1、 Precautions for Equipment Installation and Debugging

1. Foundation stability and horizontal calibration
   • flatness of groundEnsure that all modules of the production line (extruders, molds, cooling systems, etc.) are installed on a flat and sturdy surface to avoid vibration causing equipment displacement or loose connections.
   • Shock absorption measuresFor heavy equipment such as large extruders, concrete foundations or shock-absorbing pads are used to reduce operating noise and vibration.
   • Horizontal calibrationAdjust the levelness of the equipment using a spirit level to prevent uneven material flow or mechanical wear caused by tilting.
2. Module connection and sealing inspection
   • Interface alignmentCheck whether the connections of each module (such as flanges and bolts) are aligned to avoid material leakage or pressure loss caused by misalignment.
   • sealing treatmentInstall a sealing ring or sealant at the connection to ensure that there is no air or material leakage.
   • Adjustment of transmission componentsAdjust the tension of the chain and belt to avoid slipping or wear due to looseness or tightness.
3. Electrical System Safety and Debugging
   • voltage matchingCheck whether the rated voltage of the equipment is consistent with the power supply voltage to avoid connecting the wrong circuit and causing the motor to burn out.
   • grounding protectionEnsure that the equipment casing is reliably grounded to prevent electric leakage and shock accidents.
   • parameter calibrationDebug key parameters such as temperature controller and pressure sensor to ensure consistency with process requirements.
   • Safety device testingVerify the sensitivity of protective devices such as emergency stop buttons, safety light curtains, and limit switches.
4. Trial operation verification
   • No-load trial runCheck if each module operates smoothly without any abnormal noise or vibration.
   • Load test runGradually increase production load and monitor whether extrusion pressure, temperature, speed and other parameters are stable.
   • data recordingRecord trial operation data to provide reference for subsequent production.

2、 Operating standards and key points of process control

1. Raw material pretreatment and quality control
   • Drying treatmentAccording to the material characteristics (such as PVC requiring humidity ≤ 0.3%), use a dehumidification dryer to process the raw materials to avoid bubbles or degradation caused by water vapor.
   • uniform mixingUse a high-speed mixer to thoroughly mix the raw materials to prevent uneven plasticization caused by excessive concentration of local additives.
   • Raw Material ScreeningRemove impurities and clumps from the raw materials to prevent blockage of screws or molds.
2. Temperature segmented control
   • Feeding area temperatureMaintain a low temperature (such as 120-150 ℃) to prevent premature melting of raw materials and blockage.
   • Compression zone temperatureGradually raise the temperature to meet the process requirements (such as 160-180 ℃) to ensure that the material is fully plasticized.
   • Temperature in the measurement areaStabilize at the set value (such as 180-200 ℃) and control the extrusion stability.
   • mold temperatureUse a mold temperature machine to control the temperature balance of the mold and prevent product deformation or surface defects.
3. Extrusion speed and traction matching
   • Speed synchronizationAdjust the extruder speed and tractor speed to ensure consistent linear speed and avoid product stretching or stacking.
   • Traction pressureRegularly check the traction roller pressure to prevent slipping or product size deviation caused by insufficient pressure.
   • tension controlMaintain uniform tension during winding to avoid the product being wound too tightly or loosely.
4. Cooling shaping and cutting quality
   • Cooling water tankEnsure that the length of the sink is sufficient and the cooling water temperature is appropriate (usually 20-30 ℃) to prevent product stress cracking.
   • cutting bladeKeep the blade sharp and replace it regularly to prevent burrs or breakage.
   • Cutting accuracyAdjust the cutting machine parameters to ensure that the product length meets the requirements.

3、 Maintenance and preventive measures for faults

1. Daily cleaning and inspection
   • Cleaning of hopperAfter each shift, clean the extruder hopper and screw residue to prevent clumping and blockage.
   • Mold cleaningRegularly disassemble the mold, clean the residual materials in the flow channel, and avoid carbonization affecting product quality.
   • Visual inspectionCheck the appearance of the equipment for any abnormal conditions such as oil leakage or cracks.
2. Regular lubrication and replacement of vulnerable parts
   • Lubrication of transmission componentsRegularly add lubricating oil to bearings, gearboxes, etc. to reduce wear and tear.
   • Chain/belt adjustmentCheck the tension of the chain and belt, adjust or replace them in a timely manner.
   • Replacement of vulnerable parts：
     • Screw/barrelReplace every 1-2 years based on wear and tear to avoid a decrease in extrusion efficiency.
     • heating ringCheck for aging or short circuits, and replace in a timely manner to prevent temperature loss of control.
     • sealing elementReplace worn sealing rings to prevent material or air leakage.
3. Fault warning and data analysis
   • parameter monitoringReal time monitoring of motor current, extrusion pressure and other parameters, and timely shutdown for inspection in case of abnormal fluctuations.
   • data recordingRecord production data (such as output and scrap rate), analyze trends to identify potential issues in advance.
   • Establishment of Fault LibrarySummarize common faults and their solutions, and create a fault library for maintenance personnel to refer to.