意大利SIPA二步法吹瓶机.ppt

TRAINING,TRAINING,PROCESS,工艺,意大利,SIPA,二步法吹瓶机,STRETCH&BLOW,MOULDING,拉伸,吹制,1.THEORETICAL,PART,原理,部分,Table,of,contents,内容,总揽,Thermoplastic,polymers,聚合,体的热塑性,General,characteristics,of,PET,一般,特性,SBM,process,explanation,拉伸,吹制过程解释,Heating,and,conditioning,process,加热,调整过程,Stretch,/,blowing,process,拉伸,吹制过程,1,2,3,4,5,CH,2,=,CH,2,Ethylene,乙烯基,Polyethylene,聚乙烯,-CH,2,-,CH,2,-,-CH,2,-,CH,2,-,-CH,2,-,CH,2,-,-CH,2,-,CH,2,-,例如,:,Polymers,聚合体,:,definition,定义,Polymer,chains,聚合,体链,:,a,high,molecular,mass,substance characterized by,the,repetition,of one or more,types,of,monomeric,units,由,一种或多种单体副本组合而成的高分子化合物,Monomer,单体,:,a,simple,compound,whose,molecules,can,join,together,to,form,polymers,分子,组合在一起可形成聚合体的一种简单化合物,(),n,Monomer,单体,Polymer,聚合体,Polymerization,聚合,n 100,1,PET,(,P,oly,E,thylene,T,erephthalate,聚对苯二甲酸乙二醇酯,),是由,Purified,Terephthalic,Acid,纯对苯二酸,(PTA),和,Ethylene,Glycol,乙烯乙二醇,(,EG,),两种原料化合形成的聚脂,这两种石油加工物在反应器内形成聚脂,1,PET,的原料和制造,“,POLYESTER,”,聚脂,POLY=,MANY,许多,ESTER=,joining,of,an,ACID and a,GLYCOL,酸和乙二醇的连接物,EG,PTA,EG,PTA,EG,PTA,EG,PTA,EG,PTA,Polymers,聚合,体,:,结构,The,chain,structure,depending,from,the,monomer,链,结构由单体的,泛,函性,组成决定,functionality,(,2 or 3),1,Monomer,单体,直线状,(PET,HDPE),树枝状,(LDPE,),网状,(PU),F,平均,泛函性,:,F=2,线性,F,2,.,8,网状,2 F,2,.,8,树,枝状,Polymers:thermoplastic&thermosetting,(,1),聚合体,:,热塑性和热硬化性,(1),1,直线状和树枝状连接聚合体,链结构如何能影响材料性质,?,链间相互之间可以滑动,热塑性,加热变软,冷却变硬,在软化状态,(,温度高于,Tg,),通过吹制成型,聚合体举例,:,PE,PP,PET,Nylon,PVC,PC,典型工艺,:,挤压,注塑,吹制,.,网状连接聚合体,链间相互之间不能滑动,因为它们之间有非常坚固的化学连接,聚合体举例,:,Epoxy,resin,环氧树脂,silicon,resin,硅有机树脂,典型工艺,:,铸造,注射,挤出,压缩,(,聚合作用在成型后发生,),热硬化性,通过加热或其它处理,(,化学,光学,),不能通过加热软化,不可熔融和溶解,Polymers,:,thermoplastic,&,thermosetting,(,2),聚合体,:,热塑性和热硬化性,(2),1,Polymers,:,omopolymers,and,copolymers,(1),Omopolymer,:,polymer where,all the,repetitive units,are of the,same,kind,Copolymer,:,polymer where,the,repetitive units,are of two,different kinds,.In,many cases,a,small quantity,(2,4%),of,different moleculas,(i.e.,isophtalic,acid)are,added to ethylene glycol,and,terephthalic,acid in order,to improve processability,of the,resin,.,Monomer,“A”,Omopolimer,“A”,Copolimer,“A+B”,Monomer,“B”,2,Monomer,“A”,Monomer,“B”,Alternated,A blocchi,Random,Graft,The,order,and,distribution,of the B,monomers,in the,chain,change,the material,behaviour,.,Polymers,:,omopolymers,and,copolymers,(2),2,PET:,链长度,(1),The,polymer mechanical behaviour,depends,on the,chains average,lenght,.,聚合体的机械特性由链平均长度决定,链越长则链与链之间的可滑动量越小,IV=,Intrinsic,Viscosity,固有粘度,Quantity,proportionalto,chains,length.,Its the measure of the mobility,of the polymer chains.,链长度所占比例,反映了聚合物的滑动性能,短链,IV,低,链滑动性高,机械强度低,长链,IV,高,链滑动性差,机械强度高,2,PET:,链长度,(2),Fiber,grade,纤维等级,Specifications,:,短链结构,(,平均长度,100,units,),Intrinsic,Viscosity,固有粘度,=,0,5 0,7 dl/g,acetaldeyde content,乙醛含量高,(,AA),Applications,:,films,and,fibers,胶片和纤维,PET,可有两种状态存在,:,(fiber),纤维等级和瓶子等级,挤压机,Flakes,切片,切割机,单体,Reactor,反应器,冷却器,Production,process,:,Fuse state,polycondensation,2,PET:,链长度,(3),瓶子等级,Specifications,:,长链结构,(,平均长度,130,units,),Intrinsic,Viscosity,固有粘度,=,0,74 0,86,acetaldeyde,content,乙醛和水含量低,用途,:,瓶子,Production,process,生产工艺,:,polycondensation,固态缩聚,颗粒料,N,2,N,2,or,vacuum,PET,纤维等级,1st,Crystallization,结晶,150C200C,2nd,结晶,150C200C,固态缩聚,220C,冷却,N,2,or,vacuum,N,2,or,vacuum,AA and H,2,O,AA and H,2,O,AA and H,2,O,2,PET,瓶子,等级,瓶子等级,PET,是一种高,IV,低,AA,的树脂,2,机械强度差,气体渗透性高,结晶率高,熔点低,低,IV,机械性能好,气体阻隔性好,结晶率低,高,IV,熔点非常高,有热降解的危险,非常高,IV,加工性能,0.74-0.84,机械性能和气阻性能,PET:,morphology,结构,形态,(1),PET,的链之间怎么排列和组织,?,CRYSTALLINE结晶态,(,颗粒,),opaque,白色不透明,AMORPHOUS无定形态,(,瓶坯,),熔融,+,冷却,T,ransparent,透明,ORIENTED定形态,(,瓶子,),拉伸,+,吹制,T,ransparent,透明,2,Crystalline,state,结晶态,固态,Tm,250C,310C,降解态,熔融态,PET:,结构形态,(2),2,gas,gas,gas,gas,Aligned,chain,segments,按链段排列,:,Opaque,不透明,机械性能和热阻性好,易脆裂,气阻性好,熔化过程没有软化阶段,温度在,T,m,以下不能变形,PET:,结构形态,(3),Amorphous,state,无定型态,聚合体链没有特殊的排列,:,Transparent,透明的,Poor chemical,resistance,低化学阻抗,Elastic,有弹性,High gas,permeability,高气体渗透性,Softens before,melting,熔融前有软化阶段,gas,gas,玻璃态,T,g,70C,160C,弹性态,结晶态,250C,降解态,320C,粘弹性态,温度在,T,g,之上可变形,T,m,熔融态,2,定形态,(,strain induced,crystallization,应变结晶,),容器生产的理想需求,Transparent,透明,high,mechanical,property,高机械特性,high,barrier,property,高气阻性,无定形态,PET,少量结晶态被无定形态随机环绕,如何适应这种结构形态,?,加热到高于,Tg,塑性变形,定形态,PET,定形态和无定形态,PET:,结构形态,(4),2,Biaxial,oriented,双轴向的,单轴向的,PET,是一种吸湿的树脂,有从外界吸收水分的倾向。很多因素决定水分的吸收量,如,:,保存时间,温度,环境露点,树脂的结晶率。,PET,在无定形态要比结晶态吸水速度快。,The,amount,of water,absorbed depends,on,various factors that is storage,time,temperature,environment dew point,crystallization,%of the,resin,.PET in the,amorphous,state,absorbs moisture,more,quickly than,in,crystalline,state.,PET:,Environment moisture,absorption,外界湿气的吸收,2,PET:,吸,湿对拉伸吹制的影响,The water,moleculars,trapped between,the,polymers molecular chains behaves as,a,lubricant,.,聚合体分子链之间的水分子表现为润滑作用。,So,it becomes easier to stretch,the material,but this,also,has,a negative,effect,on,bottle shrinkage,through the NSR rise,.,所以它使拉伸变的容易，但同时因为自然拉伸率的上升对瓶子的收缩有负面影响,3,15-20,ppm,of H,2,0,1000-2000,ppm,of H,2,0,PET,样品,(,无定形态,),25,Kg,f,1 mm,伸长,10,Kg,f,1 mm,伸长,3,PET:,张应,力特性,Tensile,Stress,Behaviour,(1),If,an amorphous,PET,sample,is,subjected,to,a,tensile,stress,important,consequences,can,be,obtained,on,its molecular structure,.,They basically depends,on the temperature at,which stresses,are,applied to,the material.,Elastic,Strain,弹性应变,:,Oriented,被导向,Plastic,Strain,塑性应变,:,Stretched,拉伸,PET:,张应,力特性,Tensile,Stress,Behaviour,(2),3,How,the plastic,sample modifies during,the,elongation,steps,塑料样本在延长过程中如何变形,ELONGATION,延长,STRESS,压力,SBM,拉伸,吹制管理工艺,:,基本原理,拉伸是自我限制的,为什么,PET,能被拉伸,?,延长,NSR,自然拉伸率,STRESS,压力,STEEL,钢,CRACKING,断裂,PET,FOR HAVING FURTHER DEFORMATION IS NECESSARY STRESS,INCREASING,如果需要更大的变形需要增加压力,3,SBM,拉伸,吹制管理工艺,:,基本原理,哪种情况是最好的拉伸,?,延长,NSR,自然拉伸率,STRESS,压力,UNSTABLE,不稳定拉伸,过度拉伸,最适宜的拉伸,3,SBM,拉伸吹制管理工艺,:,基本,原理,The,stretching,can,be,adjusted,by,working on the,thermal,profile,拉伸的调整可通过改变加热曲线来完成,ELONGATION,伸长,STRESS,压力,拉伸度越高需要的温度越高,2.,厚度是由加热曲线控制的,T,T,2,T,1,e,2,e,1,3.,拉伸速度越快，需要的温度越高,V,3,SBM,拉伸吹制管理工艺,:,拉伸率,The,stretching,ratio,depends,on,preform,and,bottle,design,实际拉伸率由瓶坯和瓶子的设计决定,(,几何形状,),L,BOTT,L,PREF,F,BOTT,F,PREF,rad,=,F,bott,F,pref,_,avrg,ax,=,L,bott,L,pref,tot =,ax,x,rad,2.4,ax,3.5,3,rad,5,7,tot,只在必要时,!,加热和调整,纵向温度曲线,To,be,choosed,in 2,steps,分两步选择,:,瓶坯的统一加热,(,因瓶坯底部和支撑环下部边缘影响的结果,),2.,根据瓶子的料分布定制,(,由外形决定,),由以下参数控制,:,灯管加热功率输出百分比,4,细节,1,在瓶坯底部和瓶颈下部有边界效应,细节,2,瓶颈下部区域厚度小,不需要很长的热转换时间,瓶坯底部厚度大，需要的加热量大，甚至可能使用超出瓶坯范围的加热灯管（如底部下方）,有热分配问题的危险,!,加热和调整,4,瓶坯,底部和瓶颈下部的加热,加热和调整,内侧,外侧温度曲线,内侧需要比外侧高的温度,烘箱外一段时间,的调整是必要的,由以下参数控制,:,1.,功率和加热灯管的数量,(,如：,5,个灯管,100%,加热比,10,个灯管,50%,加热温差要高,),2.,风扇,(=,冷却外侧,),3.,烘箱进出口加热功率的平衡,4.,烘箱外调整的时间,热转换,4,瓶坯内侧的拉伸,比外侧要多,热转换,:,瓶坯,加热,4,105C,95C,理想的调整时间,热转换,:,厚度,厚瓶坯,如：,CSD,瓶坯,厚部位,如：瓶身和瓶底,出烘箱后有更多的时间,烘箱进口一侧更多的加热,更多的排风,灯管更高的功率,更多的热转换,薄瓶坯,如：纯净水瓶坯,薄部位,如：瓶颈下部,较少的热转换,4,出烘箱后有较少的时间,烘箱两侧同样的加热,较少的排风,灯管较少的功率,一般都没有问题,!,热转换,:,生,产量,1.The time at,disposal for,heating,penetration,加热处理的时间,2.The,conditioning,time after the exit,from,the,ovens,出烘箱后的调整时间,灯管加热和排风,烘箱进口一侧加热功率,烘箱出口一侧加热功率,SFL,系列,生产量变化改变了什么,?,产量,不充分的,热转换,产量,过度,热转换,烘箱进口一侧加热功率,(,甚至关闭烘箱进口的第一组灯管,),4,怎么解决,?,5,拉伸吹制,:,过程,描述,(1),一次气,(10bar),二次气,(40bar),减压,拉伸吹制,:,过程描述,(2),拉伸杆下降,速度,一次气进入,压力,流量,延时,5,气泡的形成,Omogeneous stretch,Volume 60-70%,No,uncentered,二次气进入,压力,延时,减压排气,时间,一次气吹制时间,二次气吹制时间,STRETCH&BLOW-MOULDING,2.PRACTICAL TRAINING,Topics,:,Recipe,setting,工艺,参数设定,:,Find,a,thermal,profile,寻找,适合的温度曲线,Primary,air,blow,一,次气吹制,Secondary,air,blow,二,次气吹制,Optimization,in,continuous,production,连续,生产的优化,Long,period,variations,长时期后的变化,1,2,3,4,5,加热,:,瓶坯,温度,需要使用多少个灯管参与加热,?,在瓶坯上标记每个灯管的位置,(,作为最终模板,eventually,use,a,template,),1,设定灯管和风扇的参数,Decision,taken according,to,the,productivity,preform characteristics,(,thickness,color.),Es,.,lamps,60%,ventilation,70%,Modify,heating,parameters,Global,temperature,is,correct,?,Should be,from,90C and,100C(,pirometer,or,other,kind,of,sensor,),Thermal,profile,setting,NO,YES,Heating,:,thermal,profile,setting,Mark,the position of the,lamps,in,preform,1,Heatings,Free,blow,p=2.5-3.5 bar,It depends,of the,preform,thickness,Thermal,profile,is,OK?,Preform,should be,stretched,with,uniformity,Power,lamps,adjustment,until,the,uniformity,of,stretch,has,been reached,NO,YES,Primary,air,blowing,Heating,:,thermal,profile,setting,1,Practical,example,Heating,of L3 and,L4,not,enough,Optimum,profile,Heating,of L1and,L2,not,enough,Primary,air,blowing,Settings,of,primary,/,secondary,air,blowing,primary,:,when,the,stretch,rod,touches,the,preform,bottom,secondary,:,when,the,stretch,rod,reaches,the,lowest,position,2,Primary,air,blowing,description,:,without,the,secondary,air,blow,a,batch,of,preforms only,with,primary,air,Air and,stretch,rod,should be,syncronized,.,Adjustments to,carry,out in the,following,order,:,1.,Setting,of the best,primary,air,pressure,and the best,stretch,rod,speed,2.,Setting,of the,primary,air,delay,/,advance,3.,Adjustment,of,primary,air,flow regulator,in,each,blow,cavity,Primary,air,blowing,2,Check,the,conformation,of the,bubbles,target:,the,bubbles should be,stretched,with,uniformity,with,a,good,disposition,of,thickness,and,centered,Secondary,air,blow,Secondary,air,enabled,:,When,:,stretch rod,reaches,the,lowest,position,How much,time:,all,the,remaining,time,before,decompression,with,30bar of pressure,for,natural,water,light,bottle,40bar,for,CSD,3,Blow,a,batch,of,preforms with secondary,air,The,following defects,can,happen,:,White,area in the,bottom,low,temperature of,preform,change,the,lamps,power set,set T of,ovens,air,adjust,the,fans speed,Schretched,logos,excess,of,formation,in,primary,air,delay,the,primary,air,reduce the air,pressure,advance,the,secondary,air,Material bad,distribution,thermal profile,or,primary,air,delay not optimized,optimize,the,heating,and the,primary,air,delay,Optimization,in,continuous,production,4,Found,the best recipe,loading,little,preform,batches,set the,pyrometer,with,the,read value,switch,on the,feedback,and start the production,for,at,least,3,minutes,.,Defects,due,to,the temperature,variation,of,ovens,air can,appear,(,too much,material in the,bottom,craters,).,What,can I do?,Follow,the,suggestions,:,Increase,the set T of air and,ventilation,Attention,:,if,T air,is too,high,the,risk is,:,overheating,the,ovens,and,stabilization,time,too,long,T,max,=85C,More power,to,the,lamp,and more,ventilation,reduction,of air temperature,gap,between,start up and,continuous,production,Reduction,of,preform,set T(max 3C),Balancing,the,effect,due,to,the,different,temperature of the air,In,continuous,production,the feedback,should,work,around,-4%,Optimization,in,continuous,production,4,set,T,air,空气设定温度,set,T,preform,瓶坯设定温度,T,air,空气实际温度,T,preform,瓶坯实际温度,时间,温度,之后,时间,温度,以前,1st.,解决方法,Increase,Tair,set and,ventilation,增加空气设定温度和排风,Optimization,in,continuous,production,4,T,air,T,preform,set,T,air,set,T,preform,time,temperature,After,2nd.,解决方法,Increasing lamp,and,ventilation,power,增加灯管加热功率和排风,time,temperature,Before,Optimization,in,continuous,production,4,T,air,T,preform,set,T,air,set,T,preform,3rd.SOLUTION,Preform,temperature set,reduction,降低瓶坯设定温度,time,temperature,Before,time,temperature,After,Long,period variations,5,What,can,change,in the long,period,?,1.,Environment,temperature,环境温度,2.Temperature of,preforms,in,stock,瓶坯库存温度,What,should,I do?,Optimize again,the,process,:,find,the new set of the total power,for,the,ovens,ventilation,and,modify,the set temperature of air and,preform,.,The ideal,thermal profile doesnt change,!,Productivity change,Which,are the,settings need to be changed,in case of,higher productivity,?,1.,Heatings,:,the,preform,temperature and the,thermal profile need to remain,the,same,2.,Thermal inversion,:,it is needed to guarantee,the,same difference,of temperature,between internal,and,external,(the,inversion must be increased,),3.,Primary pressure,:,increasing,the,speed,of the,stretching rod,the,primary,air,pressure,must be increased,(the,bubble,in,primary has to remain,the,same,),4.Air,inlet,set:,it could be necessary,re-,adjust,the,settings for primary,and,secondary,air entry,5,Productivity change,:,high,productivity,Which,are the,productivity,limits?,1.,Ovens,:,To guarantee,the,sufficient heating,power and a,higher thermal inversion it should need increase,the,percentages,of the,lamps,and,increase,the,ventilation,.,Beyond,a,limit,the,lamps,will arrive to,the,saturation,.,For being able to heat ulteriorly,the,preform,the,ventilation needs to be decreased,.,This will involve,a minor,thermal inversion,and,an overheating,of the air of the,oven,(,possible problem,of,overheating,of the,neck,).,2.Air,inlet,:,Higher is,the,speed,of the,stretching rods,greater must be,the,precision,of the,valves,.,3.High,pressure,time:,Decreasing,the,permanence,time in,cavity,the time,available to cool,the,possible,hot zone,not stretched,(,bottle bottom,),decreases,.,5,Productivity change,:,low productivity,Which,are the,productivity,limits?,1.,Oven,:,for too low,speeds,there could be,a,very,high,thermal inversion,or,even,a,thermal preform degradation,.In,order to decrease,the,inversion,it,is,possible to switch,off the first,lamps,or,all,the,inlet,side,oven,.No,other particular problems need to be,note,except to remember,the PT100.,2.Air,inlet,:,lower is,the,stretching rod speed,lower must be,the air,pressure,.,It cannot be adjusted lower than,6.5-7 bar and,this,can,be,a,problem,.,3.,Stretching speed,:,decreasing,the,strecthing speed it,can,result,a,not good uniformity,and,obtain bottles with low mechanical proprties,.,Practically,decreasing,the,stretching speed it is equivalent to have low stretching,ratio.,5,