PA66 is dried at 100-120℃ for 6-8 masaa, PBT is dried at 120-140℃ for 2-4 masaa, PPS is dried at 150-160℃ for 3-5 masaa. The moisture content of the dried raw materials should be controlled below 0.1%-0.2%.
- Premixing Treatment: Kulingana na uwiano wa formula, the dried engineering plastic resin, modifiers and additives are put into a high-speed mixer for premixing. The purpose of premixing is to make the modifiers and additives uniformly adhere to the surface of the resin particles, improve the mixing effect during extrusion, and avoid local agglomeration of modifiers. Kasi ya kuchanganya ni kwa ujumla 800-1200 rpm, na wakati wa kuchanganya ni 5-10 dakika. For some modifiers with poor compatibility (such as glass fiber and PA), a compatibilizer should be added during premixing to improve the compatibility between the modifier and the resin.
- Crushing and Sieving: For engineering plastic resins with large particle size or modifiers with uneven particle size (kama vile nyuzi za glasi), crushing and sieving treatment should be carried out to ensure the uniformity of raw materials and avoid affecting the mixing and dispersing effect during extrusion. The particle size of the crushed raw materials should be controlled at 20-40 matundu.
2.2.2 Feeding and Conveying
The premixed raw materials are sent to the feeding hopper of the twin-screw extruder through a screw feeder or a belt feeder. Kifaa cha kulisha cha extruder kawaida huwa na kazi ya udhibiti wa kasi ya ubadilishaji wa mzunguko, ambayo inaweza kurekebisha kasi ya kulisha kulingana na kasi ya screw na kasi ya extrusion ili kuhakikisha kuwa vifaa vinaingia kwenye cavity ya extrusion kwa utulivu na kwa usawa., kuepuka mrundikano wa nyenzo au ulishaji wa kutosha. Hopper ya kulisha pia ina kifaa cha kukausha ili kuzuia malighafi kunyonya unyevu tena wakati wa kulisha..
2.2.3 Kuyeyuka, Kuchanganya na Kunyoa
Nyenzo zinazoingia kwenye cavity ya extrusion ya extruder-screw-pacha zinasukumwa mbele kwa mfululizo na skrubu zinazozunguka.. Cavity ya extrusion inaundwa na screw na pipa, na kiasi cha cavity extrusion hatua kwa hatua hupungua pamoja na mwelekeo wa mhimili. Wakati screws mzunguko, vifaa vinasisitizwa hatua kwa hatua chini ya hatua ya screws na pipa, na shinikizo katika cavity extrusion hatua kwa hatua huongezeka (kwa ujumla 5-15MPa).
Wakati huo huo, nyenzo zinakabiliwa na nguvu kali ya kukata na nguvu ya msuguano inayotokana na harakati za jamaa kati ya screws na pipa., na vile vile kati ya ndege za screw. Nguvu ya kufyeka na nguvu ya msuguano inaweza kuvunja kikamilifu miunganisho ya virekebishaji, kufanya modifiers enhetligt kutawanywa katika uhandisi melted plastiki resin, na kukuza muunganisho na utangamano kati ya kirekebishaji na resini. Nguvu ya msuguano inaweza pia kutoa kiasi fulani cha joto, ambayo ni pamoja na inapokanzwa nje ya pipa (inapokanzwa umeme au inapokanzwa mvuke) kufanya uhandisi plastiki resin hatua kwa hatua kuyeyuka na plastiki.
Pipa ya extruder kawaida imegawanywa katika 4-6 sehemu za udhibiti wa joto (sehemu ya kulisha, sehemu ya kuyeyuka, sehemu ya kuchanganya, sehemu ya homogenizing, sehemu ya kichwa cha kufa), na hali ya joto ya kila sehemu inadhibitiwa kwa usahihi kulingana na aina ya plastiki ya uhandisi. Kwa mfano, wakati wa kuchakata PA66+GF30 (kioo fiber iliyoimarishwa PA66), joto la sehemu ya kulisha ni 120-140 ℃, sehemu ya kuyeyuka ni 250-260 ℃, sehemu ya kuchanganya ni 260-270 ℃, sehemu ya homogenizing ni 250-260 ℃, na sehemu ya kichwa cha kufa ni 240-250 ℃. Udhibiti sahihi wa joto unaweza kuhakikisha kwamba resin inayeyuka kikamilifu bila mtengano wa joto, na virekebishaji hutawanywa kwa usawa.
2.2.4 Uchimbaji na Uundaji
Yaliyeyuka kabisa, nyenzo mchanganyiko na kutawanywa ni kusukuma kwa kichwa kufa ya extruder na screws. Kichwa cha kufa kimeundwa kulingana na sura ya bidhaa ya mwisho: kwa ajili ya uzalishaji wa misombo ya plastiki ya uhandisi (chembechembe), kichwa cha kufa kina vifaa vya mashimo mengi ya mviringo (idadi na ukubwa wa mashimo ya kufa hutambuliwa kulingana na ukubwa wa chembe ya granules); kwa ajili ya uzalishaji wa mabomba, karatasi, fibers, kichwa cha kufa kimeundwa kwa maumbo yanayolingana (such as circular die for pipes, flat die for sheets).
The material is extruded from the die head at a high speed to form continuous semi-finished products (such as strips for granules, mabomba, karatasi). Joto la kichwa cha kufa ni chini kidogo kuliko ile ya sehemu ya homogenizing, which can prevent the material from decomposing due to excessive temperature and ensure the shaping effect of the semi-finished products. The extrusion speed is controlled according to the type of engineering plastic and the shape of the product, generally ranging from 0.5-5m/min.
2.2.5 Cooling and Solidification
The extruded semi-finished products are sent to a cooling device for rapid cooling and solidification. The cooling method is determined according to the shape of the product: for strips (granule production), water tank cooling is usually used, and the cooling water temperature is controlled at 20-30℃, na wakati wa baridi ni 2-5 dakika; for pipes and sheets, air cooling or water spray cooling is used, and the cooling speed should be controlled to avoid product deformation due to uneven cooling. Rapid cooling can make the semi-finished products solidify quickly, maintain the shape and size of the products, and improve the mechanical properties of the products.
2.2.6 Cutting and Post-Processing
After cooling and solidification, the semi-finished products are processed into the final product through cutting or other post-processing steps. For the production of engineering plastic compounds (chembechembe), the cooled strips are sent to a granulator for cutting, and the granulator is equipped with a rotary knife, which can cut the strips into granular products with uniform size (ukubwa wa chembe kwa ujumla ni 2-5mm, ambayo inaweza kurekebishwa kulingana na mahitaji ya mteja). For the production of pipes and sheets, the cooled semi-finished products are cut into the required length through a cutting machine; for the production of fibers, the cooled filaments are drawn and wound to form fiber products.
Aidha, the final product also needs to undergo post-processing steps such as screening, inspection and packaging. The screening step is to remove unqualified products (kama kubwa mno, chembe ndogo sana au zilizounganishwa); the inspection step is to detect the performance (such as mechanical strength, upinzani wa joto, usahihi wa dimensional) of the product to ensure that it meets the customer’s requirements; the packaging step is to package the qualified product in a sealed and moisture-proof manner to prevent the product from absorbing moisture and affecting the quality.
2.3 Key Factors Affecting Engineering Plastics Twin-Screw Extrusion Effect
The effect of twin-screw extrusion directly affects the quality and performance of engineering plastic products. There are many factors affecting the extrusion effect, hasa ikiwa ni pamoja na sifa za malighafi, uwiano wa formula, athari ya kuchanganya, vigezo vya extrusion na muundo wa kichwa cha kufa. Mastering these key factors and making scientific adjustments can ensure the stability of the extrusion effect and the consistency of product quality.
2.3.1 Sifa za Malighafi
Aina, ukubwa wa chembe, moisture content and purity of raw materials have a great impact on the extrusion effect. Kwa mfano, the particle size of engineering plastic resin and modifiers should be uniform; if the particle size is uneven, it will lead to uneven melting and mixing of materials. The moisture content of raw materials must be strictly controlled below 0.1%-0.2%; ikiwa unyevu ni wa juu sana, it will cause hydrolytic degradation of the material and bubbles in the product. Usafi wa malighafi pia ni muhimu sana; uchafu katika malighafi (such as metals, stones, vumbi) will not only affect the product quality, lakini pia kuvaa screw na pipa ya extruder, na hata kusababisha kuziba kwa vifaa.
2.3.2 Uwiano wa Mfumo
Uwiano wa formula ya misombo ya plastiki ya uhandisi (uwiano wa resin, modifiers na viungio) ndio ufunguo wa kuamua utendaji wa bidhaa. Aina na kipimo cha virekebishaji vinapaswa kuamuliwa kulingana na mahitaji ya utendaji wa bidhaa. Kwa mfano, kuongeza 20%-40% ya kioo fiber kwa PA inaweza kwa kiasi kikubwa kuboresha nguvu zake na utulivu dimensional, lakini nyuzinyuzi nyingi za glasi zitapunguza ushupavu na usindikaji wa majimaji ya bidhaa. Aina na kipimo cha viongeza pia vinahitaji kuendana kwa njia inayofaa: viwianishi vinaweza kuboresha utangamano kati ya virekebishaji na resini, na kipimo ni kwa ujumla 0.5%-2%; mafuta yanaweza kupunguza msuguano kati ya vifaa na vifaa, kuboresha fluidity usindikaji, na kipimo ni kwa ujumla 0.3%-1%; antioxidants inaweza kuzuia nyenzo kutoka kwa uharibifu wa oxidation ya joto wakati wa usindikaji, na kipimo ni kwa ujumla 0.1%-0.5%.
2.3.3 Athari ya Kuchanganya
Premixing ni msingi wa usindikaji wa extrusion. The uniformity of premixing directly affects the mixing and dispersing effect of modifiers during extrusion. If the premixing is uneven, the modifiers cannot be uniformly adhered to the surface of the resin, resulting in local agglomeration of modifiers, uneven mixing of materials during extrusion, and reduced product performance. To ensure the premixing effect, it is necessary to control the mixing speed, mixing time and mixing temperature: the mixing speed is 800-1200 rpm, the mixing time is 5-10 dakika, and the mixing temperature is controlled at 40-60℃ (appropriate temperature can improve the adhesion of additives and promote uniform mixing).
2.3.4 Extrusion Parameters
Extrusion parameters are the most important factors affecting the extrusion effect, mainly including screw speed, extrusion temperature and extrusion pressure.
- Screw Speed: The screw speed of twin-screw extruders for engineering plastics generally ranges from 100 kwa 1000 rpm. Our HTS series extruders can reach a maximum speed of 1000 rpm. The higher the screw speed, the greater the shear force and friction force received by the materials, the better the mixing and dispersing effect of modifiers, and the higher the production efficiency. Hata hivyo, if the screw speed is too high, the residence time of the materials in the extrusion cavity is too short, resulting in incomplete melting of the resin, insufficient mixing of materials, and uneven product quality; if the screw speed is too low, the shear force and friction force are insufficient, the modifiers cannot be fully dispersed, and the production efficiency is low. Kasi ya screw inapaswa kubadilishwa kulingana na aina ya plastiki ya uhandisi na aina ya kurekebisha: kwa plastiki za uhandisi za juu-mnato (kama vile PPS, PEEK), kasi ya chini ya screw inahitajika ili kuhakikisha kuyeyuka na kuchanganya kutosha; kwa plastiki za uhandisi zilizoimarishwa (kama vile nyuzi za glasi iliyoimarishwa PA), kasi ya skrubu ya juu inahitajika ili kuhakikisha mtawanyiko sawa wa nyuzi za glasi.
- Extrusion Joto: Joto la extrusion ni ufunguo wa kuhakikisha kuyeyuka na plastiki ya plastiki ya uhandisi. Joto la kila sehemu ya pipa na kichwa cha kufa lazima lidhibitiwe kwa usahihi kulingana na aina ya plastiki ya uhandisi.. Joto la sehemu ya kulisha ni ya chini (juu kidogo kuliko joto la kukausha kwa malighafi), ambayo ni hasa kuzuia vifaa kutoka kwa keki na kuhakikisha kulisha laini; the temperature of the melting section is medium, which is mainly to promote the melting and plasticization of the resin; the temperature of the mixing section is higher, which is mainly to enhance the shear and mixing effect, and promote the uniform dispersion of modifiers; the temperature of the homogenizing section is slightly lower than the mixing section, which is mainly to ensure the uniform temperature and viscosity of the materials, and avoid thermal decomposition; the temperature of the die head section is slightly lower than the homogenizing section, which is to ensure the shaping effect of the semi-finished products. The temperature control precision should reach ±1℃ to avoid local overheating and thermal decomposition of the material.
- Extrusion Pressure: shinikizo extrusion ya uhandisi uhandisi screw screw extrusion ujumla ni kati ya 5 hadi 15MPa. Shinikizo katika cavity extrusion ni hasa kuamua na uwiano compression ya screw, ukubwa wa shimo la kufa na kasi ya screw. Juu ya shinikizo la extrusion, bora ya kuchanganya na kutawanya athari ya vifaa, na mnene wa bidhaa. Hata hivyo, ikiwa shinikizo ni kubwa sana, itaongeza matumizi ya nishati na kuvaa kwa vifaa, na hata kusababisha kichwa cha kufa kuzuia; ikiwa shinikizo ni ndogo sana, vifaa haviwezi kusisitizwa kikamilifu na kuchanganywa, bidhaa ni huru, na utendaji si thabiti. Shinikizo la extrusion linapaswa kubadilishwa kulingana na aina ya plastiki ya uhandisi na sura ya bidhaa: kwa vifaa vya juu-mnato na bidhaa zilizo na mashimo madogo ya kufa, a higher extrusion pressure is needed.
2.3.5 Die Head Structure
The die head structure mainly includes the shape, size and number of die holes, which directly affects the shaping effect and quality of the product. For the production of engineering plastic compounds (chembechembe), the die head should be equipped with multiple uniform die holes, and the size of the die holes should be matched with the particle size of the product; for the production of pipes and sheets, the die head should be designed according to the shape and size of the product, and the flow channel of the die head should be smooth to avoid material accumulation and local overheating. The die head should also be equipped with a temperature control device to ensure the uniform temperature of the die head and the stable shaping of the product.
3. Our HTS Series Extruders: Professional Solutions for Engineering Plastics Processing
We have long been engaged in the research, development and production of high-performance twin-screw extruders, and have accumulated rich experience in the field of engineering plastics processing. According to the processing characteristics of engineering plastics (sensitivity to overheating and hydrolytic degradation, high requirements on mixing and dispersing effect, high viscosity) and application needs, we have developed the HTS series twin-screw extruders specially for engineering plastics processing. Our HTS series extruders adopt high-torque gearboxes, with a specific torque of 14Nm/cm³ and a maximum speed of up to 1000rpm, which can obtain higher output, shorter residence time, better dispersibility and more precise temperature control, kikamilifu kukabiliana na mahitaji ya usindikaji wa plastiki mbalimbali za uhandisi.
3.1 Manufaa ya Msingi ya Viongezeo vya Mfululizo wa HTS kwa Usindikaji wa Plastiki za Uhandisi
3.1.1 Torque ya Juu na Kasi ya Juu, Ufanisi wa Juu wa Uzalishaji
Plastiki za uhandisi zina mnato wa juu na unyevu duni wa usindikaji, ambayo yanahitaji extruder kuwa na torque kali na uwezo wa kufikisha. Extruder zetu za mfululizo wa HTS hupitisha visanduku vya gia za torque ya juu vilivyotengenezwa kwa kujitegemea na kutengenezwa nasi (Mfululizo wa HTS PLUS na mfululizo wa HTS SUPER) au kuagizwa kutoka kwa wazalishaji wakuu wa Uropa (HTS BASIC mfululizo), na torque maalum ya 14Nm/cm³, ambayo ni ya juu zaidi kuliko ile ya extruder ya kawaida ya screw pacha (torque ya jumla ni 8-12Nm/cm³). Ubunifu wa torque ya juu huhakikisha kuwa kiboreshaji kinaweza kusambaza vifaa vya plastiki vya uhandisi wa mnato wa hali ya juu, avoid material accumulation and equipment blockage, and improve the stability of the extrusion process.
Wakati huo huo, the HTS series extruders have a high speed design, with a maximum speed of up to 1000rpm. The high speed can generate strong shear force and mixing force, which can fully break the agglomerates of modifiers, make the modifiers uniformly dispersed in the resin matrix, and improve the mixing and dispersing effect. Aidha, the high speed design also greatly improves the production efficiency: compared with ordinary extruders, the production efficiency of HTS series extruders can be increased by 30%-50%, which can meet the large-scale production needs of engineering plastics enterprises.
3.1.2 Short Residence Time, Effectively Avoiding Thermal Degradation
As engineering plastics are sensitive to overheating and hydrolytic degradation, the residence time of materials in the extruder is crucial. Extruder zetu za mfululizo wa HTS hupitisha muundo wa skrubu ulioboreshwa na muundo wa pipa, kwa muda mfupi wa kuishi tu 1-3 dakika, ambayo ni fupi zaidi kuliko ile ya extruder ya kawaida ya screw pacha (5-10 dakika) na extruders single-screw (10-15 dakika). Muda mfupi wa makazi unaweza kupunguza kwa ufanisi muda wa mawasiliano kati ya nyenzo na joto la juu, kuepuka mtengano wa joto na uharibifu wa hidrolitiki wa nyenzo, na kuhakikisha mali ya mitambo na upinzani wa joto wa bidhaa.
Aidha, screw ya HTS mfululizo extruders inachukua muundo wa msimu, na vipengele tofauti vya screw vinaweza kuunganishwa kwa uhuru kulingana na aina ya plastiki ya uhandisi, ambayo inaweza kurekebisha zaidi wakati wa makazi ya nyenzo, kuhakikisha kuwa aina tofauti za plastiki za uhandisi zinaweza kupata wakati mzuri wa makazi wakati wa usindikaji.
3.1.3 Udhibiti Sahihi wa Joto, Utendaji Imara
Watoaji wa mfululizo wa HTS hutumia mfumo wa hali ya juu wa kudhibiti halijoto, ambayo inaweza kutambua udhibiti sahihi wa joto la kila sehemu ya pipa na kichwa cha kufa. Usahihi wa udhibiti wa halijoto unaweza kufikia ±1℃, ambayo inaweza kudhibiti kwa ukali joto la usindikaji ndani ya safu bora ya plastiki ya uhandisi, epuka overheating ya ndani na mtengano wa joto wa nyenzo. Mfumo wa kudhibiti hali ya joto una vifaa vya ufuatiliaji wa wakati halisi na kazi ya kengele: ikiwa halijoto ya sehemu yoyote inazidi masafa yaliyowekwa, mfumo utatoa arifa ya kengele kwa wakati, na hata kurekebisha moja kwa moja nguvu ya joto au kuzima vifaa ikiwa ni lazima, ili kuepuka kushindwa kwa vifaa na matatizo ya ubora wa bidhaa.
Aidha, pipa la watoaji wa safu ya HTS inachukua muundo wa koti ya safu mbili, ambayo inaweza kutambua inapokanzwa haraka na baridi, and improve the response speed of temperature control. The die head is also equipped with an independent temperature control device, which ensures the uniform temperature of the die head and the stable shaping of the product.
3.1.4 Excellent Mixing and Dispersing Effect
The HTS series extruders adopt an intermeshing co-rotating twin-screw structure, with a reasonable screw pitch, lead and compression ratio design. Kuunganisha na kuzungusha skrubu pacha kunaweza kutoa nguvu kali ya kukata manyoya na nguvu ya kukandia, which can fully break the agglomerates of modifiers (kama vile nyuzi za glasi, fiber kaboni, ulanga), make the modifiers uniformly dispersed in the engineering plastic resin matrix, na hakikisha athari ya kuchanganya na kutawanya. The mixing uniformity of the HTS series extruders can reach more than 95%, ambayo ni ya juu zaidi kuliko ile ya extruder ya kawaida ya screw pacha (85%-90%).
The screw of the HTS series extruders adopts a modular design, and different types of screw elements (kama vile kusambaza vipengele, kuchanganya vipengele, vipengele vya kunyoa) can be freely combined according to the type of engineering plastic and modifier. Kwa mfano, when processing reinforced engineering plastics with glass fiber, more shearing elements can be configured to enhance the shearing effect and ensure the uniform dispersion of glass fiber; when processing engineering plastics with high viscosity (kama vile PPS), more mixing elements can be configured to improve the mixing effect and ensure the uniform viscosity of the material.
3.1.5 High Wear Resistance, Long Service Life
Katika usindikaji wa plastiki za uhandisi zilizoimarishwa (kama vile nyuzi za glasi iliyoimarishwa PA, fiber kaboni iliyoimarishwa PPS), the added modifiers have high hardness, which will cause serious wear to the screw and barrel of the extruder. Our HTS series extruders adopt high-quality wear-resistant materials and advanced manufacturing technology to ensure the wear resistance of the core components.
The screw and barrel of the HTS series extruders are made of imported wear-resistant alloy steel (such as 38CrMoAlA), na upate matibabu ya mchanganyiko wa bimetallic au matibabu ya kufunika kwa laser. The surface hardness of the screw and barrel can reach ≥65 HRC (HTS BASIC mfululizo) and ≥70 HRC (Mfululizo wa HTS PLUS na mfululizo wa HTS SUPER), which has extremely strong wear resistance and corrosion resistance, and can effectively resist the wear caused by high-hardness modifiers. This greatly extends the service life of the screw and barrel: the service life of the screw and barrel of the HTS series extruders is 2-3 times that of ordinary extruders, reducing the frequency of component replacement and the maintenance cost of the equipment.
Aidha, we also provide professional wear detection services for the screw and barrel. Our technical team will regularly detect the wear degree of the screw and barrel for customers, issue a detailed wear report, and put forward targeted replacement and maintenance suggestions, ensuring that customers only replace components when necessary, avoiding unnecessary waste.
3.1.6 Wide Application Range, Strong Flexibility
Extruders za mfululizo wa HTS zina anuwai ya utumizi, ambayo inaweza kukabiliana na mahitaji ya usindikaji wa plastiki mbalimbali za uhandisi, ikiwa ni pamoja na plastiki ya uhandisi ya jumla (PA, Kompyuta, POM, PET, PBT) na plastiki maalum za uhandisi (PPS, PEEK, PSU, PES). Extruders pia inaweza kukabiliana na usindikaji wa plastiki mbalimbali za uhandisi zilizobadilishwa, kama vile plastiki za uhandisi zilizoimarishwa (fiber kioo kuimarishwa, fiber kaboni kuimarishwa), plastiki ngumu za uhandisi, plastiki za uhandisi zinazozuia moto, plastiki za uhandisi za antistatic, nk.
Muundo wa kawaida wa mfululizo wa HTS extruders (screw, pipa, kufa kichwa, nk.) hufanya uingizwaji wa vifaa kuwa rahisi zaidi na haraka. Wakati wateja wanahitaji kurekebisha aina ya bidhaa (kama vile kubadilisha kutoka kwa usindikaji wa PA hadi uchakataji wa PPS) au kurekebisha fomula, wanahitaji tu kuchukua nafasi ya vipengele vinavyolingana, bila kubadilisha vifaa vyote, ambayo inapunguza gharama ya mabadiliko ya vifaa na inaboresha kubadilika na kubadilika kwa vifaa. Aidha, extruders ya mfululizo wa HTS pia inaweza kuendana na vifaa tofauti vya msaidizi (kama vile vichanganyaji vya kasi ya juu, vikaushio, vipozea, granulators, mashine za uchunguzi, mashine za ufungaji) kuunda laini kamili ya uzalishaji otomatiki, kutambua uzalishaji unaoendelea kutoka kwa utayarishaji wa malighafi hadi ufungashaji wa bidhaa.
3.1.7 Udhibiti wa Akili, Uendeshaji Rahisi na Matengenezo
Watoaji wa mfululizo wa HTS hupitisha mfumo wa udhibiti wa akili wa PLC na kiolesura cha uendeshaji wa skrini ya kugusa, ambayo ni rahisi na angavu, rahisi kufanya kazi. Mfumo unaweza kuhifadhi seti nyingi za fomula za bidhaa na vigezo vya usindikaji. Wakati wateja wanazalisha aina tofauti za plastiki za uhandisi, wanahitaji tu kuita fomula inayolingana na vigezo, bila kurekebisha mara kwa mara, which saves time and improves production efficiency.
The system is also equipped with a real-time monitoring function, which can monitor the key parameters of the extrusion process (such as temperature, shinikizo, kasi ya screw, feeding speed) in real time, and record the production data (such as output, processing time) for later query and analysis. For the HTS SUPER series extruders, we also provide a cloud control function, which can realize remote parameter adjustment, production data monitoring and predictive maintenance of equipment, realizing intelligent production management.
Aidha, the HTS series extruders adopt a reasonable structural design, which makes the maintenance more convenient. The screw, pipa, die head and other components can be disassembled and assembled quickly, which reduces the maintenance time and labor intensity. Timu yetu ya huduma baada ya mauzo itatoa usakinishaji wa kitaalamu, kuwaagiza na kutoa huduma za mafunzo kwa wateja, kuhakikisha kuwa wateja wanaweza kutumia vifaa vizuri.
3.2 Aina za Bidhaa za Msururu wa HTS na Marekebisho Yake kwa Plastiki za Uhandisi
Ili kukidhi mahitaji mbalimbali ya usindikaji wa makampuni ya biashara ya plastiki ya mizani tofauti na aina za bidhaa, tumezindua aina tatu za bidhaa kuu katika mfululizo wa HTS: HTS BASIC mfululizo, Mfululizo wa HTS PLUS na mfululizo wa HTS SUPER. Kila mfululizo una sifa zake na hali zinazolengwa za urekebishaji, ambayo inaweza kuchaguliwa na wateja kulingana na kiwango chao cha uzalishaji, aina ya bidhaa, bajeti na mambo mengine.
3.2.1 HTS BASIC Series Extruders: Chaguo Inayobadilika na ya Gharama kwa Plastiki za Uhandisi Mkuu
Extruders ya mfululizo wa HTS BASIC ni mfululizo wa bidhaa wa gharama nafuu iliyoundwa kwa ajili ya makampuni ya usindikaji wa plastiki ya uhandisi na mizani ya kati na ndogo ya uzalishaji au kuingia kwa awali katika sekta hiyo.. Msururu huu wa extruder hutumia sanduku za gia za torque ya kati kutoka kwa wazalishaji wakuu wa Uropa, ambayo ina faida za utendaji thabiti, kelele ya chini, ufanisi wa juu na maisha ya huduma ya muda mrefu. Muundo wa torque ya kati (torque maalum 10-12Nm/cm³) inaweza kukidhi mahitaji ya usindikaji wa plastiki nyingi za uhandisi za jumla (kama vile PA6, PA66, POM, PET, PBT) na plastiki za uhandisi zilizoboreshwa za chini hadi za kati (kama vile nyuzi za glasi iliyoimarishwa PA na kiasi cha kujaza ≤30%).
Kwa upande wa muundo wa muundo, vichochezi vya mfululizo wa HTS BASIC hupitisha muundo wa kupokezana kwa screw pacha, na kipenyo cha screw kuanzia 30mm hadi 65mm, na uwiano wa mgandamizo wa 4～8, ambayo inaweza kubadilishwa kulingana na aina ya plastiki ya uhandisi. Pipa limetengenezwa kwa chuma cha aloi kinachostahimili kuvaa na matibabu ya nitridi, na skrubu imetengenezwa kwa aloi ya aloi isiyoweza kuvaa na sugu ya kutu, ambayo ina upinzani mzuri wa kuvaa. Extruder ina vifaa vya kudhibiti PLC na interface ya uendeshaji wa skrini ya kugusa, ambayo inaweza kutambua kulisha moja kwa moja, udhibiti wa joto moja kwa moja, kudhibiti shinikizo moja kwa moja na kukata moja kwa moja, na ni rahisi na rahisi kufanya kazi.
Uwezo wa uzalishaji wa mfululizo wa HTS BASIC extruders ni kati ya 100kg/h hadi 500kg/h., ambayo yanafaa kwa biashara za uhandisi za uhandisi za ukubwa wa kati na ndogo ambazo hutengeneza plastiki za uhandisi wa jumla na plastiki za uhandisi zilizobadilishwa za chini hadi za kati.. Moja ya faida kubwa za mfululizo huu ni kwamba inaweza kutoa chaguo rahisi kupitia mchanganyiko tofauti wa usanidi. Wateja wanaweza kuchagua vipengele tofauti vya screw, kufa vichwa, vifaa vya kulisha, kukausha vifaa na vifaa vya baada ya usindikaji kulingana na aina zao za bidhaa, uwezo wa uzalishaji na bajeti, ili kuunda mstari wa uzalishaji unaofaa kwa mahitaji yao wenyewe. Viboreshaji vya mfululizo wa HTS BASIC vina bei nzuri, ambayo inaweza kusaidia makampuni kupunguza gharama ya awali ya uwekezaji.
3.2.2 HTS PLUS Series Extruders: Chaguo la Utendakazi wa Juu kwa Plastiki za Uhandisi na Bidhaa Zilizobadilishwa
Extruders za mfululizo wa HTS PLUS hupitisha visanduku vya gia za torque ya juu kwa kujitegemea vilivyotengenezwa na kutengenezwa na sisi, na torque maalum ya 14Nm/cm³, ambayo ina torque kali na uwezo wa kubeba mzigo kuliko mfululizo wa HTS BASIC. This series of extruders is mainly designed for the processing of high-performance engineering plastics, high-modified engineering plastics and special engineering plastics (kama vile PPS), which is suitable for medium and large-scale engineering plastics processing enterprises that pursue high performance and high efficiency.
The HTS PLUS series extruders have a screw diameter ranging from 65mm to 110mm, a compression ratio of 5～10, and a screw speed range of 200～800 rpm. The screw and barrel adopt bimetallic composite treatment, which has higher wear resistance and corrosion resistance (surface hardness ≥65 HRC), and can adapt to the processing of reinforced engineering plastics with high filling amount (such as glass fiber reinforced PA with filling amount 30%-50%, fiber kaboni iliyoimarishwa PPS) and high-hardness modifiers. Extruder ina mfumo wa hali ya juu wa kudhibiti hali ya joto na sensor ya shinikizo la usahihi wa juu, ambayo inaweza kutambua udhibiti sahihi wa vigezo vya extrusion na ufuatiliaji wa wakati halisi wa data ya uzalishaji, kuhakikisha utulivu wa mchakato wa extrusion na ubora wa bidhaa.
Uwezo wa uzalishaji wa mfululizo wa HTS PLUS extruders ni kati ya 500kg/h hadi 2000kg/h., ambayo yanafaa kwa uzalishaji mkubwa wa plastiki ya uhandisi ya jumla, high-modified engineering plastics and special engineering plastics (kama vile PPS). Mfululizo huu wa extruders una mchanganyiko bora na athari ya kutawanya, muda mfupi wa makazi na ufanisi mkubwa wa uzalishaji, ambayo inaweza kutatua kwa ufanisi matatizo ya usindikaji wa plastiki ya juu-mnato na ya juu-iliyobadilishwa uhandisi, na kusaidia makampuni kuboresha ubora wa bidhaa na ufanisi wa uzalishaji.
3.2.3 HTS SUPER Series Extruders: Top-End Choice for High-End Engineering Plastics
The HTS SUPER series extruders adopt the latest ultra-high torque transmission device independently developed by us, with a specific torque of 14Nm/cm³ and a maximum speed of up to 1000rpm. Aiming at the high torque and high speed characteristics of this series, the structural design of each key component of the extruder has been completely optimized, which is our highest-end extruder series, representing the advanced level of China’s extruder development. This series of extruders is mainly designed for the processing of high-end special engineering plastics (such as PEEK, PI, PSU, PES) and high-performance modified engineering plastics (such as carbon fiber reinforced PEEK, glass fiber reinforced PI), which is suitable for large-scale high-end engineering plastics processing enterprises that pursue high precision, high performance and intelligence.
Vichujio vya mfululizo wa HTS SUPER vina kipenyo cha skrubu kuanzia 80mm hadi 130mm, uwiano wa mgandamizo wa 6～12, na kasi ya skrubu ya 250 ~ 1000 rpm. Screw na pipa hutumia aloi ya aloi inayostahimili uchakavu kutoka nje na teknolojia ya kufunika leza, ambayo ina upinzani wa juu sana wa kuvaa na upinzani wa kutu (ugumu wa uso ≥70 HRC), na inaweza kukabiliana na usindikaji wa plastiki maalum za uhandisi na upinzani wa joto la juu, viscosity ya juu na modifiers high-ugumu. Extruder ina vifaa vya PLC yenye akili + mfumo wa kudhibiti skrini ya kugusa ya wingu, which can realize remote parameter adjustment, ufuatiliaji wa data za uzalishaji, matengenezo ya utabiri wa vifaa na uchambuzi wa data, realizing intelligent production management.
Uwezo wa uzalishaji wa mfululizo wa HTS SUPER extruders ni kati ya 1000kg/h hadi 3000kg/h., which is suitable for the large-scale production of high-end special engineering plastics and high-performance modified engineering plastics. This series of extruders has the advantages of high precision, strong customization, multi-function and stable performance, which can meet the most stringent processing requirements of high-end engineering plastics. The short residence time (1-2 dakika) and precise temperature control can effectively avoid the thermal decomposition of special engineering plastics, ensuring the excellent performance of the product. Aidha, the HTS SUPER series extruders can also be customized according to the special processing needs of customers, providing personalized solutions.
3.3 Selection Suggestions for Engineering Plastics Extruders
When selecting twin-screw extruders for engineering plastics processing, makampuni ya biashara yanahitaji kuzingatia kikamilifu mahitaji yao ya uzalishaji, aina za bidhaa, kiwango cha usindikaji, bajeti na mambo mengine ili kuhakikisha kwamba vifaa vilivyochaguliwa vinaweza kukidhi mahitaji halisi ya usindikaji na kuleta manufaa ya juu ya kiuchumi. Yafuatayo ni baadhi ya mapendekezo maalum ya uteuzi:
3.3.1 Amua Msururu wa Extruder Kulingana na Aina ya Plastiki za Uhandisi
Aina tofauti za plastiki za uhandisi zina mahitaji tofauti ya usindikaji, ambayo huamua uteuzi wa safu za extruder. Kwa plastiki ya uhandisi ya jumla (PA6, PA66, POM, PET, PBT) na kiwango cha chini cha marekebisho (kiasi cha kujaza ≤30%), mfululizo wa HTS BASIC unatosha kukidhi mahitaji ya usindikaji. Torque yake ya kati na usanidi unaonyumbulika unaweza kusawazisha athari ya usindikaji na gharama, which is very suitable for small and medium-sized enterprises that just start to engage in engineering plastics processing or focus on general-purpose products. For high-modified engineering plastics (kiasi cha kujaza 30%-50%, kama vile nyuzi za glasi iliyoimarishwa PA, carbon fiber reinforced PBT) and special engineering plastics with moderate processing difficulty (kama vile PPS), the HTS PLUS series is the preferred choice. Its high torque of 14Nm/cm³ and excellent mixing and dispersing capacity can effectively solve the problem of uneven dispersion of high-content modifiers, and its wear-resistant screw and barrel can adapt to the wear of hard modifiers, ensuring stable production. For high-end special engineering plastics (PEEK, PI, PSU, PES) and high-performance modified engineering plastics (filling amount ≥50%, such as carbon fiber reinforced PEEK), the HTS SUPER series must be selected. Its ultra-high torque, kasi ya juu ya 1000rpm na muundo wa ufunguo ulioboreshwa kikamilifu unaweza kukabiliana na mnato wa juu, upinzani wa joto la juu na mahitaji kali ya usindikaji wa vifaa vya juu, kuepuka mtengano wa joto na uharibifu wa nyenzo, na kuhakikisha utendaji wa juu wa bidhaa ya mwisho.
3.3.2 Amua Kipenyo cha Parafujo na Uwezo wa Uzalishaji Kulingana na Kiwango cha Uchakataji
Kipenyo cha screw ya extruder pacha-screw huamua moja kwa moja uwezo wa uzalishaji, na makampuni ya biashara yanahitaji kuchagua kipenyo cha skrubu kinachofaa kulingana na kiwango chao cha uzalishaji na mahitaji ya kuagiza. Kwa uzalishaji mdogo (100kg/h – 500kg/h), kama vile ubinafsishaji wa bechi ndogo, utafiti wa bidhaa na maendeleo au maagizo madogo, mfululizo wa HTS BASIC wenye kipenyo cha skrubu cha 30mm – 65mm inafaa; kwa uzalishaji wa kati (500kg/h – 2000kg/h), kama vile uzalishaji mkubwa wa plastiki za uhandisi zilizobadilishwa kwa ujumla, mfululizo wa HTS PLUS wenye kipenyo cha skrubu cha 65mm – 110mm inaweza kukidhi mahitaji; kwa uzalishaji mkubwa (1000kg/h – 3000kg/h), kama vile uzalishaji mkubwa wa plastiki maalum za uhandisi wa hali ya juu au maagizo makubwa kutoka kwa makampuni ya chini ya mkondo, mfululizo wa HTS SUPER wenye kipenyo cha skrubu cha 80mm – 130mm ni chaguo bora. Ikumbukwe kwamba wakati wa kuchagua, makampuni ya biashara haipaswi kufuata kwa upofu uwezo mkubwa wa uzalishaji. Wanapaswa pia kuzingatia mabadiliko ya kiasi cha utaratibu. Ikiwa idadi ya agizo sio thabiti, wanaweza kuchagua vifaa vyenye kasi inayoweza kubadilishwa na uwezo wa uzalishaji unaobadilika (kama vile mfululizo wa HTS BASIC wenye kitendakazi cha udhibiti wa kasi ya ubadilishaji wa masafa) ili kuepuka upotevu wa rasilimali za vifaa na nishati.
3.3.3 Fikiria Mahitaji ya Kurekebisha na Athari ya Mchanganyiko
Ikiwa bidhaa kuu za biashara ni plastiki za uhandisi zilizobadilishwa, athari ya kuchanganya na kutawanya ya extruder ni jambo muhimu kuzingatiwa. Kwa bidhaa zinazohitaji kuongeza aina mbalimbali za kurekebisha (kama vile vizuia moto, viwianishi, mawakala wa kuimarisha) wakati huo huo, ni muhimu kuchagua extruders na utendaji bora wa kuchanganya, kama vile mfululizo wa HTS PLUS na mfululizo wa HTS SUPER wenye vipengee vya skrubu vya kuchanganya. Misururu hii miwili inaweza kuchanganya kwa uhuru vipengele vya kuwasilisha, kuchanganya vipengele na vipengele vya kukata nywele kulingana na aina ya kurekebisha, kurekebisha kiwango cha kuchanganya na wakati wa makazi, na uhakikishe kuwa virekebishaji mbalimbali hutawanywa kwa usawa kwenye matrix ya resin. Kwa mfano, wakati wa kuchakata PBT iliyorekebishwa isiyozuia moto, vipengele zaidi vya kuchanganya vinaweza kusanidiwa ili kuhakikisha mtawanyiko sawa wa vizuia moto, avoid local flame retardancy insufficiency; when processing glass fiber reinforced PA, more shearing elements can be configured to break the agglomeration of glass fiber and improve the bonding force between glass fiber and resin. Aidha, if the enterprise has the demand of multi-variety and small-batch modification, it is recommended to select the extruder with quick replacement of screw elements (such as the modular screw design of HTS series), which can reduce the time of equipment adjustment and improve production efficiency.
3.3.4 Consider the Cost Budget and Comprehensive Benefits
Cost budget is an important factor for enterprises to select equipment, but it is not advisable to pursue low cost blindly. It is necessary to balance the initial purchase cost, later maintenance cost, matumizi ya nishati na ufanisi wa uzalishaji ili kuongeza manufaa ya kina. Mfululizo wa HTS BASIC una gharama ya chini kabisa ya ununuzi, matumizi ya chini ya nishati na matengenezo rahisi, ambayo yanafaa kwa biashara zilizo na bajeti ndogo na kiwango kidogo cha uzalishaji; mfululizo wa HTS PLUS una gharama ya wastani ya ununuzi wa awali, lakini ufanisi wake wa juu wa uzalishaji, maisha marefu ya huduma na athari thabiti ya usindikaji inaweza kupunguza gharama ya matengenezo ya baadaye na kuboresha kiwango cha kufuzu kwa bidhaa, ambayo yanafaa kwa biashara za ukubwa wa kati na kubwa zilizo na bajeti fulani na harakati za utendaji wa juu; mfululizo wa HTS SUPER una gharama ya juu zaidi ya ununuzi, lakini inaweza kusindika bidhaa za hali ya juu zenye thamani ya juu, na udhibiti wake wa busara na maisha marefu ya huduma inaweza kupunguza gharama ya wafanyikazi na gharama ya matengenezo katika kipindi cha baadaye, ambayo yanafaa kwa makampuni makubwa yenye bajeti ya kutosha na kuzingatia soko la juu. Aidha, makampuni ya biashara yanapaswa pia kuzingatia huduma ya baada ya mauzo ya vifaa. Watoa huduma wetu wa mfululizo wa HTS hutoa mfumo kamili wa huduma baada ya mauzo, ikiwa ni pamoja na ufungaji, kuwaagiza, mafunzo ya kiufundi, matengenezo ya mara kwa mara na uingizwaji wa haraka wa vipuri, ambayo inaweza kupunguza hatari ya baadaye ya uendeshaji wa makampuni ya biashara.
3.3.5 Fikiria Utangamano na Vifaa vya Usaidizi
Usindikaji wa extrusion ya screw-mawili ya plastiki ya uhandisi inahitaji kuendana na mfululizo wa vifaa vya msaidizi, kama vile vifaa vya kukausha malighafi, mchanganyiko wa kasi ya juu, baridi zaidi, granulator, mashine ya uchunguzi, mashine ya ufungaji, nk. Wakati wa kuchagua extruder, makampuni ya biashara yanahitaji kuzingatia utangamano kati ya extruder na vifaa vya msaidizi ili kuhakikisha uendeshaji mzuri wa mstari mzima wa uzalishaji.. Extruders zetu za mfululizo wa HTS zinaweza kuendana kikamilifu na vifaa mbalimbali vya kawaida vya usaidizi, na pia inaweza kubinafsishwa kulingana na vifaa vya msaidizi vilivyopo vya biashara ili kuzuia upotezaji unaosababishwa na kutolingana kati ya vifaa vipya na vifaa vya zamani vya msaidizi.. Kwa mfano, ikiwa biashara tayari ina mchanganyiko wa kasi ya juu na uwezo wa kuchanganya wa 500kg, inaweza kuchagua mfululizo wa HTS PLUS extruder yenye uwezo wa kutoa 500kg/h – 800kg/h ili kuendana nayo, kuhakikisha uratibu wa uchanganyaji wa malighafi na uzalishaji wa extrusion.
4. Sehemu za Utumiaji za Plastiki za Uhandisi na Suluhisho za Mfululizo wa HTS zinazolingana
Plastiki za uhandisi, with their excellent comprehensive performance, have been widely used in automotive, umeme na elektroniki, matibabu, anga, kemikali, construction and other fields. Different application fields have different requirements on the performance of engineering plastic products, which also puts forward different requirements on extrusion processing equipment. Chini, we will elaborate on the application characteristics of engineering plastics in major fields and the matching HTS series extruder solutions, providing targeted reference for enterprises in different fields.
4.1 Automotive Field: Nyepesi, High Temperature Resistance and Wear Resistance
With the development of automotive lightweight and energy-saving and emission-reduction, engineering plastics have become an important material for automotive parts, gradually replacing traditional metal materials. Plastiki za uhandisi zinazotumiwa katika uwanja wa magari ni pamoja na PA, POM, Kompyuta, PBT, PPS, nk., ambayo hutumiwa hasa katika sehemu za injini, sehemu za ndani, sehemu za nje na vipengele vya umeme. Mahitaji ya msingi ya usindikaji wa extrusion ni: nyepesi, upinzani wa joto la juu, wear resistance, utulivu wa dimensional na VOC ya chini (misombo ya kikaboni tete), ambayo yanahitaji extruder kuwa na udhibiti sahihi wa joto, bora kuchanganya na kutawanya athari na uwezo imara wa uzalishaji.
Kwa sehemu za ndani za magari (kama vile paneli za vyombo, paneli za mlango, njia za hewa) iliyotengenezwa kwa plastiki ya uhandisi ya jumla (PA6, POM, Aloi ya PC/ABS), viboreshaji vya mfululizo wa HTS BASIC vinaweza kukidhi mahitaji ya usindikaji. Configuration yake rahisi inaweza kurekebisha vigezo vya usindikaji kulingana na mahitaji ya utendaji wa sehemu za ndani, kuhakikisha uso laini na utulivu dimensional ya bidhaa, and its low energy consumption and cost can reduce the production cost of automotive parts. For automotive engine parts (such as intake manifolds, cylinder head covers, oil pans) made of high-temperature resistant and wear-resistant engineering plastics (PA66+GF30, PPS), the HTS PLUS series extruders are more suitable. Its high torque and excellent mixing and dispersing effect can ensure the uniform dispersion of glass fiber, improve the strength and high temperature resistance of the product, and its wear-resistant screw and barrel can adapt to the wear of glass fiber, ensuring long-term stable production. For high-end new energy vehicle parts (such as battery shell, motor insulation parts) made of high-end special engineering plastics (PEEK, PI), the HTS SUPER series extruders are required. Its ultra-high torque, Udhibiti sahihi wa halijoto na muda mfupi wa makazi unaweza kuzuia mtengano wa joto wa nyenzo zinazostahimili joto la juu., hakikisha utendaji wa insulation na upinzani wa kutu wa bidhaa, na kukidhi mahitaji madhubuti ya magari mapya ya nishati kwenye utendaji wa sehemu.
Uchunguzi kifani: Mtengenezaji mkubwa wa vipuri vya magari anayebobea katika visehemu vya betri za gari la nishati alichagua viboreshaji vyetu vya mfululizo wa HTS SUPER (kipenyo cha screw 100mm) kuchakata maganda ya betri ya PEEK yaliyoimarishwa ya nyuzinyuzi kaboni. Nyenzo za PEEK zina viscosity ya juu na upinzani wa joto la juu, na kiasi cha kujaza nyuzi za kaboni hufikia 40%, ambayo ina mahitaji ya juu sana kwenye vifaa vya extrusion. HTS SUPER mfululizo extruders, na torque yao ya juu zaidi ya 14Nm/cm³ na kasi ya juu ya 1000rpm, kuzalisha nguvu kali ya kukata manyoya na nguvu ya kuchanganya, which makes the carbon fiber uniformly dispersed in the PEEK matrix; the precise temperature control system (precision ±1℃) strictly controls the processing temperature at 380-400℃, avoiding thermal decomposition of PEEK; the short residence time (1.5 dakika) effectively reduces the material degradation, ensuring the strength and insulation performance of the battery shell. After using the HTS SUPER series extruders, the production efficiency of the enterprise is increased by 40%, the product qualification rate is increased from 88% kwa 99%, and the production cost is reduced by 15%, which has won high recognition from the enterprise.
4.2 Electrical and Electronic Field: Electrical Insulation, Flame Retardancy and Dimensional Stability
The electrical and electronic field is one of the earliest and most widely used fields of engineering plastics. Plastiki za uhandisi hutumiwa hasa katika viunganisho vya umeme, bodi za wiring, reli, motors, mahusiano ya cable, vifuniko vya taa na vipengele vingine. Mahitaji ya msingi ya usindikaji wa extrusion ni: insulation bora ya umeme, kuchelewa kwa moto, utulivu wa dimensional, upinzani wa kutu na sumu ya chini, ambayo yanahitaji extruder kuwa na udhibiti sahihi wa joto, mchanganyiko mzuri na athari ya kutawanya na uwezo mkali wa kudhibiti ubora.
Kwa vipengele vya jumla vya umeme (kama vile vifungo vya kebo, viunganishi) iliyotengenezwa kwa plastiki ya uhandisi ya jumla (PA6, PBT, Kompyuta), extruders za mfululizo wa HTS BASIC zinafaa. Usanidi wake unaonyumbulika unaweza kuendana na vichwa tofauti vya kufa ili kutoa vipengee vya maumbo na ukubwa tofauti; udhibiti sahihi wa joto huhakikisha utendaji wa insulation ya umeme ya bidhaa, na gharama ya chini inaweza kukidhi mahitaji ya uzalishaji wa wingi wa vipengele vya jumla vya umeme. Kwa vipengele vya umeme vya usahihi wa juu (kama vile relay, windings motor) iliyotengenezwa kwa plastiki za uhandisi zilizorekebishwa zisizo na moto (PBT+GF30+kizuia moto, PA66+kizuia moto), viboreshaji vya mfululizo wa HTS PLUS vinapendelewa. Its high mixing and dispersing effect can ensure the uniform dispersion of flame retardants, avoid local flame retardancy insufficiency, and meet the UL94 V-0 flame retardant standard; the precise dimensional control can ensure the dimensional accuracy of high-precision components, avoiding assembly failure. For high-end electrical components (such as high-temperature resistant connectors, aerospace electrical components) made of special engineering plastics (PPS, PSU, PES), the HTS SUPER series extruders are required. Its ultra-high torque and excellent wear resistance can cope with the high viscosity and high hardness of special engineering plastics, and the precise temperature control and short residence time can ensure the electrical insulation performance and high temperature resistance of the product, meeting the strict requirements of high-end electrical and electronic products.
4.3 Medical Field: Biocompatibility, Sterility and Precision
The medical field has extremely strict requirements on materials, and engineering plastics used in the medical field must have good biocompatibility, sterility, corrosion resistance and dimensional stability, and must not produce toxic and harmful substances. The main engineering plastics used in the medical field include PC, PA, PEEK, PSU, nk., which are mainly used in medical containers, medical catheters, medical implants, surgical instruments and other products. Mahitaji ya msingi ya usindikaji wa extrusion ni: high precision, no pollution, stable performance, which require the extruder to have high cleanliness, precise temperature control and strict quality control capacity.
For general medical products (such as medical containers, ordinary catheters) made of medical-grade general engineering plastics (medical-grade PC, medical-grade PA), the HTS BASIC series extruders with special cleanliness configuration can meet the requirements. We can customize the screw and barrel with high cleanliness, no dead angle design for the HTS BASIC series, avoid material residue and pollution, and match the sterile feeding and packaging system to ensure the sterility of the product. For high-precision medical products (such as precision catheters, medical implants) made of medical-grade special engineering plastics (PEEK ya kiwango cha matibabu, medical-grade PSU), the HTS SUPER series extruders with high-precision configuration are required. Its fully optimized screw structure and precise temperature control can ensure the dimensional accuracy of the product (tolerance ≤±0.01mm), and the clean production environment and no pollution design can meet the biocompatibility requirements of medical products; the cloud control function can realize real-time monitoring and recording of the production process, ambayo ni rahisi kwa ufuatiliaji wa bidhaa za matibabu na hukutana na GMP (Mazoezi Bora ya Utengenezaji) mahitaji ya uwanja wa matibabu.
4.4 Uwanja wa Anga: Upinzani wa Joto la Juu, Uzito wa Chini na Nguvu ya Juu
Sehemu ya anga ina mahitaji ya juu sana juu ya utendaji wa nyenzo, na plastiki za uhandisi zinazotumiwa katika uwanja wa anga lazima ziwe na upinzani bora wa joto la juu, uzito mdogo, nguvu ya juu, upinzani wa kutu na upinzani wa mionzi. Plastiki kuu za uhandisi zinazotumiwa katika uwanja wa anga ni pamoja na PEEK, PI, PSU, PES, nk., ambayo hutumiwa hasa katika vipengele vya anga, sehemu za ndani za ndege, vipengele vya satelaiti na bidhaa nyingine. Mahitaji ya msingi ya usindikaji wa extrusion ni: usahihi wa hali ya juu, upinzani wa joto la juu, stable performance, ambayo yanahitaji extruder kuwa na kiwango cha juu cha torque, kasi na uwezo wa kudhibiti joto.
Due to the extremely strict processing requirements of aerospace-grade engineering plastics, only the HTS SUPER series extruders can meet the demand. Its ultra-high torque transmission device, maximum 1000rpm speed and fully optimized key components can cope with the high viscosity and high temperature resistance of aerospace-grade materials (long-term use temperature up to 300℃); the laser-clad screw and barrel have extremely high wear resistance and corrosion resistance, which can adapt to the processing of high-hardness modifiers (such as carbon fiber, ceramic fiber); the intelligent PLC + cloud touch screen control system can realize precise control of extrusion parameters, and the remote monitoring and predictive maintenance function can ensure the stable operation of equipment in long-term continuous production; the customizable configuration can meet the special processing needs of various aerospace components, ensuring the high performance and high reliability of the product.
4.5 Chemical Field: Corrosion Resistance and Wear Resistance
The chemical field has harsh working environment, and engineering plastics used in the chemical field must have excellent corrosion resistance, wear resistance, high temperature resistance and pressure resistance. The main engineering plastics used in the chemical field include PPS, PEEK, PVDF (polyvinylidene fluoride), nk., which are mainly used in chemical equipment, pipelines, valves, pumps and other products. Mahitaji ya msingi ya usindikaji wa extrusion ni: upinzani wa kutu, wear resistance, stable performance, which require the extruder to have excellent wear resistance and corrosion resistance, and stable pressure control capacity.
For chemical pipelines and valves made of general corrosion-resistant engineering plastics (PPS, PVDF), extruders za mfululizo wa HTS PLUS zinafaa. Screw yake ya bimetallic composite na pipa ina upinzani bora wa kutu na upinzani wa kuvaa, ambayo inaweza kukabiliana na kutu ya vyombo vya habari vya kemikali na kuvaa kwa vifaa; uwezo thabiti wa kudhibiti shinikizo unaweza kuhakikisha unene wa ukuta sare wa mabomba na vali, kuzuia uvujaji unaosababishwa na unene wa ukuta usio sawa. Kwa vifaa vya kemikali vya shinikizo la juu na vifaa vinavyostahimili kutu vilivyotengenezwa kwa plastiki za uhandisi zinazostahimili kutu. (PEEK, PI), the HTS SUPER series extruders are required. Torque yake ya juu sana na uwezo thabiti wa kusafirisha unaweza kukabiliana na mnato wa juu wa nyenzo zinazostahimili kutu., na skrubu ya leza na pipa ina upinzani wa juu sana wa kutu na upinzani wa kuvaa, ambayo inaweza kukidhi mahitaji ya matumizi ya muda mrefu katika mazingira magumu ya kemikali; udhibiti sahihi wa joto unaweza kuzuia mtengano wa joto wa vifaa, kuhakikisha upinzani wa kutu na upinzani wa shinikizo la bidhaa.
5. Matatizo na Suluhu za Kawaida katika Uchakataji wa Uchimbaji wa Parafujo pacha za Uhandisi wa Plastiki
Katika usindikaji halisi wa extrusion ya twin-screw ya plastiki ya uhandisi, kutokana na ushawishi wa malighafi, vigezo vya usindikaji, utendaji wa vifaa na mambo mengine, matatizo mbalimbali hutokea mara nyingi, ambayo huathiri ubora wa bidhaa na ufanisi wa uzalishaji. Chini, tutafanya muhtasari wa shida za kawaida katika usindikaji wa uhandisi wa plastiki, kuchambua sababu zao, na kutoa masuluhisho yanayolingana pamoja na sifa za viboreshaji vya mfululizo wetu wa HTS, kusaidia makampuni ya biashara kutatua matatizo ya usindikaji wa vitendo na kuboresha ufanisi wa uzalishaji.
5.1 Tatizo 1: Mtengano wa Joto na Kubadilika rangi kwa Nyenzo
Dalili: Wakati wa mchakato wa extrusion, nyenzo inaonekana njano, weusi, carbonization na matukio mengine, na bidhaa ya mwisho ina kubadilika rangi, mapovu, nyufa na kasoro nyingine, na sifa za mitambo zimepunguzwa sana. Tatizo hili linasababishwa hasa na unyeti wa plastiki ya uhandisi kwa overheating na uharibifu wa hidrolitiki.
Sababu: 1. Joto la extrusion ni kubwa sana au joto la sehemu fulani ya pipa ni kubwa sana, kusababisha mtengano wa joto wa nyenzo; 2. Wakati wa kukaa kwa nyenzo kwenye extruder ni ndefu sana, kusababisha joto kupita kiasi na mtengano; 3. Malighafi hazikaushwa vizuri, na unyevu katika nyenzo husababisha uharibifu wa hidrolitiki wakati wa usindikaji wa joto la juu; 4. Kasi ya skrubu ni ya chini sana, resulting in insufficient shear force and prolonged residence time; 5. The flow channel of the die head is blocked, resulting in material accumulation and local overheating.
Solutions: 1. Adjust the extrusion temperature according to the type of engineering plastic, strictly control the temperature of each section of the barrel and die head within the optimal range, and use the precise temperature control function of the HTS series extruders (temperature control precision ±1℃) to avoid local overheating; 2. Increase the screw speed appropriately (within the range suitable for the material) to shorten the residence time of the material. The HTS series extruders can reach a maximum speed of 1000rpm, which can effectively shorten the residence time to 1-3 dakika; 3. Strengthen the drying treatment of raw materials, strictly control the moisture content below 0.1%-0.2%, and use the drying device matched with the HTS series extruders to prevent the raw materials from absorbing moisture again during feeding; 4. Check and clean the die head regularly to ensure the smooth flow channel, avoid material accumulation; 5. If the problem persists, adjust the screw element combination, increase the number of conveying elements, and reduce the number of mixing elements to speed up the material conveying and shorten the residence time.
5.2 Tatizo 2: Uneven Dispersion of Modifiers
Dalili: The final product has uneven texture, obvious agglomeration of modifiers (kama vile nyuzi za glasi, fiber kaboni), and the mechanical properties (nguvu, ukakamavu, wear resistance) are uneven, which cannot meet the use requirements. This problem is common in the processing of modified engineering plastics.
Sababu: 1. The premixing effect of raw materials is poor, and the modifiers are not uniformly adhered to the surface of the resin; 2. Kasi ya skrubu ni ya chini sana, resulting in insufficient shear force and kneading force, and the modifiers cannot be fully broken and dispersed; 3. The combination of screw elements is unreasonable, and the number of mixing elements and shearing elements is insufficient; 4. The extrusion temperature is too low, the material is not fully melted, and the modifiers cannot be uniformly dispersed in the resin matrix; 5. The particle size of the modifier is too large or uneven.
Solutions: 1. Optimize the premixing process, increase the mixing speed (800-1200rpm) and mixing time (5-10 dakika), add an appropriate amount of compatibilizer to improve the compatibility between the modifier and the resin, and use a high-speed mixer matched with the HTS series extruders to ensure uniform premixing; 2. Increase the screw speed appropriately, tumia utendaji wa kasi wa juu wa viboreshaji vya mfululizo wa HTS ili kutoa nguvu kali ya kukata manyoya na nguvu ya kukandia., na kuvunja kikamilifu agglomerates ya modifiers; 3. Kurekebisha mchanganyiko wa vipengele vya screw, kuongeza idadi ya vipengele vya kuchanganya na vipengele vya kukata nywele, na utumie muundo wa skrubu wa msimu wa viboreshaji vya safu ya HTS ili kubinafsisha mchanganyiko bora wa skrubu kulingana na aina ya kirekebishaji.; 4. Ongeza kwa usahihi joto la extrusion ili kuhakikisha kuwa nyenzo zimeyeyuka kikamilifu, ambayo inafaa kwa mtawanyiko sawa wa virekebishaji; 5. Ponda na ungo kirekebishaji ili kuhakikisha kwamba ukubwa wa chembe yake ni sare (20-40 matundu) na inakidhi mahitaji ya usindikaji.
5.3 Tatizo 3: Vaa ya Parafujo na Pipa
Dalili: Baada ya muda wa matumizi, uwezo wa extruder wa extruder hupungua, nguvu ya kukata na athari ya kuchanganya hupunguzwa, the product quality is unstable, and even the screw and barrel are stuck. This problem is mainly caused by the wear of high-hardness modifiers (kama vile nyuzi za glasi, fiber kaboni) on the screw and barrel during the processing of reinforced engineering plastics.
Sababu: 1. The screw and barrel are made of materials with poor wear resistance, which cannot resist the wear of high-hardness modifiers; 2. The filling amount of the modifier is too high (≥50%), and the wear is intensified; 3. The particle size of the modifier is too large, which increases the wear on the screw and barrel; 4. The extrusion pressure is too high, which increases the friction between the material and the screw and barrel; 5. The screw and barrel are not maintained regularly, and the material residue accelerates the wear.
Solutions: 1. Select extruders with high wear resistance, such as HTS PLUS series and HTS SUPER series. Their screws and barrels are made of imported wear-resistant alloy steel and undergo bimetallic composite treatment or laser cladding treatment, with surface hardness ≥65 HRC (HTS PLUS) and ≥70 HRC (HTS SUPER), which can effectively resist the wear of high-hardness modifiers; 2. Control the filling amount of the modifier within a reasonable range. If high filling amount is required, select the HTS SUPER series extruders with better wear resistance; 3. Crush and sieve the modifier to reduce its particle size and reduce wear; 4. Adjust the extrusion parameters to control the extrusion pressure within the optimal range (5-15MPa), avoid excessive pressure; 5. Regularly maintain the screw and barrel, clean the material residue in time, na weka mafuta ya kulainisha ipasavyo ili kupunguza msuguano na kupanua maisha ya huduma. Aidha, timu yetu ya kitaalamu ya kiufundi inaweza kutoa huduma za mara kwa mara za kugundua uvaaji kwa skrubu na pipa, and put forward targeted replacement and maintenance suggestions.
5.4 Tatizo 4: Ukubwa wa Bidhaa usio imara na Ubadilishaji wa Dimensional
Dalili: Ukubwa wa bidhaa extruded (kama vile chembechembe, mabomba, karatasi) haina usawa, kiwango cha kupungua kinazidi kiwango (＞1.5%), na bidhaa ina deformation, warpage na matukio mengine, ambayo huathiri mkusanyiko na matumizi ya bidhaa.
Sababu: 1. Joto la extrusion si thabiti, kusababisha kuyeyuka kwa usawa na plastiki ya nyenzo, na shrinkage kutofautiana wakati wa baridi; 2. Kasi ya extrusion si dhabiti, kusababisha kiasi kisicho sawa cha extrusion na saizi isiyo thabiti ya bidhaa; 3. Kasi ya baridi haina usawa, kusababisha mkazo usio sawa wa ndani na nje wa bidhaa, kusababisha deformation; 4. The die head structure is unreasonable, the flow channel is not smooth, and the material flow is uneven; 5. The raw materials have high water absorption, and the moisture causes uneven shrinkage during processing.
Solutions: 1. Use the precise temperature control system of the HTS series extruders to ensure the stability of the extrusion temperature, and avoid temperature fluctuation; 2. Adjust the feeding speed and screw speed to ensure the stability of the extrusion speed, and use the frequency conversion speed regulation function of the HTS series extruders to realize the synchronous adjustment of feeding and extrusion; 3. Optimize the cooling process, ensure uniform cooling speed, adjust the cooling water temperature (20-30℃) and cooling time (2-5 dakika) for strip cooling, and use air cooling or water spray cooling for pipes and sheets to avoid uneven cooling; 4. Check and optimize the die head structure, ensure the smooth flow channel, and adjust the die head temperature to ensure uniform material flow; 5. Strengthen the drying treatment of raw materials, strictly control the moisture content, and reduce the impact of moisture on product shrinkage.
5.5 Tatizo 5: Low Extrusion Efficiency and High Energy Consumption
Dalili: The production capacity of the extruder is lower than the design standard, the energy consumption per unit product is high, and the production cost is increased, which affects the economic benefits of the enterprise.
Sababu: 1. Kasi ya skrubu ni ya chini sana, the conveying capacity is insufficient; 2. The extrusion temperature is too low, the material viscosity is too high, the conveying resistance is increased, and the production capacity is reduced; 3. The combination of screw elements is unreasonable, the conveying efficiency is low; 4. The feeding device is blocked or the feeding speed is insufficient, resulting in insufficient feeding; 5. The screw and barrel are worn, the conveying capacity is reduced, and the energy consumption is increased.
Solutions: 1. Increase the screw speed appropriately (within the range suitable for the material) to improve the conveying capacity and production efficiency. The HTS series extruders can reach a maximum speed of 1000rpm, which can significantly improve production efficiency; 2. Properly increase the extrusion temperature to reduce the material viscosity, reduce the conveying resistance, and improve the conveying efficiency; 3. Kurekebisha mchanganyiko wa vipengele vya screw, increase the number of conveying elements, optimize the screw lead and compression ratio, and improve the conveying efficiency. The modular screw design of the HTS series extruders can realize the quick adjustment of screw elements; 4. Check and clean the feeding device regularly, ensure the smooth feeding, and adjust the feeding speed to match the screw speed, avoid insufficient feeding; 5. Regularly detect the wear degree of the screw and barrel, badala ya vipengele vilivyovaliwa kwa wakati, na kudumisha uwezo wa kuwasilisha wa extruder, kupunguza matumizi ya nishati. Aidha, wapanuaji wa mfululizo wa HTS hupitisha muundo ulioboreshwa wa muundo na injini ya ubora wa juu, ambayo inaweza kupunguza matumizi ya nishati kwa 15%-20% compared with ordinary extruders.
6. Hitimisho na Mwenendo wa Maendeleo ya Baadaye
Plastiki za uhandisi, kama nyenzo muhimu ya utendaji wa juu, wanacheza jukumu muhimu zaidi katika uboreshaji wa viwanda duniani, na teknolojia ya upanuzi wa screw-pacha ni msaada wa msingi kwa usindikaji wa hali ya juu wa plastiki za uhandisi. Utendaji wa vifaa vya extrusion huamua moja kwa moja ubora, ufanisi wa uzalishaji na athari ya matumizi ya bidhaa za plastiki za uhandisi. HTS mfululizo wetu wa extruders pacha-screw, ikiwa ni pamoja na HTS BASIC, HTS PLUS na HTS SUPER, zimeundwa mahsusi kwa sifa za usindikaji wa plastiki za uhandisi (sensitivity to overheating and hydrolytic degradation, high requirements on mixing and dispersing effect, high viscosity), na faida za torque ya juu, high speed, precise temperature control, upinzani bora wa kuvaa, mbalimbali ya maombi na udhibiti wa akili. They can provide targeted processing solutions for different types of engineering plastics and different scales of enterprises, helping enterprises solve processing difficulties, improve product quality and production efficiency, and enhance market competitiveness.
Looking forward to the future, with the continuous upgrading of downstream industries such as automotive lightweight, electrical and electronic intelligence, new energy and medical high-endization, the demand for high-performance, functional and environmentally friendly engineering plastics will continue to grow, which will also put forward higher requirements on twin-screw extrusion technology and equipment. The future development trend of engineering plastics twin-screw extruders will be mainly reflected in four aspects:
Kwanza, intelligence and digitalization. With the development of Industry 4.0, twin-screw extruders will be more integrated with intelligent technologies such as Internet of Things, big data and artificial intelligence. The HTS series extruders will further optimize the cloud control function, realize real-time monitoring, data analysis, predictive maintenance and intelligent adjustment of the entire production process, reduce labor intervention, and improve production efficiency and product consistency. Wakati huo huo, digital simulation technology will be widely used in the design and debugging of extruders, reducing the research and development cycle and debugging time of equipment.
Pili, high performance and high efficiency. The demand for high-end engineering plastics (such as PEEK, PI) will continue to increase, which will promote the continuous upgrading of extruder performance. The future extruders will have higher torque, higher speed and more precise temperature control capacity, and the key components (screw, pipa, gearbox) will be further optimized to improve wear resistance, corrosion resistance and service life. Wakati huo huo, the energy consumption of the equipment will be further reduced, realizing high-efficiency and energy-saving production.
Tatu, customization and diversification. Different application fields and different products have increasingly personalized requirements for extrusion processing. The future extruders will adopt a more flexible modular design, which can quickly replace screw elements, die heads and other components according to customer needs, realizing the processing of multiple varieties and small batches. Wakati huo huo, we will provide more personalized customized solutions according to the special processing needs of customers, meeting the diverse market demands.
Nne, ulinzi wa mazingira na kijani. Pamoja na uimarishaji wa sera za kimataifa za ulinzi wa mazingira, ulinzi wa mazingira utakuwa mwelekeo muhimu wa maendeleo ya vifaa vya extrusion. Extruders ya baadaye itapitisha vifaa vya kirafiki zaidi na michakato ya utengenezaji, kupunguza matumizi ya nishati na utoaji wa hewa chafuzi; wakati huo huo, zitaendana zaidi na plastiki za uhandisi zinazoweza kutumika tena na plastiki za uhandisi zinazoweza kuharibika, kukuza maendeleo ya kijani ya tasnia ya plastiki ya uhandisi.
Daima tutazingatia dhana ya uvumbuzi wa kiteknolojia, kuzingatia mahitaji ya maendeleo ya tasnia ya plastiki ya uhandisi, kuendelea kuwekeza katika utafiti na maendeleo, boresha utendakazi wa viboreshaji vya mfululizo wa HTS, kuboresha huduma baada ya mauzo, na kutoa taaluma zaidi, masuluhisho bora na ya akili ya upanuzi wa screw-pacha kwa biashara za usindikaji wa plastiki za uhandisi wa kimataifa, kusaidia maendeleo ya hali ya juu ya tasnia ya plastiki ya uhandisi.