ABA吹膜机使用过程中如何避免故障

1、 The basic working principle of ABA blown film machine

ABA blown film machine is a common plastic film production equipment that uses three-layer co extrusion technology to produce composite films with A-B-A structure. Its working principle is to melt plastics of different materials through three extruders, form tubular film bubbles through co extrusion die heads, and finally form thin film products through processes such as blowing, cooling, and pulling. This structural design combines the performance advantages of the inner and outer layers with the cost advantage of the intermediate layer, making it widely used in fields such as packaging and agriculture.

2、 Common fault types and cause analysis

1. Unstable membrane bubbles

The instability of membrane bubbles is manifested by membrane bubble shaking, swinging, or rupture, mainly due to:

Improper temperature control and inconsistent melt flowability

Uneven cooling of the wind ring

Compressed air pressure fluctuation

The traction speed does not match the extrusion speed

2. Uneven film thickness

Uneven thickness can directly affect product quality, and the main causes are:

Improper adjustment of die gap

Unreasonable temperature settings in each section of the extruder

Filter blockage leads to uneven pressure

Uneven plasticization caused by screw wear

3. Surface defects

Common surface defects such as crystal dots, stripes, fish eyes, etc. are often caused by the following factors:

Raw materials contain impurities or moisture

Incomplete plasticization

Incomplete cleaning of the mold head

Low efficiency of cooling system

4. Mechanical failure

Common mechanical issues include:

Wear and tear of screws or barrels

Abnormal noise or overheating of the gearbox

Heating coil damaged

Poor lubrication of bearings

3、 Preventive maintenance measures

1. Standardize the operation process

Strictly follow the operating procedures to start and stop, avoiding emergency stop and start

Fully preheat before starting up, usually taking 30-60 minutes

Thoroughly clean the mold head and screw during shutdown to prevent resin carbonization

Regularly check the fasteners of each part to prevent looseness

2. Maintenance of temperature control system

Regularly calibrate thermocouples to ensure accurate temperature display

Check the working status of the heating coil and replace damaged components in a timely manner

Keep the cooling system unobstructed and regularly clean the scale

Set reasonable temperature curves based on the characteristics of different raw materials

3. Maintenance of mechanical components

Regularly replace lubricating oil according to the equipment manual requirements

Check the wear of the screw and barrel, and repair or replace them in a timely manner

Keep the transmission system clean and avoid dust accumulation

Regularly check the oil level and quality of the gearbox

4. Maintenance of pneumatic system

Regularly discharge accumulated water from the gas storage tank

Check the working status of the air pressure regulating valve

Clean the air outlet of the air ring to ensure even airflow

Check the sealing of the gas path to prevent air leakage

4、 Raw material processing and process control

1. Raw material pretreatment

Strictly screen raw materials and remove impurities

Fully dry the hygroscopic raw materials

Accurately mix ingredients in proportion to ensure even mixing

Avoid significant differences in performance between different batches of raw materials

2. Optimization of process parameters

Adjust the die gap according to product requirements

Control the appropriate inflation ratio and traction ratio

Optimize cooling system parameters to improve cooling efficiency

Maintain stable extrusion pressure and melt temperature

3. Production process monitoring

Regularly measure the thickness of the film and adjust it in a timely manner

Observe the morphology of the membrane bubbles and immediately handle any abnormalities found

Record key process parameters and establish a production database

Implement SPC statistical process control to prevent quality fluctuations

5、 Operator training and management

1. Professional skills training

Training on equipment structure and working principle

Training on common fault identification and handling

Training on Safety Operating Procedures

Training on Quality Standards and Inspection Methods

2. Establish a responsibility system

Clarify the responsibilities and operational authority of each position

Implement a shift handover record system

Establish equipment maintenance records

Implement performance evaluation and incentive mechanism

3. Safety precautions

Wear protective gear to avoid burns

Prohibit maintenance during device operation

Electrical maintenance requires power-off operation

Press the emergency stop button immediately in case of emergency

6、 Emergency handling of faults

1. Quick response to common faults

Bubble rupture: Immediately reduce traction speed, check temperature and gas circuit

Uneven thickness: Adjust the gap between the mold heads and check the filter screen

Surface defects: Check the quality of raw materials, clean the mold head

Mechanical abnormal noise: Stop the machine for inspection, troubleshoot before running again

2. Fault recording and analysis

Detailed record of fault symptoms and handling process

Analyze the root cause to avoid recurrence

Establish a database of fault cases for training reference

Regularly summarize fault patterns and improve preventive measures

7、 Long term maintenance strategy

1. Develop a maintenance plan

Daily inspection items and frequency

Weekly maintenance content and standards

Key monthly maintenance tasks

Annual overhaul plan and budget

2. Spare parts management

Establish a list of key spare parts

Reasonably set safety stock

Choose excellent suppliers

Standardize spare parts replacement records

3. Technological upgrade

Pay attention to the development of new technologies in the industry

Assess the feasibility of equipment renovation

Gradually achieve automation control

Improve energy efficiency and environmental performance

Through the above systematic measures, the failure rate of ABA blown film machine can be reduced, the stability and production efficiency of equipment operation can be improved, the service life of equipment can be extended, and greater value can be created for enterprises. The key lies in prevention first, standardized operation, fine management, and continuous improvement.