Material Drying
4 مشاهدة
Filament Breakage/Floating Filament
ظاهرة المشكلة
During the spinning process, individual filaments break, and the broken ends float and wind around the yarn guides or equipment, seriously affecting production continuity and yarn package quality.
Filament breakage is the most destructive production failure in melt spinning — one broken filament can trigger chain breakage of adjacent filaments, causing the entire spinning position to stop.
A filament breakage frequency exceeding once per hour is regarded as abnormal production, requiring shutdown to investigate the cause.
Frequent filament breakage leads to reduced output, increased waste yarn, and increased labor intensity for operators.
تحليل الأسباب
1.
Comprehensive factor: melt temperature fluctuation causes instantaneous unevenness of individual filament strength (breakage at weak points).
2.
Mold/tooling factor: local clogging of the spinneret causes the filament from that hole to be too fine.
3.
Material/formulation factor: moisture or impurities in the chips cause local degradation and embrittlement.
4.
Process parameter factor: excessive winding tension or instantaneous impact.
5.
Cooling/environmental factor: uneven side-blowing air/ring-blowing air causes individual filaments to cool rapidly and harden.
الحل
1.
Process parameter optimization and adjustment: stabilize the melt temperature and pressure.
2.
Mold/tooling improvement and maintenance: keep the spinneret clean and clean it regularly.
3.
Equipment inspection and system maintenance: fully dry the chips and filter out impurities.
4.
Material/formulation optimization: reduce the winding tension and optimize the acceleration ramp curve.
5.
Operating specifications and preventive measures: adjust the uniformity of side-blowing/ring-blowing air.
الخلاصة الأساسية
The essence of filament breakage is that the stress borne by an individual filament at a certain instant exceeds its breaking strength at that moment.
The core of the solution is "eliminating weak points + stabilizing conditions": fully dry the chips to eliminate hydrolysis weak points, stabilize the melt temperature and pressure to eliminate instantaneous strength fluctuations, keep the spinneret clean to eliminate clogging weak points, and optimize the winding tension to eliminate impact loads.
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