臥式丁基膠涂布機(jī)作為中空玻璃、光伏組件等精密制造領(lǐng)域的關(guān)鍵設(shè)備，其操作安全性與工藝穩(wěn)定性直接影響產(chǎn)品質(zhì)量與生產(chǎn)效率。本文從設(shè)備啟停、工藝控制、安全防護(hù)、日常維護(hù)四個(gè)維度，系統(tǒng)梳理操作核心要點(diǎn)。

　　The horizontal butyl rubber coating machine, as a key equipment in precision manufacturing fields such as insulating glass and photovoltaic modules, directly affects product quality and production efficiency in terms of operational safety and process stability. This article systematically outlines the core operational points from four dimensions: equipment start stop, process control, safety protection, and daily maintenance.

　　一、操作前準(zhǔn)備規(guī)范

　　1、 Preparation standards before operation

　　設(shè)備狀態(tài)核查

　　Equipment status verification

　　開機(jī)前需執(zhí)行三重檢查：首先確認(rèn)電源電壓穩(wěn)定在380V±10%范圍內(nèi)，接地電阻≤4Ω，避免電氣故障；其次檢查氣路壓力是否達(dá)標(biāo)，壓縮空氣需經(jīng)干燥過濾，壓力維持在0.6-0.8MPa，防止氣動(dòng)元件動(dòng)作異常；最后驗(yàn)證液壓系統(tǒng)油位，確保液壓油清潔度達(dá)NAS 7級以上，避免油泵卡滯。

　　Before starting up, perform a triple check: first, confirm that the power supply voltage is stable within the range of 380V ± 10%, and the grounding resistance is ≤ 4 Ω to avoid electrical faults; Next, check if the air path pressure meets the standard. Compressed air needs to be dried and filtered, and the pressure should be maintained at 0.6-0.8MPa to prevent abnormal operation of pneumatic components; Finally, verify the oil level of the hydraulic system to ensure that the cleanliness of the hydraulic oil reaches NAS level 7 or above, and avoid oil pump jamming.

　　溫度校準(zhǔn)與預(yù)熱

　　Temperature calibration and preheating

　　丁基膠需在110-150℃環(huán)境下充分融化，設(shè)備配備的雙溫區(qū)控制系統(tǒng)需分別設(shè)定膠缸與擠膠頭溫度。以某型設(shè)備為例，其加熱系統(tǒng)采用PID算法，升溫階段需觀察溫度曲線，確保膠缸溫度達(dá)到設(shè)定值后保溫20分鐘，使膠體粘度均勻。嚴(yán)禁在溫度未達(dá)標(biāo)時(shí)啟動(dòng)液壓裝置，否則可能導(dǎo)致膠體流動(dòng)性不足引發(fā)堵料。

　　Butyl rubber needs to be fully melted in an environment of 110-150 ℃, and the dual temperature zone control system equipped with the equipment needs to set the temperature of the rubber cylinder and extrusion head separately. Taking a certain type of equipment as an example, its heating system adopts PID algorithm. During the heating stage, the temperature curve needs to be observed to ensure that the temperature of the rubber cylinder reaches the set value and is kept warm for 20 minutes to make the viscosity of the colloid uniform. It is strictly prohibited to start the hydraulic device when the temperature does not meet the standard, otherwise it may cause insufficient fluidity of the colloid and lead to material blockage.

　　機(jī)械部件調(diào)試

　　Mechanical component debugging

　　調(diào)整兩擠膠頭間距時(shí)，需使用千分尺測量，確保間距誤差≤0.05mm，并保持?jǐn)D膠嘴、小壓輪、間隔框三點(diǎn)共線。傳送帶速度需根據(jù)基材厚度動(dòng)態(tài)調(diào)節(jié)，例如處理2mm鋁條時(shí)，速度應(yīng)控制在8-12m/min，避免因速度不匹配導(dǎo)致涂膠重疊或斷膠。

　　When adjusting the spacing between the two extrusion heads, a micrometer should be used to measure, ensuring that the spacing error is ≤ 0.05mm, and keeping the extrusion nozzle, small pressure wheel, and spacing frame in line. The speed of the conveyor belt needs to be dynamically adjusted according to the thickness of the substrate. For example, when processing 2mm aluminum strips, the speed should be controlled at 8-12m/min to avoid overlapping or breaking of the adhesive due to mismatched speeds.

　　二、運(yùn)行中關(guān)鍵控制

　　2、 Key controls during operation

　　工藝參數(shù)監(jiān)控

　　Process parameter monitoring

　　實(shí)時(shí)監(jiān)測三項(xiàng)核心指標(biāo)：擠膠壓力需穩(wěn)定在8-18MPa，壓力波動(dòng)超過±1MPa時(shí)需檢查膠路密封性；涂布厚度采用激光測厚儀在線檢測，允許偏差為設(shè)定值的±5%；傳送帶張力通過張力控制器維持180-280N，防止基材跑偏。

　　Real time monitoring of three core indicators: the extrusion pressure should be stable at 8-18MPa, and the sealing of the rubber path should be checked when the pressure fluctuation exceeds ± 1MPa; The coating thickness is measured online using a laser thickness gauge, with an allowable deviation of ± 5% of the set value; The tension of the conveyor belt is maintained at 180-280N through a tension controller to prevent substrate deviation.

　　安全防護(hù)執(zhí)行

　　Safety protection execution

　　操作人員必須佩戴防燙手套、護(hù)目鏡及防塵口罩，嚴(yán)禁在設(shè)備運(yùn)行中觸碰擠膠嘴，其表面溫度可達(dá)150℃。當(dāng)檢測到壓輪振動(dòng)幅度超過0.1mm或軸承溫升至65℃時(shí)，系統(tǒng)將自動(dòng)觸發(fā)急停，此時(shí)需排查機(jī)械卡滯或潤滑不良問題。

　　Operators must wear heat-resistant gloves, goggles, and dust masks. It is strictly prohibited to touch the extrusion nozzle during equipment operation, as its surface temperature can reach 150 ℃. When the vibration amplitude of the pressure roller exceeds 0.1mm or the bearing temperature rises to 65 ℃, the system will automatically trigger an emergency stop. At this time, mechanical jamming or poor lubrication problems need to be investigated.

　　異常處理流程

　　Exception handling process

　　若遇膠頭不出膠，應(yīng)立即檢查膠溫及膠路電磁閥狀態(tài)；發(fā)生斷膠時(shí)，需在10秒內(nèi)暫停設(shè)備并清理膠嘴，避免殘膠固化堵塞噴孔。某企業(yè)實(shí)踐數(shù)據(jù)顯示，85%的工藝故障可通過標(biāo)準(zhǔn)化處置流程在5分鐘內(nèi)解決。

　　If the glue head does not release glue, immediately check the glue temperature and the status of the glue circuit solenoid valve; When glue breakage occurs, the equipment should be paused within 10 seconds and the glue nozzle should be cleaned to avoid residual glue solidifying and blocking the spray hole. Practical data from a certain enterprise shows that 85% of process failures can be resolved within 5 minutes through standardized disposal processes.

　　三、停機(jī)維護(hù)要點(diǎn)

　　3、 Key points for shutdown maintenance

　　清潔與保養(yǎng)

　　Cleaning and maintenance

　　每日生產(chǎn)結(jié)束后，需用60℃熱風(fēng)槍配合專用清洗劑清理膠嘴、光眼及皮帶殘留，避免膠體碳化。每周對氣泵液壓油進(jìn)行取樣檢測，當(dāng)粘度變化超過15%時(shí)需更換，確保動(dòng)力傳輸效率。

　　After daily production, it is necessary to use a 60 ℃ hot air gun combined with a special cleaning agent to clean the glue nozzle, light eye, and belt residue to avoid colloid carbonization. Sample and test the hydraulic oil of the air pump every week, and replace it when the viscosity changes by more than 15% to ensure power transmission efficiency.

　　易損件管理

　　Management of vulnerable parts

　　建立易損件壽命臺(tái)賬，例如密封圈更換周期為500-800小時(shí)，皮帶張緊度需每日檢查，當(dāng)伸長率超過3%時(shí)需調(diào)整或更換。某企業(yè)通過實(shí)施預(yù)防性維護(hù)，使設(shè)備故障率降低62%。

　　Establish a service life ledger for vulnerable parts, such as a seal replacement cycle of 500-800 hours, daily inspection of belt tension, and adjustment or replacement when elongation exceeds 3%. A certain enterprise reduced the equipment failure rate by 62% by implementing preventive maintenance.

　　長期停用保護(hù)

　　Long term disuse protection

　　若設(shè)備停機(jī)超過72小時(shí)，需將膠缸活塞提升至高位，涂抹防銹油并覆蓋防塵罩。再次啟用前，需執(zhí)行完整加熱循環(huán)并驗(yàn)證所有安全聯(lián)鎖功能。

　　If the equipment is shut down for more than 72 hours, the rubber cylinder piston should be raised to a high position, coated with anti rust oil, and covered with a dust cover. Before enabling again, a complete heating cycle must be performed and all safety interlock functions verified.

　　四、安全風(fēng)險(xiǎn)管控

　　4、 Security risk control

　　人員培訓(xùn)制度

　　Personnel training system

　　操作人員需通過三級安全教育，考核內(nèi)容包括設(shè)備原理、應(yīng)急處置及防護(hù)用品使用。某企業(yè)實(shí)施“理論+實(shí)操”雙認(rèn)證后，人為事故率下降89%。

　　Operators need to undergo three-level safety education, which includes assessment of equipment principles, emergency response, and the use of protective equipment. After implementing the dual certification of "theory+practice" in a certain enterprise, the human accident rate decreased by 89%.

　　環(huán)境要求

　　Environmental requirements

　　作業(yè)區(qū)域需保持通風(fēng)，可燃?xì)怏w濃度控制在爆炸下限的25%以下。夜間作業(yè)時(shí)，工作面照度需≥500lx，避免視覺誤差導(dǎo)致操作失誤。

　　The work area should be kept ventilated, and the concentration of combustible gases should be controlled below 25% of the lower explosive limit. When working at night, the illumination of the work surface should be ≥ 500lx to avoid visual errors that may cause operational errors.

　　應(yīng)急預(yù)案

　　Emergency plan

　　制定專項(xiàng)應(yīng)急預(yù)案，明確膠體泄漏、機(jī)械傷害、電氣火災(zāi)等場景的處置流程，并每季度組織演練，確保全員掌握急停按鈕位置及滅火器材使用方法。

　　Develop a special emergency plan, clarify the disposal process for scenarios such as colloid leakage, mechanical injury, and electrical fires, and organize quarterly drills to ensure that all personnel are familiar with the location of emergency stop buttons and the use of firefighting equipment.

　　通過嚴(yán)格執(zhí)行上述操作規(guī)范，企業(yè)可使臥式丁基膠涂布機(jī)運(yùn)行穩(wěn)定性提升至99.5%以上，涂膠合格率達(dá)99.8%，同時(shí)延長設(shè)備使用壽命至10年以上。標(biāo)準(zhǔn)化作業(yè)不僅是質(zhì)量保障的基礎(chǔ)，更是生產(chǎn)安全的生命線。

　　By strictly implementing the above operating standards, enterprises can improve the stability of the horizontal butyl rubber coating machine to over 99.5%, achieve a coating qualification rate of 99.8%, and extend the equipment's service life to over 10 years. Standardized operations are not only the foundation of quality assurance, but also the lifeline of production safety.

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