Online tension monitoring system suitable for carbon fiber production process

Abstract

The invention relates to the technical field of carbon fiber production tension monitoring, in particular to an online tension monitoring system suitable for a carbon fiber production process, which comprises the following components: a tension detection unit, which comprises GT-S1001B, GT-S1001C, GT-S1001D and GT-S1003 tensiometers arranged at outlets of different temperature zones of an oxidation furnace, the GT-S1004 tensiometer is arranged at an outlet of the low-temperature carbonization furnace, and the GT-S1005 tensiometer is arranged at an outlet of the high-temperature carbonization furnace. According to the on-line tension monitoring system suitable for the carbon fiber production process, the tension of the carbon filaments at different positions is continuously monitored on line, and the process is adjusted in time, so that on one hand, related detection indexes, including strength, modulus, density and the like, of the pre-oxidized filaments and the carbon filaments can be regulated and controlled; on the other hand, the appearance quality of the carbon filaments can be improved, and broken filaments, split filaments and other phenomena are reduced.

Description

Technical Field

[0001] This invention relates to the field of tension monitoring technology in carbon fiber production, specifically to an online tension monitoring system suitable for the carbon fiber production process. Background Technology

[0002] Carbon fiber possesses excellent properties such as light weight, high strength, high modulus, electrical conductivity, thermal conductivity, corrosion resistance, fatigue resistance, high temperature resistance, and low coefficient of thermal expansion. It boasts the highest specific strength and specific modulus among currently mass-produced high-performance fibers. my country is a major consumer of carbon fiber, yet it still heavily relies on imports. Domestic production falls short of demand, indicating a huge market potential. However, most domestically produced carbon fiber products remain in the low-to-mid-range category, characterized by high cost, high energy consumption, and inconsistent quality, placing them at a significant disadvantage in market competition.

[0003] Currently, during the carbonization stage of carbon fiber production, handheld tension meters are mostly used to detect and count the tension of pre-oxidized fibers and carbon fibers. This method is prone to detection errors. In addition, manual detection is intermittent and cannot obtain the tension status of each process point during carbon fiber production in a timely manner. If quality problems occur in the carbon fiber, there is no alarm prompt. Furthermore, manual detection can easily damage the fibers, affecting the mechanical properties and appearance quality of the product. Summary of the Invention

[0004] The purpose of this invention is to provide an online tension monitoring system suitable for carbon fiber production processes, so as to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an online tension monitoring system suitable for carbon fiber production processes, comprising the following components: The tension detection unit includes GT-S1001B, GT-S1001C, GT-S1001D, and GT-S1003 tension gauges installed at the outlets of different temperature zones of the oxidation furnace, GT-S1004 tension gauge installed at the outlet of the low-temperature carbonization furnace, and GT-S1005 tension gauge installed at the outlet of the high-temperature carbonization furnace.

[0006] The oxidation furnace includes six temperature zones Z1, Z2, Z3, Z4, Z5 and Z6, wherein GT-S1001B is located at the Z1 outlet, GT-S1001C is located at the Z3 outlet, GT-S1001D is located at the Z5 outlet and GT-S1003 is located at the Z6 outlet.

[0007] The data processing unit is used to receive the detection data from each tension gauge and to process and analyze the data.

[0008] An alarm unit is used to issue an alarm signal when the detected tension value exceeds a preset alarm threshold.

[0009] The monitoring system is used to display the real-time tension monitoring values, range parameter settings, alarm parameter settings, and alarm interface information at each process point.

[0010] The carbonization stage of carbon fiber production mainly includes the following stages: pre-oxidation, low-temperature carbonization, and high-temperature carbonization.

[0011] The main purpose of the pre-oxidation is to transform the linear macromolecular chains of thermoplastic PAN into a non-plastic, heat-resistant trapezoidal structure, so that it does not melt or burn at high carbonization temperatures and maintains the fiber morphology. The pre-oxidized trapezoidal structure can improve the carbonization efficiency. During the pre-oxidation stage, tension needs to be applied to the thermoplastic PAN filaments to maintain the orientation of the macromolecular chains to the fiber axis and control the degree of chemical shrinkage.

[0012] Preferably, the tension control range of the six temperature zones of the oxidation furnace is as follows: Zone Z1 1500-3000 cN / dtex, Zones Z2 and Z3 1500-2500 cN / dtex, Zones Z4 and Z5 1500-2500 cN / dtex, and Zone Z6 1000-3000 cN / dtex.

[0013] Preferably, the tension control range of the low-temperature carbonization furnace process stage is 500-2000 cN / dtex. The main purpose of the low-temperature carbonization is to remove non-carbon elements, form a preliminary disordered graphite structure, and increase the carbon content, laying the foundation for subsequent high-temperature carbonization. Applying a certain tension in the low-temperature carbonization stage maintains the stability of its physical morphology (straightness), guides its orderly shrinkage to retain and optimize the orientation of the molecular chains formed by pre-oxidation to the maximum extent, promotes structural densification, and ensures the continuous and stable operation of the production process, ultimately laying the structural foundation for obtaining high-performance carbon fibers. During the low-temperature carbonization stage, the tension control range is 500-2000 cN / dtex.

[0014] Preferably, the tension control range of the high-temperature carbonization furnace process stage is 1000-3000 cN / dtex; the main purpose of the high-temperature carbonization is to deeply remove residual non-carbon elements, significantly increase the carbon content, and promote the ordering and growth of the disordered graphite structure. Applying a certain tension in the high-temperature carbonization stage guides the carbon layer to be highly oriented along the fiber axis, further improving the preferred orientation, which significantly increases the fiber modulus. In the high-temperature carbonization stage, the tension control range is 1000-3000 cN / dtex.

[0015] Preferably, the range of the tension gauges is set to 0-5000 cN / dtex.

[0016] Preferably, the alarm threshold of the alarm unit is set as follows: The upper alarm limit for the GT-S1001B, GT-S1001C, GT-S1001D, and GT-S1003 tension gauges is 3500 cN / dtex, and the lower alarm limit is 1000 cN / dtex. The GT-S1004 tension meter has an alarm upper limit of 2000 cN / dtex and an alarm lower limit of 500 cN / dtex. The GT-S1005 tension meter has an alarm upper limit of 3500 cN / dtex and an alarm lower limit of 500 cN / dtex.

[0017] Preferably, the tension gauges are all fixedly connected to the outlet of the corresponding process point to fix the wire path and prevent the pre-oxidized wire or carbon wire from abrading during operation.

[0018] Preferably, the data processing unit includes: The data acquisition module is used to collect the detection data of each tension gauge in real time; The data storage module is used to store the collected tension data, range parameters, alarm parameters, and process history data. The data analysis module is used to analyze the collected tension data, generate tension change trend curves, and predict abnormal tension conditions based on preset algorithms.

[0019] Preferably, the monitoring system includes: The process interface module is used to display the process flow of the oxidation furnace, low-temperature carbonization furnace and high-temperature carbonization furnace, as well as the real-time tension monitoring values ​​at each process point; The parameter setting interface module is used to set the range parameters and alarm parameters of each tension gauge; The alarm interface module is used to display detailed alarm information, including alarm time, corresponding process point, and alarm reason.

[0020] Preferably, the system further includes a process adjustment unit that is communicatively connected to the data processing unit. The process adjustment unit is used to automatically adjust the process parameters in the carbon fiber production process according to the analysis results of the data processing unit, so as to maintain the tension at each process point within a preset control range.

[0021] Compared with the prior art, the beneficial effects of the present invention are: 1. This online tension monitoring system is applicable to the carbon fiber production process. By continuously monitoring the tension of carbon filaments at different positions online, the system can make timely process adjustments. On the one hand, it can control the relevant test indicators of pre-oxidized filaments and carbon filaments, including strength, modulus, density, etc. On the other hand, it can help improve the appearance quality of carbon filaments, including reducing phenomena such as fuzz and splitting. Furthermore, it is equipped with an alarm unit that issues an alarm signal when the detected tension value exceeds the preset alarm threshold.

[0022] 2. This online tension monitoring system for carbon fiber production applies a certain tension in the low-temperature carbonization section to maintain the stability (straightness) of its physical morphology, guides its orderly shrinkage to maximize the retention and optimization of the molecular chain orientation formed by pre-oxidation, promotes structural densification, and ensures the continuous and stable operation of the production process, ultimately laying the structural foundation for obtaining high-performance carbon fibers.

[0023] 3. This online tension monitoring system for carbon fiber production includes a process adjustment unit that is communicatively connected to a data processing unit. The process adjustment unit automatically adjusts the process parameters in the carbon fiber production process based on the analysis results of the data processing unit to maintain the tension at each process point within a preset control range. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 This is a schematic diagram of the process interface 1, the oxidation furnace, in the monitoring system of the present invention. Figure 2 This is a schematic diagram of the process interface 2, the low-temperature carbonization furnace, in the monitoring system of the present invention. Figure 3 This is a schematic diagram of the high-temperature carbonization furnace structure in the monitoring system of the present invention, which is the process interface 3. Figure 4 This is a parameter setting diagram for the monitoring system of the present invention; Figure 5 This is a diagram of alarm parameters in the monitoring system of the present invention. Detailed Implementation

[0026] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0027] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0028] Please see Figure 1-5 The present invention provides the following technical solutions: An online tension monitoring system for carbon fiber production processes includes the following components: The tension detection unit includes GT-S1001B, GT-S1001C, GT-S1001D, and GT-S1003 tension gauges installed at the outlets of different temperature zones of the oxidation furnace, GT-S1004 tension gauge installed at the outlet of the low-temperature carbonization furnace, and GT-S1005 tension gauge installed at the outlet of the high-temperature carbonization furnace.

[0029] The oxidation furnace includes six temperature zones: Z1, Z2, Z3, Z4, Z5, and Z6. GT-S1001B is located at the Z1 outlet, GT-S1001C at the Z3 outlet, GT-S1001D at the Z5 outlet, and GT-S1003 at the Z6 outlet.

[0030] The data processing unit is used to receive the detection data from each tension gauge and to process and analyze the data.

[0031] An alarm unit is used to issue an alarm signal when the detected tension value exceeds a preset alarm threshold.

[0032] The monitoring system displays the process interface, real-time tension monitoring values, range parameter settings, alarm parameter settings, and alarm interface information for each process point. The process interface includes the oxidation furnace, low-temperature carbonization furnace, and high-temperature carbonization furnace. The parameter setting interface shows that the tension metering range for each process point is 0-5000 cN / dtex. The alarm parameter interface displays the upper and lower alarm limits for each process point's tension meter. Specifically, the upper and lower alarm limits for GT-S1001B, GT-S1001C, GT-S1001D, and GT-S1003 are 3500 cN / dtex and 1000 cN / dtex, respectively; for GT-S1004, they are 2000 cN / dtex and 500 cN / dtex, respectively; and for GT-S1005, they are 3500 cN / dtex and 500 cN / dtex, respectively. The alarm interface displays detailed alarm information, including time, process point, and reason.

[0033] The carbonization stage of carbon fiber production mainly includes the following stages: pre-oxidation, low-temperature carbonization, and high-temperature carbonization.

[0034] The main purpose of pre-oxidation is to transform the linear macromolecular chains of thermoplastic PAN into a non-plastic, heat-resistant trapezoidal structure, so that it does not melt or burn at high carbonization temperatures and maintains the fiber shape. The trapezoidal structure of pre-oxidation can improve the carbonization efficiency. During the pre-oxidation stage, tension needs to be applied to the thermoplastic PAN filaments to maintain the orientation of the macromolecular chains to the fiber axis and control the degree of chemical shrinkage.

[0035] The tension control range for the six temperature zones of the oxidation furnace is as follows: Zone Z1 1500-3000 cN / dtex, Zones Z2 and Z3 1500-2500 cN / dtex, Zones Z4 and Z5 1500-2500 cN / dtex, and Zone Z6 1000-3000 cN / dtex.

[0036] The tension control range for the low-temperature carbonization furnace process is 500-2000 cN / dtex. The main purpose of low-temperature carbonization is to remove non-carbon elements, form a rudimentary disordered graphite structure, and increase the carbon content, laying the foundation for subsequent high-temperature carbonization. Applying a certain tension in the low-temperature carbonization stage maintains the stability of its physical morphology (straightness), guides its orderly shrinkage to retain and optimize the orientation of the molecular chains formed by pre-oxidation to the maximum extent, promotes structural densification, and ensures the continuous and stable operation of the production process, ultimately laying the structural foundation for obtaining high-performance carbon fibers. During the low-temperature carbonization stage, the tension control range is 500-2000 cN / dtex.

[0037] The tension control range during the high-temperature carbonization furnace process is 1000-3000 cN / dtex. The main purpose of high-temperature carbonization is to deeply remove residual non-carbon elements, significantly increase carbon content, and promote the ordering and growth of disordered graphite structures. Applying a certain tension during the high-temperature carbonization stage guides the carbon layer to be highly oriented along the fiber axis, further improving the preferred orientation and significantly increasing the fiber modulus. During the high-temperature carbonization stage, the tension control range is 1000-3000 cN / dtex.

[0038] The measuring range of each tension gauge is set to 0-5000 cN / dtex.

[0039] The alarm threshold of the alarm unit is set as follows: The upper alarm limit for the GT-S1001B, GT-S1001C, GT-S1001D, and GT-S1003 tension gauges is 3500 cN / dtex, and the lower alarm limit is 1000 cN / dtex. The GT-S1004 tension meter has an alarm upper limit of 2000 cN / dtex and an alarm lower limit of 500 cN / dtex. The GT-S1005 tension meter has an alarm upper limit of 3500 cN / dtex and an alarm lower limit of 500 cN / dtex.

[0040] Each tension gauge is fixedly connected to the outlet of the corresponding process point to fix the wire path and prevent the pre-oxidized or carbon wire from abrading during operation.

[0041] The data processing unit includes: The data acquisition module is used to collect the detection data of each tension gauge in real time; The data storage module is used to store the collected tension data, range parameters, alarm parameters, and process history data. The data analysis module is used to analyze the collected tension data, generate tension change trend curves, and predict abnormal tension conditions based on preset algorithms.

[0042] The monitoring system includes: The process interface module is used to display the process flow of the oxidation furnace, low-temperature carbonization furnace and high-temperature carbonization furnace, as well as the real-time tension monitoring values ​​at each process point; The parameter setting interface module is used to set the range parameters and alarm parameters of each tension gauge; The alarm interface module is used to display detailed alarm information, including alarm time, corresponding process point, and alarm reason.

[0043] It also includes a process adjustment unit that is connected to the data processing unit. The process adjustment unit is used to automatically adjust the process parameters in the carbon fiber production process according to the analysis results of the data processing unit, so as to maintain the tension at each process point within the preset control range.

[0044] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0045] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An online tension monitoring system suitable for carbon fiber production processes, characterized in that, Includes the following components: Tension detection unit, the tension detection unit includes GT-S1001B, GT-S1001C, GT-S1001D and GT-S1003 tension meters installed at the outlets of different temperature zones of the oxidation furnace, GT-S1004 tension meter installed at the outlet of the low temperature carbonization furnace, and GT-S1005 tension meter installed at the outlet of the high temperature carbonization furnace. The oxidation furnace includes six temperature zones: Z1, Z2, Z3, Z4, Z5, and Z6. GT-S1001B is located at the Z1 outlet, GT-S1001C at the Z3 outlet, GT-S1001D at the Z5 outlet, and GT-S1003 at the Z6 outlet. The data processing unit is used to receive the detection data from each tension gauge and to process and analyze the data. An alarm unit is used to issue an alarm signal when the detected tension value exceeds a preset alarm threshold. The monitoring system is used to display the process interface, real-time tension monitoring value, range parameter settings, alarm parameter settings, and alarm interface information for each process point.

2. The online tension monitoring system for carbon fiber production process according to claim 1, characterized in that, The tension control range for the six temperature zones of the oxidation furnace is as follows: Zone Z1 1500-3000 cN / dtex, Zones Z2 and Z3 1500-2500 cN / dtex, Zones Z4 and Z5 1500-2500 cN / dtex, and Zone Z6 1000-3000 cN / dtex.

3. The online tension monitoring system for carbon fiber production process according to claim 1, characterized in that, The tension control range for the low-temperature carbonization furnace process is 500-2000 cN / dtex.

4. The online tension monitoring system for carbon fiber production process according to claim 1, characterized in that, The tension control range for the high-temperature carbonization furnace process is 1000-3000 cN / dtex.

5. The online tension monitoring system for carbon fiber production process according to claim 1, characterized in that, The range of the tension gauges is set to 0-5000 cN / dtex.

6. The online tension monitoring system for carbon fiber production process according to claim 1, characterized in that, The alarm threshold of the alarm unit is set as follows: The upper alarm limit for the GT-S1001B, GT-S1001C, GT-S1001D, and GT-S1003 tension gauges is 3500 cN / dtex, and the lower alarm limit is 1000 cN / dtex. The GT-S1004 tension meter has an alarm upper limit of 2000 cN / dtex and an alarm lower limit of 500 cN / dtex. The GT-S1005 tension meter has an alarm upper limit of 3500 cN / dtex and an alarm lower limit of 500 cN / dtex.

7. The online tension monitoring system for carbon fiber production process according to claim 1, characterized in that, Tension gauges are fixedly connected to the outlet of the corresponding process point to fix the wire path and prevent the pre-oxidized or carbon wire from abrading during operation.

8. The online tension monitoring system for carbon fiber production process according to claim 1, characterized in that, The data processing unit includes: The data acquisition module is used to collect the detection data of each tension gauge in real time; The data storage module is used to store the collected tension data, range parameters, alarm parameters, and process history data. The data analysis module is used to analyze the collected tension data, generate tension change trend curves, and predict abnormal tension conditions based on preset algorithms.

9. The online tension monitoring system for carbon fiber production process according to claim 1, characterized in that, The monitoring system includes: The process interface module is used to display the process flow of the oxidation furnace, low-temperature carbonization furnace and high-temperature carbonization furnace, as well as the real-time tension monitoring values ​​at each process point; The parameter setting interface module is used to set the range parameters and alarm parameters of each tension gauge; The alarm interface module is used to display detailed alarm information, including alarm time, corresponding process point, and alarm reason.

10. The online tension monitoring system for carbon fiber production process according to claim 1, characterized in that, It also includes a process adjustment unit that is communicatively connected to the data processing unit. The process adjustment unit is used to automatically adjust the process parameters in the carbon fiber production process according to the analysis results of the data processing unit, so as to maintain the tension at each process point within a preset control range.

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