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- Overview
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I-Description
This production line fully draws on the advantages of similar equipment at home and abroad, and is a highly advanced prepreg production line designed and manufactured through continuous improvement and improvement in the actual production and manufacturing process. Mainly using Japanese technology, suitable for carbon fiber prepreg. (The total length of the production line is 24 meters)
Features:
1. Yarn spreading method: 4 movements left and right, 1 vibration up and down.
2. Constant tension unwinding, the unwinding part is equipped with a tension sensor, which can control the unwinding with constant tension.
3. The winding is automatically corrected, and the winding part is equipped with an automatic correction device.
4. Touch screen CNC control interface, with separate control console, 10-inch touch screen + PLC operating system, easy to operate and stable performance.
5. The automatic temperature control system is equipped with a temperature recorder, which can monitor the temperature changes of the production line in real time.
6. The roller is equipped with a gap controller, which can accurately control the roller gap, thereby achieving precise control of the quality of the carbon cloth.
II- Raw material parameters
Fiber material: glass fiber and carbon fiber
Release paper: CCK/PEK
(1)Thickness: 100～150 micron, maximum width 1270mm.
(2) The maximum unwinding diameter is φ800, and the maximum load-bearing capacity is 1000KG.
(3) It is a double-sided silicone film paper, which needs to be moisture-proof after being coated with glue.
Protective film: PE film Thickness: 20 - 50 micron
Resin: Epoxy resin: 8,000 - 200,000 cps
The inner diameter of the rewinding and unwinding paper tube is φ76., Max. Uncoiling diameter of release paper is 800mm
2 Equipment parameters
(1)Roller surface width: 1400mm, roller diameter: φ400mm
(2) Fiber cloth width: 500~1000mm
(3) Carbon fiber cloth production speed: 2m-15m/min, can be adjusted through the touch screen operation interface
(4) Hot oil temperature: Max. 120°C, temperature balance plus or minus 0.5°C
(5) Cold water temperature: Min. 8°C
3 Finished product specification
(l) Product specifications: 100g - 800g carbon fiber cloth or matching glass fiber cloth
(2) Product width: Maximum 1270mm
(3) Resin content: 24%-60% ± 3% weight deviation ≤ ±3%)
3 Auxiliary equipment （prepared by buyer）
(1) Power: 380V x 50Hz x 3 Phase
(2) One 2.2kW air compressor, air supply pressure: 0.6MPa, one 0.8 cubic air storage tank
(3) The crane hook should be no less than 3.5 meters above the ground
II Equipment composition
The equipment is divided into yarn rack, lower paper and film rewinding device, upper paper and film rewinding device , combined yarn spreading part, prepreg pressing part, heating, cooling and upper
paper and film rewinding part.
1- Yarn rack, including yarn rack, middle comb frame and yarn support rack
Carbon yarn or glass fiber yarn cones are placed on the creel before pre-impregnation and lamination. The yarn cones are placed symmetrically on the left and right on the creel. They are divided into six layers up and down. There are a total of 15 yarn cone columns in the front and rear. A total of 180 cones of yarn can be preset at the same time. Unwind to produce carbon cloth or fiberglass cloth. A yarn support rod is installed above each layer of yarn cones, and the yarn support rod is made of a φ12 bright shaft. The yarn bundles pass through the yarn supporting rod so that the yarn bundles do not interfere with each other and avoid the yarn bundles from being entangled, pulling each other, twisting and twisting.
The creel is 4 meters long, 2.15 meters high and 1.12 meters wide. The front end is equipped with yarn dividing teeth and creel guide rollers for each layer of yarn cones. The yarn splitting teeth and guide rollers allow each bundle of yarn to enter the combined yarn spreading mechanism without interfering with each other as much as possible.
Before entering the yarn spreading mechanism, the yarn bundle will pass through the middle comb frame and the yarn supporting frame to further regulate the yarn traveling posture and make the yarn bundle concentrate in the middle in the up and down direction.
2- Lower paper film rewinding unit
The resin-coated release paper roll is placed on the lowering paper and film-retracting vehicle using an air expansion shaft. It is divided into main body, track, correction and unwinding vehicle, locking mechanism, etc.
The track allows the car body to be accurately parked in the same position after each loading and unloading. It is mainly a frame with one end open welded by 60x40x4 angle steel and 60x10 flat steel. There is a limiting device at the opening end, and the front wheel of the paper cart slides out of the track. There are four limit buckle seats.
The four corners of the lower side of the main body are equipped with frame wheels to provide support for the body. The frame wheels include wheels and limit rollers. The main function is to facilitate dragging the car out of the working position, unloading the recycled film roll, loading the resin-coated release paper roll, and pushing it back to the working position. A limited wheel frame is installed in the middle of the lower side of the main body, and there are also limited rollers. The rollers of the wheel frame and the limiting wheel frame prevent the paper placing and film collecting vehicle from deviating from the working position.
The correction and unwinding car is placed on the left side of the main car body and is connected to the main car body with a slide rail slider, which can slide and facilitate the correction movement; on the right side is a film rewinding bracket fixed on the car body.
The main car body has a locking mechanism on the side of the correction vehicle. After the car body reaches the working position, the locking mechanism fixes the car body on the track to prevent the car body from moving out of position when the pulling force is too large.
The main body has a set of unwinding fork shaft assembly, a set of deflection correction system, two sets of air expansion shaft seats, two paper guide rollers, and film winding fork shaft assembly, including servo motor, reducer, support and Fork shaft etc. The unwinding fork shaft assembly includes the bracket, fork shaft, magnetic powder brake, transmission gear set, etc.
The associated flattening and bending rollers are installed on the yarn spreading frame.
The tension sensor roller group is installed inside the yarn spreading frame, including a pair of brackets, 3 guide rollers, and 2 tension sensors. Two air-expanding shafts are equipped with a set of air guns and spiral tubes, and are also installed at the front end of the yarn spreading frame.
Drag chains are installed on the sides of the car body to standardize various pipelines in the car body.
3- Upper paper film rewinding unit
The upper paper-laying and film-retracting mechanism is installed on the upper yarn-spreading tray on the upper side of the yarn-spreading mechanism. The equipment included is roughly equivalent to that of the lower paper-laying and film-winding vehicle. One set of unwinding fork shaft assembly, one set of correction system, three sets of air expansion shaft seats, 2 sets of film take-up fork shaft assembly, one set of correction and unwinding truck, tension sensor roller set (including a pair of brackets, 3 guide rollers, 2 tension sensors). Three air-expanding shafts come with a set of air guns and spiral tubes.
Before the upper release paper enters the prepreg pressing roller group, the protective film will be peeled off from the release paper. Two sets of film winding fork shafts are assembled and alternately responsible for the film winding work.
4- Combine yarn spreading part
The combined yarn spreading part is installed on the yarn spreading chassis, including yarn splitter assembly, traction rubber roller assembly, flower roller yarn spreading assembly, large yarn spreading assembly, etc.
-1. Yarn splitter assembly
The yarn bundle first enters the yarn splitter after passing through the creel. The frame consists of 2 wall panels, 1 support and two brackets. The front end of the yarn splitter has a full-diameter shaft combination and a straightening combination. Here, a small amount of twisted yarn bundles are straightened by the two combinations. Towards the back there are yarn splitting comb buckles, initial yarn spreading rollers, etc. The straightening combination includes 2 straightening seat plates, a reduction motor, a transmission shaft, a pair of transmission gear sets, two pairs of slide rails, a cam, a shaking roller, 2 slides, etc.
-2. Traction rubber roller assembly
Use it during initial yarn introduction and debugging, and do not use it at other times. It consists of a pair of rubber rollers, a reduction motor, transmission sprockets and gears, a pressing cylinder, a slide rail slider and a corresponding bracket.
-3. Flower roller yarn spreading assembly
The support system consists of a pair of supporting wall panels and two supports. The working parts include a moving flower roller and two traction flower rollers. The moving flower roller is driven by a servo motor, and the two traction flower rollers are driven by a right-angle reduction motor respectively. The speed can be adjusted at will by the motor driver. There is a baking lamp lining plate on the lower side of the pattern roller, and three 1.5Kw carbon fiber baking lamps are installed to preheat the yarn bundle so that the yarn bundle can unfold.
-4. Dazhan Yarn Assembly
The support system consists of a pair of large support wall panels and three supports. The working parts include 3 yarn splitting guide rollers, two lifting guide rollers, 4 shifting rollers, and 2 yarn shaking rollers arranged alternately. There are two transition rollers behind them to send the neatly arranged yarns to the first Pre-preg laminating roller set.
Both ends of the lifting roller are respectively fixed on the mounting seats at the ends of the screws of two vertically installed synchronous elevators. A synchronous shaft is connected between the two elevators to maintain lifting synchronization. When used, it rises; when not used, it falls.
Each of the moving rollers is driven by a servo motor, and controlled separately to alternately coordinate the movement to spread out and arrange the yarn bundles. Other accessory parts include motor bracket, eccentric shifting H wheel, bearings and graphite copper sleeves, etc.
Yarn shaking roller system: composed of a servo motor, coupling, motor bracket, vibration cam, camshaft, slide rail pair, compression spring, brake clutch combination, bearings, etc.
Two transition roller combination: This is the final adjustment roller combination after yarn unfolding and before prepreg pressing. It consists of fixed bracket, transition roller, bearing, clutch ring, separate shaft fixed ring and corresponding accessories. Both ends of the first transition roller are equipped with separate shaft fixing rings to standardize the edge positions of the gauze on both sides. The clutch ring allows the first transition roller to choose whether to rotate or not.
A paper guide roller is installed on the belly of the dazhan yarn to assist in recycling the protective film.
5- Pre- preg pressing part, which is used for forming fabric with yarn and resin
The process of pre-impregnating synthetic fabrics is mainly completed by six sets of heating rollers. The structures of the four roller groups are basically the same. Only two cooling rollers are added in front of the first roller group, one at the upper part and one at the lower part. When the upper release paper passes through the upper cooling roller, the PE film is peeled off from the release paper and is assembled and recycled by the upper film take-up fork shaft. When the lower release paper passes through the lower cooling roller, the PE film is also peeled off from the release paper and is assembled and recycled by the film winding fork shaft of the paper unwinding car.
The adhesive surface of the upper release paper is downward, and the adhesive surface of the lower release paper is upward. The flat and evenly arranged yarns enter the counter-rotating hot-pressed steel roller combination in the middle to form a cloth.
The main working parts of the roller set are composed of fixed and moving parts. There is a precision gap adjustment system and a gear transmission system in the middle.
The immovable part consists of two vertical plates, a heated steel roller, 4 guide pillars, two power cylinders, two cylinder base plates and three horizontal support rods. The moving part consists of a heated steel roller, two bearing seats, bearings, and two double-force cylinders. When working, the hot steel roller of the dynamic group is squeezed downward by the guide pillar driven by the multi-power cylinder.
The outer diameter of the heating roller is φ400mm, and the roller surface width is 1200mm. The cylinder bore diameter is 160, and each roller set is equipped with a 1.5Kw Xinjie servo motor and matching reducer to provide power. The gear transmission system is uniquely designed. Even when the moving group and the fixed group are separated, power can be transmitted to maintain rotation, making it easier for the roller group to be scrubbed and cleaned.
The precision gap adjustment system is also divided into a moving group and a fixed group. The fixed group is installed on the top of the vertical plate of the fixed part of the roller group, and consists of a lower fixed guide rail, a needle bearing, an adjusting slider, an adjusting screw, a gear, a connecting plate, a servo motor and a reducer. The moving group is installed at the lower part of both sides of the moving part of the roller group, and is composed of special fixed inclined iron, needle roller bearings and corresponding holding mechanisms. The servo motor rotates the adjustment screw and pulls the adjustment slider to move, causing misalignment with the fixed inclined iron of the fixed group to accurately adjust the height. During operation, the moving part of the roller assembly is tightly pressed against the adjustment slider to ensure that the gap between the two hot steel rollers remains unchanged and to accurately control the thickness of the product.
The two hot steel rollers are heated by the hot oil of the mold temperature machine, and the temperature can be adjusted at will according to requirements. The precision gap adjustment system can be adjusted on the operation panel of the roller set.
There is a light box between the first roller group and the heating plate support to facilitate observation of the yarn spreading effect.
6- Heating
The initially pressed gauze must be further stably heated to increase the activity of the viscose resin and better bond with the gauze. Two heating plates are installed between the first roller set and the second roller set. The heating power of each heating plate is 3Kw, and it is installed in parallel with a support frame. The heating plate is composed of aluminum plate, electric heating plate, pt100 temperature sensor and insulation material.
7- Cooling
The initially pressed gauze is heated stably, and the activity of the adhesive resin is further improved. After being pressed and formed by the three roller groups, the upper layer of clutch paper needs to be recycled. The lower release paper can be replaced as needed, so that the molded carbon cloth or fiberglass cloth can be better separated in future use. The finished cloth needs to be cooled by cooling plates.
A support frame installs two cooling plates in parallel behind the fourth roller set. Each cooling plate is 55mm thick, 900mm long, and 1260mm wide. It is divided into three layers - a lower steel plate, a middle water channel plate, and an upper aluminum plate. The water channel board is processed as a whole without splicing to better ensure no leakage. The lower steel plate and the water channel plate are welded and sealed to form a water channel groove, and the water cooled by the chiller flows in the water channel in a closed manner.
There is a cooling roller behind the two cooling plates to further cool the upper release paper, reduce the resin viscosity, and make the upper release paper easier to peel off.
8- Upper paper winding and unwinding film
The upper paper and film release system is installed on the upper tray of the rear frame, including one set of film take-up fork shaft assembly, two sets of film release fork shaft assembly, 3 sets of three sets of air expansion shaft seats, 2 paper guide rollers, a Flatten the bent roll. The flattening and bending rollers are installed on the cylinder base plate of the fifth roller group.
The film release fork shaft assembly consists of a bracket, a fork shaft, and a 25N.m magnetic powder brake. Three air expansion shafts with air gun and a set of spiral tubes
9- Lower paper changing system
The lower paper changing system mainly consists of a paper changing car, an unwinding tension sensor guide roller group, a rewinding guide roller group, etc.
The paper changing car is divided into car body, track, locking mechanism, etc.
The track is the same as that of the paper putting and film collecting car. The installation of the wheels and limiting rollers on the lower side of the car body is the same as that of the paper placing and film collecting vehicle.
There is no correction and unwinding car on the car body, but two sets of air-expanding axle seats are installed side by side. One set is equipped with the unwinding fork shaft assembly, and the other set is equipped with the rewinding fork shaft assembly. The locking mechanism is the same as that of the paper unloading and film collecting car.
The car body has a set of unwinding fork shaft assembly, two sets of air expansion shaft seats, and a film retracting fork shaft assembly, including servo motor, reducer, support and fork shaft, etc. The unwinding fork shaft assembly includes the bracket, fork shaft, magnetic powder brake, transmission gear set, etc.
The system's tension sensor guide roller group is installed at the front end of the rear frame, including a pair of brackets, 2 guide rollers, and 2 tension sensors. The winding paper guide roller group of the system is installed on the cooling plate support frame.
Two air-expanding shafts are equipped with an air gun and a set of spiral tubes, which are installed at the front end of the rear frame. Drag chains are installed on the sides of the car body to standardize and protect various pipelines in the car body.
10- Rewinding
Including laminating and paper changing, paper edge cutting, meter counting, winding and other technological processes. The equipment includes the fifth roller group, pneumatic paper cutting roller knife, paper cutting edge roller, paper edge winding mechanism, sixth roller group, rear light box, rear guide roller, cloth collecting machine, etc.
The upper pressure roller of the fifth roller group is still a hot steel roller, and the lower roller is a silicone rubber roller. The down pressure cylinder is a single output cylinder with a bore diameter of 160. The flattening and bending roller of the film placing system is installed on the top. The rear part is equipped with a pneumatic paper cutting roller knife and a paper cutting edge roller. The thicker frame in the middle of the fifth roller group and the sixth roller group is equipped with a paper edge winding mechanism at the bottom. The paper edge winding mechanism has a soft connection between the output shaft and the motor, which will not tear the paper edge.
The sixth roller group does not have hot-pressed steel rods. The upper and lower rollers are nitrile rubber rollers. The lower pressure cylinder is a single-output cylinder with a bore of 160. A rear light box, guide rail, meter counting wheel, meter counting display, etc. are installed behind the roller group.
The collecting machine is the final step in the production of carbon cloth or fiberglass cloth. There are two sets of collecting cantilevers. The center of the cantilever is the main shaft, and the outer layer is the sleeve and the cloth tube support bar. There is a cylinder at the inner end of the main shaft to tighten the support bar through the tie rod, supporting the paper tube to rotate and collect the cloth. Powering the rotation of the two spindles is a 3.7Kw torque motor and a reducer. The torque is transmitted to the transmission shaft through the chain. Electromagnetic clutches are installed on both sides of the transmission shaft. The electromagnetic clutches are controlled together to realize the free switching of power between the two collecting cantilevers.
The front PE film is on top, the bare fabric is in the middle, and the release paper is on the bottom before entering the fifth roller group. Since the upper roller is a hot steel roller, the PE film and the lower release paper can be better bonded together. The sixth roller group no longer heats the carbon cloth, but only further compresses and provides traction for the movement of the carbon cloth. When the operator completes the slitting and winding work of the cloth, the entire carbon cloth production process is completed.
III Technical data
| No. | Technical | Data |
| 1 | Gluing line speed (m/min) | 2～15m/min |
| 2 | Effective width (mm) | 1270mm |
| 3 | Resin viscosity (cps) | 8,000～200,000cps |
| 4 | Product specifications | 100g - 800g carbon fiber cloth |
| 5 | Resin content | 24%-60%±3% |
| 6 | Paper tube inner diameter | φ76mm |
| 7 | Maximum unwinding diameter | 800mm |
| 8 | Hot steel roller | 13 sticks |
| 9 | Heating medium | Hot oil |
| 10 | Roller surface temperature uniformity (°C) | ±1°C |
| 11 | Maximum heating temperature (°C) | 180°C |
| 12 | Number of hot press roller sets | 10 |
| 13 | Rubber roller | 3 pieces (1 silicone rubber, 2 nitrile rubber) |
| 14 | Roller diameter | 346mm |
| 15 | Paired steel roller diameter difference | 0.001mm |
| 16 | Roller runout tolerance | ±0.002mm |
| 17 | Maximum number of packages loaded on creel | 360 |
| 18 | Guide roller surface treatment | Surface hard oxidation anodizing treatment |
| 19 | Servo motor brand | Xinjie |
| 20 | Power supply requirements | AC380V±5% 50HZ three-phase four-wire system (with neutral wire) |
| 21 | Compressed air requirements | 0.6MPa |
| 22 | Circulating water volume | 2.4m³/h |
| 23 | Circulating water power | 0.75kW |
| 24 | Total heating power | 33kW |
| 25 | Tension control form | Magnetic particle braking |
| 26 | Tension detection range (kg) | 5~50kg |
| 27 | Number of correction systems | 2 places |
| 28 | Correction accuracy | ±1mm |
| 29 | Number of yarn guide rollers | 3 pcs |
| 30 | Number of shifting rollers | 4 pcs |
| 31 | Shaker roller quantity | 1 pcs |
| 32 | Lifting roller quantity | 3 pcs |
| 33 | Number of transition rollers | 2 pcs |
| Cooling water system | ||
| 1 | Temperature control range | 8~10°C |
| 2 | Temperature control accuracy | ±1°C |
| 3 | Circulating water volume | 2.4m³/h |
| 4 | Circulation pump power | 0.75kw |
| Oil heating system | ||
| 1 | Temperature control range | Normal temperature ~130°C |
| 2 | Temperature control accuracy | ±1°C |
| 3 | Temperature control method | PID |
| 4 | Total heating power (kW) | 33kW |
