CN112318763A - Control and inspection method for pouring process with filler - Google Patents
Control and inspection method for pouring process with filler Download PDFInfo
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- CN112318763A CN112318763A CN202011063792.9A CN202011063792A CN112318763A CN 112318763 A CN112318763 A CN 112318763A CN 202011063792 A CN202011063792 A CN 202011063792A CN 112318763 A CN112318763 A CN 112318763A
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- mixture
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/02—Mixing; Kneading non-continuous, with mechanical mixing or kneading devices, i.e. batch type
- B29B7/22—Component parts, details or accessories; Auxiliary operations
- B29B7/28—Component parts, details or accessories; Auxiliary operations for measuring, controlling or regulating, e.g. viscosity control
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- Mechanical Engineering (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
A control and inspection method for a pouring process with a filler comprises a single-impulse weight deviation inspection method, a mixture density inspection method and a liquid level difference inspection method, wherein the single-impulse weight deviation inspection method and the mixture density inspection method are applied before the pouring process, and the liquid level difference inspection method is applied after the pouring process.
Description
Technical Field
The invention belongs to the technical field of pouring, and particularly relates to a method for controlling and inspecting a pouring process with a filler
Background
Most of the devices with fillers in the prior art adopt a method of mixing two tanks (namely a resin tank and a curing agent tank) for pouring: the filler is respectively placed in two tanks for mixing, resin, toner (or color paste) and the filler are added in the resin tank, a curing agent and the filler are added in the curing agent tank, all components are heated, vacuumized and fully mixed in the two tanks according to a certain proportion, thorough defoaming is carried out, and then the mixture in the two tanks is fully mixed again through a static mixer and poured.
In the whole mixing process, the manual work cannot detect whether the components are added in proportion or not and whether the equipment is abnormal or not. Problems can be found only after the casting process is finished or the baking and curing process is finished, however, once the casting process is in a problem, the whole tank coil is damaged (generally, one tank coil is calculated according to the 1000KVA capacity, and the number of the coils is about 5). Meanwhile, as the product mixing time is long, a manufacturer starts to perform the next tank of product mixing, pouring, baking and curing processes after the pouring is finished, and the residual materials in each sub-tank are mixed with the next batch of materials, so that the problem of the whole tank of the next batch is caused, and two tanks or even three tanks are usually poured when the problem is found.
Disclosure of Invention
The invention aims to solve the defects of the prior art and provides a method for controlling and checking the pouring process with a filler, which comprises a single-impulse weight deviation checking method, a mixture density checking method and a liquid level difference checking method.
Preferably, the single-impulse weight deviation checking method comprises the following steps:
(1) the electronic scale performs zero calibration, the material cup is placed on the electronic scale to be weighed, and the weight of the material cup is recorded;
(2) putting the single-stroke epoxy resin mixture into a material cup through a static mixer, removing the weight of the material cup, measuring the weight for a plurality of times, taking an average value, and recording the average value as M1;
(3) Putting the single-stroke curing agent mixture into a material cup through a static mixer, removing the weight of the material cup, measuring the weight for a plurality of times, taking an average value, and recording the average value as M2;
(4) Putting the single-stroke total mixed liquid into a material cup through a static mixer, removing the weight of the material cup, measuring the weight for a plurality of times, taking an average value, and recording the average value as M3;
(5) Substituting the M1, M2 and M3 obtained in the step (2), the step (3) and the step (4) into the following calculation formulas to calculate:
M3≈M1+M2
wherein: mTree (R)-theoretical discharge weight of epoxy resin mixture per stroke;
Mfixing device-theoretical discharge weight of curing agent-grease mixture per stroke.
Preferably, the number of measurements in step (2), step (3) and step (4) in the single-impulse weight deviation test method is not less than 3.
Preferably, the single-impulse weight-deviation testing method according to claim 2, wherein the epoxy-resin-compound weight deviation measured in step (5) is ratioed (M)Tree-M1)/MTree (R)Weight deviation of the mixture of the curing agent (M)Solid and liquid medicineM2)/MFixing deviceThe difference value of the mixture is controlled within +/-2%, and the deviation of the total mixture obtained by a calculation formula is controlled within +/-1.5%, and the limit deviation is +/-2%.
Preferably, the batch density testing method comprises the following steps:
(1) zeroing with electronic scale, weighing the specific gravity cup on the electronic scale, and recording the weight M of the specific gravity cupCup with elastic band。
(2) Pouring the epoxy resin mixture into the specific gravity cup, filling the specific gravity cup, tightly covering the cup cover, wiping the resin mixture flowing out of the cup cover hole, measuring the weight for a plurality of times, averaging, and recording as the total weight MGeneral assembly;
(3) M obtained in the step (1) and the step (2)Cup with elastic bandAnd MGeneral assemblySubstituting the following calculation formula for calculation:
M=Mgeneral assembly-MCup with elastic band
ρMeasuring=M/V
Wherein: rho is the theoretical density of the epoxy resin mixture;
ρmeasuring-the measured density of the epoxy resin compound;
v is the volume of the gravity cup.
Preferably, the number of measurements in step (2) in the batch density testing method is not less than 3.
Preferably, the deviation calculated in step (3) of the mix density test method should be controlled to within 2%.
Preferably, the density of the curing agent mixture and the total mixture can be checked by a mixture density check method.
Preferably, the liquid level difference checking method comprises the following steps:
(1) sampling and analyzing the epoxy resin mixture, cleaning the pipeline, closing the stirring of the resin tank after cleaning the pipeline, removing the vacuum device, and opening the observation cover of the pre-poured resin tank.
(2) Vertically and slowly placing a clean 1200mm steel ruler into a resin tank filled with resin mixed liquid, enabling one end of the steel ruler to be in contact with the bottom of the resin tank, measuring the liquid level of the resin tank, and recording that the liquid level of the resin mixed material in the resin tank is L1。
(3) Measuring the liquid level of the curing agent tank by adopting the methods in the step (1) and the step (2), and recording the liquid of the curing agent mixture in the curing agent tank as h1。
(4) After the pouring is finished, opening the resin tank and the curing agent tank, respectively measuring the liquid level of the resin tank and the liquid level of the curing agent tank after the pouring by adopting the methods in the step (1) and the step (2), and recording the liquid L of the resin mixture in the resin tank2Recording the curing agent mixture liquid in the curing agent tank as h2。
(5) L obtained in the step (2), the step (3) and the step (4)1、L2、h1And h2Substituting the following calculation formula for calculation:
the dosage of the resin tank mixture is as follows: l ═ L1-L2;
Curing agent tank mixture dosage: h is h1-h2;
Quality of the resin tank mixture: mTree (R)=ρ1×S1×L;
Pure resin quality of the resin tank: wPure resin=MTree (R)×M1;
Quality of the mixture of the curing agent tank: mFixing device=ρ2×S2×h;
Quality of pure curing agent in the curing agent tank: wPure curing agent=MFixing device×M2;
Wherein: rho1-theoretical density of resin tank mix
S1Inside diameter cross-sectional area of resin pot
ρ2-theoretical Density of curing agent tank mixture
S2Internal diameter section area of curing agent tank
M1Proportion of pure resin in the resin tank by weight
M2Proportion of pure curing agent in curing agent tank
Preferably, in the liquid level difference checking process, when the deviation range of the resin tank and the deviation of the curing agent tank obtained in the step (5) are both controlled within 5%, the liquid level difference is checked to be qualified.
Has the advantages that: the invention discloses a method for controlling and checking the pouring process of a belt filler, which ensures that production personnel can find the problems existing in the mixture in time before and after pouring through a single-impulse weight deviation checking method and a mixture density checking method, avoids the waste of the mixture and effectively controls the pouring quality of a product.
Detailed description of the preferred embodiments
In order to enhance the understanding of the present invention, the present invention will be described in further detail with reference to the following examples, which are only for the purpose of illustrating the present invention and are not to be construed as limiting the scope of the present invention.
The control and inspection method for the pouring process with the filler is characterized by comprising a single-impulse weight deviation inspection method, a mixture density inspection method and a liquid level difference inspection method, wherein the single-impulse weight deviation inspection method and the mixture density inspection method are applied before the pouring process, and the liquid level difference inspection method is applied after the pouring process.
The single-impulse weight deviation detection method comprises the following steps:
(1) the electronic scale performs zero calibration, the material cup is placed on the electronic scale to be weighed, and the weight of the material cup is recorded;
(2) putting the single-stroke epoxy resin mixture into a material cup through a static mixer, removing the weight of the material cup, measuring the weight for a plurality of times, taking an average value, and recording the average value as M1;
(3) Putting the single-stroke curing agent mixture into a material cup through a static mixer, removing the weight of the material cup, measuring the weight for a plurality of times, taking an average value, and recording the average value as M2;
(4) Putting the single-stroke total mixed liquid into a material cup through a static mixer, removing the weight of the material cup, measuring the weight for a plurality of times, taking an average value, and recording the average value as M3;
(6) Substituting the M1, M2 and M3 obtained in the step (2), the step (3) and the step (4) into the following calculation formulas to calculate:
M3≈M1+M2
wherein: mTree (R)-theoretical discharge weight of epoxy resin mixture per stroke;
Mfixing device-theoretical discharge weight of curing agent-grease mixture per stroke.
The method for testing the density of the mixture comprises the following steps:
(1) zeroing with electronic scale, weighing the specific gravity cup on the electronic scale, and recording the weight M of the specific gravity cupCup with elastic band。
(2) Will be provided withPouring the epoxy resin mixture into the specific gravity cup, filling the specific gravity cup, covering the cup cover tightly, wiping the resin mixture flowing out of the cup cover hole, measuring the weight for a plurality of times, taking an average value, and recording the average value as the total weight MGeneral assembly;
(3) M obtained in the step (1) and the step (2)Cup with elastic bandAnd MGeneral assemblySubstituting the following calculation formula for calculation:
M=Mgeneral assembly-MCup with elastic band
ρMeasuring=M/V
Wherein: rho is the theoretical density of the epoxy resin mixture;
ρmeasuring-the measured density of the epoxy resin compound;
v is the volume of the gravity cup.
The liquid level difference detection method comprises the following steps:
(1) sampling and analyzing the epoxy resin mixture, cleaning the pipeline, closing the stirring of the resin tank after cleaning the pipeline, removing the vacuum device, and opening the observation cover of the pre-poured resin tank.
(2) Vertically and slowly placing a clean 1200mm steel ruler into a resin tank filled with resin mixed liquid, enabling one end of the steel ruler to be in contact with the bottom of the resin tank, measuring the liquid level of the resin tank, and recording that the liquid level of the resin mixed material in the resin tank is L1。
(3) Measuring the liquid level of the curing agent tank by adopting the methods in the step (1) and the step (2), and recording the liquid of the curing agent mixture in the curing agent tank as h1。
(4) After the pouring is finished, opening the resin tank and the curing agent tank, respectively measuring the liquid level of the resin tank and the liquid level of the curing agent tank after the pouring by adopting the methods in the step (1) and the step (2), and recording the liquid L of the resin mixture in the resin tank2Recording the curing agent mixture liquid in the curing agent tank as h2。
(5) Obtained in the step (2), the step (3) and the step (4)L of1、L2、h1And h2Substituting the following calculation formula for calculation:
the dosage of the resin tank mixture is as follows: l ═ L1-L2;
Curing agent tank mixture dosage: h is h1-h2;
Quality of the resin tank mixture: mTree (R)=ρ1×S1×L;
Pure resin quality of the resin tank: wPure resin=MTree (R)×M1;
Quality of the mixture of the curing agent tank: mFixing device=ρ2×S2×h;
Quality of pure curing agent in the curing agent tank: wPure curing agent=MFixing device×M2;
Wherein: rho1-theoretical density of resin tank mix
S1Inside diameter cross-sectional area of resin pot
ρ2-theoretical Density of curing agent tank mixture
S2Internal diameter section area of curing agent tank
M1Proportion of pure resin in the resin tank by weight
M2Proportion of pure curing agent in curing agent tank
The detection method can ensure that production personnel can find the problems existing in the mixture in time before pre-pouring by a single-impulse weight deviation detection method and a mixture density detection method, and avoids the waste of the mixture; after the pouring process is finished, the detection method can also detect whether the problem occurs in the whole pouring process again through a liquid level difference detection method: if the problem is found in time after the pouring is finished, the mixture can be poured out before the gel, so that the mixture in the current tank can be wasted, the coil can not be damaged, the secondary waste of the mixture in the next tank after the material is fed again can be avoided, and the product pouring quality can be effectively controlled.
It should be noted that:
(1) the above three detection methods require sampling before pre-casting. When the liquid level difference detection method is used for detection, stirring work in the resin tank and the curing agent tank must be stopped, then the resin tank and the curing agent tank are vacuumized until the liquid level has no bubbles, pouring is carried out again, and liquid level difference detection is carried out after pouring is finished. The single stroke weight deviation measurement must be taken again for sampling and comparison after pouring.
(2) Before each casting, a single-impulse weight deviation test and a mixture density test must be performed.
(3) For different equipment and raw materials, the theoretical weight and the theoretical density of the mixture are different, and the calculation is carried out after adjustment according to actual conditions.
(4) When the deviation of any one of the three detection methods exceeds the standard, the pouring needs to be stopped immediately.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (10)
1. The control and inspection method for the pouring process with the filler is characterized by comprising a single-impulse weight deviation inspection method, a mixture density inspection method and a liquid level difference inspection method, wherein the single-impulse weight deviation inspection method and the mixture density inspection method are applied before the pouring process, and the liquid level difference inspection method is applied after the pouring process.
2. A method for controlling and testing a pouring process with a packing as claimed in claim 1, wherein said method for testing a weight deviation of a single impulse comprises the steps of:
(1) the electronic scale performs zero calibration, the material cup is placed on the electronic scale to be weighed, and the weight of the material cup is recorded;
(2) putting the single-stroke epoxy resin mixture into a material cup through a static mixer, removing the weight of the material cup, measuring the weight for a plurality of times, taking an average value, and recording the average value as M1;
(3) Putting the single-stroke curing agent mixture into a material cup through a static mixer, removing the weight of the material cup, measuring the weight for a plurality of times, taking an average value, and recording the average value as M2;
(4) Putting the single-stroke total mixed liquid into a material cup through a static mixer, removing the weight of the material cup, measuring the weight for a plurality of times, taking an average value, and recording the average value as M3;
(5) Substituting the M1, M2 and M3 obtained in the step (2), the step (3) and the step (4) into the following calculation formulas to calculate:
M3≈M1+M2
wherein: mTree (R)-theoretical discharge weight of epoxy resin mixture per stroke;
Mfixing device-theoretical discharge weight of curing agent-grease mixture per stroke.
3. The method for checking the weight deviation of single impulse according to claim 2, wherein the number of measurements in step (2), step (3) and step (4) is not less than 3.
4. The method of claim 2, wherein the step (5) is performed by measuringThe weight deviation of the epoxy resin mixture is calculated (M)Tree (R)-M1)/MTree (R)Weight deviation of the mixture of the curing agent (M)Fixing device-M2)/MFixing deviceThe difference value of the mixture is controlled within +/-2%, and the deviation of the total mixture obtained by a calculation formula is controlled within +/-1.5%, and the limit deviation is +/-2%.
5. The method for controlling and checking the pouring process with the filler according to claim 1, wherein the method for checking the density of the mixture comprises the following steps:
(1) zeroing with electronic scale, weighing the specific gravity cup on the electronic scale, and recording the weight M of the specific gravity cupCup with elastic band;
(2) Pouring the epoxy resin mixture into the specific gravity cup, filling the specific gravity cup, tightly covering the cup cover, wiping the resin mixture flowing out of the cup cover hole, measuring the weight for a plurality of times, averaging, and recording as the total weight MGeneral assembly;
(3) M obtained in the step (1) and the step (2)Cup with elastic bandAnd MGeneral assemblySubstituting the following calculation formula for calculation:
M=Mgeneral assembly-MCup with elastic band
ρMeasuring=M/V
Wherein: rho is the theoretical density of the epoxy resin mixture;
ρmeasuring-the measured density of the epoxy resin compound;
v is the volume of the gravity cup.
6. The batch density testing method according to claim 5, wherein the number of measurements in step (2) is not less than 3.
7. The batch density test method according to claim 5, wherein the deviation calculated in step (3) is controlled to be within 2%.
8. The mix density test method of claim 5, wherein the densities of the curing agent mix and the total mix can be tested by the same test method.
9. A method for controlling and testing a pouring process with a filler according to claim 1, wherein the method for testing the liquid level difference comprises the following steps:
(1) sampling and analyzing the epoxy resin mixture, cleaning a pipeline, closing the stirring of the resin tank after cleaning the pipeline, removing the vacuum device, and opening a pre-poured resin tank observation cover;
(2) vertically and slowly placing a clean 1200mm steel ruler into a resin tank filled with resin mixed liquid, enabling one end of the steel ruler to be in contact with the bottom of the resin tank, measuring the liquid level of the resin tank, and recording that the liquid level of the resin mixed material in the resin tank is L1;
(3) Measuring the liquid level of the curing agent tank by adopting the methods in the step (1) and the step (2), and recording the liquid of the curing agent mixture in the curing agent tank as h1;
(4) After the pouring is finished, opening the resin tank and the curing agent tank, respectively measuring the liquid level of the resin tank and the liquid level of the curing agent tank after the pouring by adopting the methods in the step (1) and the step (2), and recording the liquid L of the resin mixture in the resin tank2Recording the curing agent mixture liquid in the curing agent tank as h2;
(5) L obtained in the step (2), the step (3) and the step (4)1、L2、h1And h2Substituting the following calculation formula for calculation:
the dosage of the resin tank mixture is as follows: l ═ L1-L2;
Curing agent tank mixture dosage: h is h1-h2;
Quality of the resin tank mixture: mTree (R)=ρ1×S1×L;
Pure resin quality of the resin tank: wPure resin=MTree (R)×M1;
Quality of the mixture of the curing agent tank: mFixing device=ρ2×S2×h;
Quality of pure curing agent in the curing agent tank: wPure curing agent=MFixing device×M2;
Wherein: rho1-theoretical density of resin tank mix
S1Inside diameter cross-sectional area of resin pot
ρ2-theoretical Density of curing agent tank mixture
S2Internal diameter section area of curing agent tank
M1Proportion of pure resin in the resin tank by weight
M2The proportion of the pure curing agent in the curing agent tank by weight.
10. The liquid level difference inspection method according to claim 9, wherein the liquid level difference is checked to be acceptable when the deviation range of the resin tank and the deviation of the curing agent tank obtained in the step (5) are controlled to be within 5%.
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Cited By (1)
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CN115215035A (en) * | 2022-06-27 | 2022-10-21 | 江苏康众汽配有限公司 | Relay picking method and system |
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Application publication date: 20210205 |