Chemic fiber spinning--Melt Pressure Transmitter

In chemical fiber spinning production, melt pressure transmitters play a key role in improving production stability, product quality and process controllability by monitoring melt pressure in real time and feeding back to the control system.

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Overview

The chemical fiber textile industry is one of the most widely used fields for melt pressure transmitters. With the development of the chemical fiber textile industry, enterprises have continuously improved their requirements for precise control of the production process. As a key device for monitoring pressure changes in equipment such as spinning machines, the demand for melt pressure transmitters will continue to rise!

With the application of technologies such as the Internet of Things, big data, and artificial intelligence in the chemical fiber textile industry, melt pressure transmitters are also developing in the direction of intelligence.

Difficulties in Process Control

1. Melt pressure stability: Pressure fluctuations will lead to uneven fiber thickness (if the deviation is greater than 1%, it will affect the quality), which needs to be monitored in real time by a pressure transmitter (such as a high-temperature melt pressure sensor) and fed back to the extruder speed adjustment.

2. Temperature uniformity: The temperature deviation of the melting section must be less than ±1°C, otherwise the polymer is prone to degradation or solidification, and the equipment needs to use a multi-layer heating jacket + PID temperature control system.

The Solution
  • The measuring range covers 0-60MPa, with a 20% overload margin
  • Long-term working temperature must be ≥350℃ (to prevent local overheating damage)
  • Pressure fluctuations must be controlled within ±0.5% FS (affecting fiber denier uniformity)
  • Real-time feedback of pressure changes is required (response time < 5ms)
  • Adopt flush diaphragm design (to avoid solidification of melt residue), with wear-resistant and corrosion-resistant diaphragm (resistance to polymer corrosion)
  • Conforms to the standard interface of spinning equipment (such as M20×1.5 thread, G1/4 interface)
  • Equipped with high temperature and pressure resistant seals (such as fluorine rubber + metal spiral wound gasket) to prevent melt leakage
  • Screw extruder outlet (monitoring melt uniformity)
  • Melt pump inlet/outlet (control flow stability)
  • Before the spinning assembly (to ensure balanced pressure on the spinneret)
  • Pipeline after metering pump (to prevent local blockage)

Using 4-20mA current signal or HART protocol (strong anti-interference ability), with shielded cable (double-layer aluminum foil + braided mesh), the accuracy is <0.1% when the transmission distance is ≤100m.

Closed Loop Control Logic

The Advantages

Dynamically adjust melt pressure stability

Real-time acquisition of melt pressure (accuracy 0.1-0.5% FS), linkage adjustment of screw speed or melt pump frequency; when slice viscosity changes, automatic compensation of pressure parameters to avoid manual adjustment lag.

From “post-detection” to “pre-control”

Automatic alarm and linkage speed reduction when the set pressure threshold is exceeded; storage of pressure-time curve for easy tracing of quality problems.

Reduce the risk of loss and failure of key components

  • When the pressure exceeds the safety value, the heating power supply is automatically cut off and the pressure relief valve is activated;
  • Predict melt pump bearing wear through pressure fluctuation spectrum analysis and arrange maintenance in advance

Dual benefits of energy saving and consumption reduction and efficiency improvement

  • Reduce the frequency of manual inspections (from 4 times/shift to 1 time/shift), thus reducing labor costs ;
  • The equipment life is extended and the annual maintenance cost is reduced by 20-30% ;
  • After the pressure stabilizes, the waste rate is reduced to 0.8%. Based on an annual production line of 10,000 tons, the annual raw material cost savings is about 1.2 million yuan ;
  • Precisely control the melt flow rate, and reduce the power consumption per ton of wire from 350kWh to 320kWh (annual power saving of 300,000 kWh)

Open the key nodes of intelligent production

  • The pressure data is integrated with parameters such as temperature and flow, and the process model is established through machine learning ;
  • Transmit pressure data via 4G/5G to achieve centralized monitoring of remote factories

Shanghai Zhaohui Pressure Apparstus Co.,Ltd. – A comprehensive high-tech enterprise integrating R&D, production, and sales. With products distributed nationwide and exported to over 50 countries and regions, the company achieves annual sales of millions of sensing elements, sensors (transmitters), and control systems.

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