High-strength and high-modulus polyethylene spinneret plate temperature and flow velocity double-gradient fiber forming system

Abstract

The embodiment of the invention provides a high-strength and high-modulus polyethylene spinneret plate temperature and flow velocity double-gradient fiber forming system, which is applied to the technical field of chemical fiber technology, and is characterized in that a temperature acquisition module acquires the outlet temperature of a spinneret and generates a temperature deviation value; the environment compensation module realizes refined temperature compensation based on execution of layered directional heat absorption and release; the temperature judgment module judges the temperature grade and outputs a trigger signal; the flow velocity regulation and control module is provided with a scale-like microstructure at an outlet of a spinneret, and the flow velocity uniformity of the melt is regulated through a disturbance effect; and the comprehensive control module outputs a double-gradient regulation and control signal in combination with a temperature grade judgment result and a flow velocity uniformity index, and cooperatively drives the environment compensation module and the flow velocity regulation and control module. Through temperature and flow velocity dual-channel regulation and control, the problem of insufficient strength and modulus caused by non-uniform temperature field and flow field in existing fiber forming is solved, and the stability and mechanical property in the polyethylene fiber forming process are improved.

Description

Technical Field

[0001] This application relates to the field of chemical fiber technology, and in particular to a high-strength, high-modulus polyethylene spinneret temperature and flow rate dual-gradient fiber forming system. Background Technology

[0002] High-strength, high-modulus polyethylene fiber is widely used in high-end fields such as bulletproof materials, cables, security protection, and aerospace due to its extremely high specific strength and specific modulus, as well as excellent abrasion resistance and corrosion resistance. However, the fiber forming process of high-strength, high-modulus polyethylene fiber is highly process-sensitive, and its mechanical properties largely depend on the stability of the melt flow state and the degree of molecular chain orientation.

[0003] Existing polyethylene fiber spinning processes primarily achieve fiber quality stability through single methods such as temperature or flow rate control. For example, heating compensation at the spinneret temperature ensures stable melt viscosity, or disturbing structures on the spinneret improve the flow field distribution. However, these single control methods often suffer from the following problems: Traditional heating or cooling compensation methods mostly rely on overall temperature control and lack the ability to quickly respond to local temperatures at the spinneret outlet. Existing technologies mostly operate temperature control and flow rate control independently, failing to form a dual-parameter synergistic control mechanism. This makes it difficult to achieve a comprehensive effect of stable temperature and uniform flow rate, resulting in the fiber molecular chain orientation and crystallization process not reaching the optimal matching state. Summary of the Invention

[0004] The embodiments of this application provide a high-strength, high-modulus polyethylene spinneret temperature-flow-rate dual-gradient fiber forming system, which achieves improved stability and mechanical properties in the polyethylene fiber forming process. To achieve the above objectives, this application adopts the following technical solution: This application embodiment provides a high-strength, high-modulus polyethylene spinneret temperature-flow-rate dual-gradient fiber forming system, the system comprising: The temperature acquisition module is used to acquire the spinneret outlet temperature parameters and compare them with the target temperature parameters to generate a temperature deviation value ΔT. The environmental compensation module is used to perform heat absorption or heat release actions based on the temperature deviation value ΔT and output the temperature compensation result. The temperature determination module is used to receive the temperature compensation result, generate the temperature level determination result based on the temperature compensation result, and output a trigger signal when the temperature level determination result exceeds the preset threshold. The flow rate control module receives the trigger signal output by the temperature determination module. When the trigger signal exceeds the preset disturbance threshold, it performs an amplitude-adjustable action, adjusts the amplitude of the disturbance based on the disturbance coefficient, generates a disturbance result, and calculates the flow rate uniformity index based on the disturbance result.

[0005] The integrated control module receives the temperature level determination result and the flow rate uniformity index, generates an integrated control index based on the temperature level determination result and the flow rate uniformity index, and adjusts the working intensity of the environmental compensation module and the flow rate regulation module according to the integrated control index, thereby outputting a dual-gradient regulation result.

[0006] The flow rate control module includes a fish-scale-like microstructure at the spinneret outlet, specifically used for: Fish-scale-like microstructures are etched on the circumferential surface of the spinneret outlet, and the etching depth parameter corresponds to the melt flow velocity distribution parameter. Melt flow rate distribution parameters and etching depth parameters are used to geometrically map and set the fish scale-like microstructure to obtain a set of circumferential geometric parameters; The circumferential micro-perturbation action at the spinneret outlet is performed based on the circumferential geometric parameter set and melt flow state to generate perturbation results, and the flow velocity uniformity index is calculated based on the perturbation results.

[0007] The flow rate control module is specifically used for: The fish-scale-like microstructure receives the directional temperature compensation result output by the temperature determination module as a trigger signal. When the trigger signal exceeds the disturbance threshold, it performs an amplitude-adjustable action and adjusts the disturbance amplitude according to the disturbance coefficient, outputting an adjustable disturbance result. The adjustable perturbation result serves as a perturbation source, and the velocity uniformity is adjusted through geometric mapping and flow state; Based on the disturbance results and velocity distribution parameters, a velocity uniformity index is calculated, and an adjustment signal is output based on this index to optimize the melt velocity distribution.

[0008] The environmental compensation module specifically includes a phase change material compensation layer integrated into the spinneret: The phase change material compensation layer is provided with a multi-layer encapsulation structure along the thickness direction of the spinneret, and different encapsulation layers have different latent heat parameters. The temperature deviation value ΔT and the multilayer packaging structure parameter set are used to perform threshold matching judgment on the phase change material compensation layer to obtain the layer trigger sequence; The layered trigger sequence and the latent heat parameter set are used to perform layer-by-layer heat absorption on the phase change material compensation layer to obtain the layered temperature compensation result.

[0009] The environmental compensation module is specifically used for: When the phase change material compensation layer performs layer-by-layer heat absorption, the sign of the temperature deviation value ΔT is determined to be either positive or negative. When the temperature deviation value ΔT is positive, a directional compensation command is generated, and a directional heat release action is executed based on the directional compensation command; When the temperature deviation value ΔT is negative, a directional compensation command is generated, and a directional heat absorption action is executed based on the directional compensation command. The directional compensation command is combined with the layered temperature compensation result to perform directional heat absorption or release on the phase change material compensation layer and output the directional temperature compensation result. The directional temperature compensation result is input to the temperature determination module as the input parameter for subsequent temperature compensation.

[0010] The temperature determination module is specifically used for: The difference between the directional temperature compensation result and the spinneret target temperature is calculated to generate the temperature deviation ΔT; The temperature level determination result is generated by calculating the ratio of temperature deviation ΔT to a preset allowable deviation threshold or by classifying the temperature level. When the temperature level determination result exceeds the preset threshold, a trigger signal is output to the flow rate control module.

[0011] The integrated control module is specifically used for: Receive the temperature level determination result and the flow rate uniformity index, and perform parameter combination actions based on the temperature level determination result and the flow rate uniformity index to generate comprehensive input data; The integrated control module generates integrated control indicators based on the integrated input data.

[0012] The integrated control module is specifically used for: When the comprehensive control index is greater than or equal to the preset stability threshold, a full power command is generated. The full-power command is input to the environmental compensation module and the fish-scale microstructure control module respectively: The environmental compensation module executes temperature compensation actions based on full-power commands and outputs temperature stability results. The fish-scale-like microstructure control module executes disturbance actions based on full-power commands and outputs a flow velocity uniformization result. The integrated control module integrates the temperature stabilization results and the flow rate homogenization results to generate the final dual-gradient regulation results. The dual-gradient control results are used to coordinate the control of the environmental compensation module and the fish-scale-like microstructure control module to achieve temperature stability and flow rate uniformity at the spinneret outlet.

[0013] After generating the dual-gradient regulation results, the integrated control module... The temperature stabilization results and flow rate homogenization results are synchronously coupled to control the molecular chain orientation process of polyethylene melt, thereby obtaining the molecular chain orientation homogenization results. The homogenization of molecular chain orientation and the evolution parameters of crystallinity are used to synergistically optimize the fiber curing process, resulting in high-strength, high-modulus polyethylene fiber molding.

[0014] The system also includes a status display module, specifically used for: It receives and displays the temperature parameters acquired by the temperature acquisition module and the dual-gradient control results generated by the integrated control module.

[0015] As can be seen from the above technical solution, this application has the following beneficial effects: 1. This system embeds a special phase change material layer in the spinneret. This material absorbs or releases heat when the temperature changes. Combined with a module that can dynamically judge and adjust the temperature, the system can quickly respond to and compensate for local temperature changes at the spinneret outlet, achieving rapid compensation and stratified response to local temperature changes at the spinneret outlet. Compared with existing methods that rely on overall heating or cooling, this system can significantly reduce temperature fluctuations at the spinneret outlet, ensure the stability of the temperature field, and thus improve the consistency of the molecular chain orientation of polyethylene melt.

[0016] 2. Based on temperature control, this system introduces a fish-scale-like microstructure at the spinneret outlet and, through linkage with temperature determination results, achieves adaptive perturbation homogenization of the melt velocity distribution. This design not only effectively disperses local turbulence and improves the uniformity of the velocity field, but also achieves synergistic control when temperature fluctuations cause abnormal velocity, thereby forming a dual-gradient optimization effect during molecular chain orientation and crystallization, ultimately significantly improving the strength and modulus of the fiber. Attached Figure Description

[0017] The invention will now be further described with reference to the accompanying drawings.

[0018] Figure 1 This is a structural diagram of a high-strength, high-modulus polyethylene spinneret temperature and flow rate dual-gradient fiber forming system provided in an embodiment of this application. Figure 2 A flowchart of a high-strength, high-modulus polyethylene spinneret temperature and flow rate dual-gradient fiber forming system provided in an embodiment of this application. Detailed Implementation

[0019] The terms "first," "second," and "third," etc., used in this application specification, claims, and drawings are used to distinguish different objects, not to limit a specific order.

[0020] In the embodiments of this application, the terms "exemplary" or "for example" are used to indicate that something is an example, illustration, or description. Any embodiment or design that is described as "exemplary" or "for example" in the embodiments of this application should not be construed as being more preferred or advantageous than other embodiments or design. Specifically, the use of the terms "exemplary" or "for example" is intended to present the relevant concepts in a specific manner.

[0021] Research has found that traditional heating or cooling compensation methods mostly rely on overall temperature control and lack the ability to quickly respond to local temperatures at the spinneret outlet. Existing technologies mostly operate temperature control and flow rate control independently, failing to form a dual-parameter synergistic control mechanism. This makes it impossible to achieve a comprehensive effect of stable temperature and uniform flow rate, resulting in the fiber molecular chain orientation and crystallization process being difficult to achieve the best matching state.

[0022] To address the aforementioned issues, this application provides a high-strength, high-modulus polyethylene spinneret temperature-flow-rate dual-gradient fiber forming system: Example 1: To solve the above problems, such as Figure 1 As shown, the temperature acquisition module monitors the outlet temperature of the spinneret through a temperature sensor set at the spinneret outlet, obtains the actual temperature value at that location, compares this value with the preset target temperature, and calculates the temperature deviation value ΔT. The temperature deviation value ΔT will be used as the input parameter for subsequent adjustment to determine whether the temperature needs to be adjusted and to what extent. By accurately monitoring the temperature and calculating the temperature deviation value in real time, the temperature of the spinneret can be adjusted to ensure that the temperature of the spinneret is within the ideal range, thus avoiding unstable flow characteristics of polyethylene melt due to unstable temperature, thereby improving the strength and modulus of the fiber. Once the temperature deviation value ΔT is calculated, the environmental compensation module will determine whether the phase change material compensation layer needs to be activated to regulate the temperature based on this deviation value. If the temperature deviation is too large, the compensation layer will adjust the temperature of the spinneret by absorbing or releasing heat to compensate for the temperature fluctuation. The module uses the built-in phase change material to absorb or release heat according to the magnitude and direction of the temperature change to maintain the stability of the spinneret temperature. Through the adaptive temperature regulation of phase change materials, the spinneret temperature can be kept stable even when the external ambient temperature fluctuates greatly, thereby preventing uneven flow of polyethylene melt caused by uneven temperature and improving the quality and consistency of the fiber. After receiving the temperature compensation result from the environmental compensation module, the temperature determination module continues to perform the temperature assessment task. The temperature determination module generates a temperature level determination result based on the difference between the temperature compensation result and the target temperature. If the temperature deviation is large and exceeds the preset temperature threshold, the module will trigger a signal to notify the flow rate control module to start. The temperature determination module ensures that the system can respond promptly to drastic temperature fluctuations. It activates the flow rate control module through a trigger signal to achieve coordinated adjustment of temperature and flow rate, ensuring stability throughout the fiber forming process. After receiving the trigger signal from the temperature determination module, the fish-scale-like microstructure in the flow rate control module starts to work. This microstructure forms a tiny disturbance zone through circumferential etching of the spinneret, thereby intervening in the fluid flow rate. When the melt passes through the spinneret, the microstructure breaks up the macroscopic turbulence, reduces velocity fluctuations, and ensures velocity uniformity. At the same time, the system calculates the velocity uniformity index to assess whether the velocity has reached the required level of uniformity. Through micro-perturbation control, a more uniform flow rate distribution can be formed at the spinneret, reducing the uneven flow of the melt, thereby improving the molecular chain orientation of polyethylene fibers and enhancing the strength and modulus of the fibers. The integrated control module receives the temperature level determination result from the temperature determination module and the flow rate uniformity index from the flow rate control module, and performs a comprehensive analysis. Through preset calculation rules, it calculates an integrated control index. This index will be used to dynamically adjust the working intensity of the environmental compensation module and the flow rate control module to achieve the goal of dual-gradient control, that is, to maintain the dual stability of temperature and flow rate. The integrated control module ensures that both temperature and flow rate remain stable during the fiber forming process by precisely adjusting both temperature and flow rate, thereby effectively improving the forming quality of polyethylene fibers, especially their strength and modulus. Through the optimized scheme of this embodiment, the system can control the spinneret temperature and flow rate in real time, and ensure the stability of polyethylene melt during the molding process through multi-level adjustment; it can significantly improve the molecular chain orientation and crystallinity of the fiber, effectively enhance the mechanical properties of the fiber, and has important application value and technical advantages.

[0023] Example 2: As Figure 1 As shown, specifically, the system employs an environmental compensation module, which includes a phase change material compensation layer integrated into the spinneret. This module uses a multi-layered encapsulated phase change material to regulate the spinneret temperature, ensuring temperature stability during the fiber forming process. Based on different temperature deviations, the system can precisely adjust the spinneret temperature to avoid overheating or overcooling, thereby improving the quality of the polyethylene fiber.

[0024] The actual temperature at the spinneret outlet is obtained by the temperature acquisition module and compared with the target temperature to calculate the temperature deviation value ΔT. Threshold matching is performed based on the temperature deviation value ΔT and the set of latent heat parameters of the multi-layer encapsulation structure of the phase change material compensation layer; the combination of the temperature deviation value and the latent heat parameters of each encapsulation layer determines the layer trigger sequence, which layer of the phase change material is triggered to adjust the temperature. According to the matched layer trigger sequence, the system executes the layer-by-layer heat absorption action in sequence. During the heat absorption process, the encapsulation structure of each layer gradually absorbs heat according to the latent heat of molten metal, and adjusts the temperature of the spinneret nozzle layer by layer. During the heat absorption process of each layer, the system outputs the temperature compensation result of that layer in real time. Through this layer-by-layer heat absorption mechanism, the system can precisely adjust the spinneret temperature.

[0025] During the stratified heat absorption process, the system monitors the sign change of the temperature deviation ΔT in real time; When ΔT is positive, it indicates that the temperature is too high. The system will generate a directional compensation command and execute a directional heat release action to reduce the temperature. When ΔT is negative, it indicates that the temperature is too low. The system will generate a directional compensation command and execute a directional heat absorption action to replenish the temperature. Based on the generated directional compensation command, the system will perform directional heat release or heat absorption actions respectively for cases of excessively high or low temperatures; If ΔT is positive, the system releases excess heat through an exothermic action to reduce the spinneret temperature to the target value. If ΔT is negative, the system introduces the required heat through heat absorption, thereby raising the spinneret temperature to the target range; After performing the directional heat release or heat absorption action, the system outputs the directional temperature compensation result and transmits it to the temperature determination module. The temperature determination module receives the directional temperature compensation result and uses it as the input parameter for subsequent temperature compensation, continuing to monitor the spinneret temperature to ensure that the system continuously optimizes temperature control.

[0026] Through the multi-layer encapsulation structure of the phase change material compensation layer and the layered heat absorption / release mechanism, the system can precisely regulate the temperature of the spinneret, avoiding excessive temperature rise or fall, thereby ensuring temperature stability during the polyethylene fiber molding process.

[0027] The layer-by-layer heat absorption and directional compensation strategy of phase change materials makes thermal energy management more efficient, avoids unnecessary heat waste, and ensures precise heat distribution. The system can dynamically adjust the temperature control strategy based on the real-time temperature deviation, so that the fiber forming process is always within the ideal temperature control range, which greatly improves production efficiency and finished product quality.

[0028] This embodiment describes in detail how to use a phase change material compensation layer and a layered heat absorption and release strategy to achieve precise control of the spinneret temperature. Through directional compensation and layer-by-layer heat absorption mechanism, the system can effectively optimize the temperature during the fiber forming process and ensure the stability of fiber quality.

[0029] Example 3: As Figure 1 As shown, specifically: the etching of the fish-scale-like microstructure is performed on the circumferential surface of the spinneret outlet, and the etching depth is designed to correspond to the melt flow velocity distribution. The etching depth is optimized according to the melt flow velocity distribution, with the aim of disturbing the fluid flow state through the microstructure; Through geometric mapping and optimized design, the setting of these microstructures reduces turbulence in melt flow, achieving a more uniform flow velocity distribution. Precise control of the etching depth and geometry of the microstructures effectively guides melt flow, reducing flow velocity unevenness, and ultimately helps improve fiber uniformity and quality. Better flow velocity control optimizes the orientation and crystallinity of polyethylene molecular chains during the molding process, thereby improving the mechanical properties of the fiber, such as tensile strength and modulus. This provides a foundation for subsequent disturbance generation. By precisely designing the microstructure, a physical structural basis is provided for flow rate regulation and temperature compensation, ensuring that the system can efficiently and uniformly regulate the melt flow rate. Based on the melt velocity distribution and etching depth parameters, the system sets a circumferential geometric parameter set based on geometric mapping. This parameter set determines the influence of microstructure disturbance on the velocity distribution and precisely controls the melt flow state at the spinneret outlet. The system dynamically adjusts the circumferential geometric parameters based on the real-time flow status to ensure that the flow velocity remains consistent during the forming process; Precise adjustment of circumferential geometric parameters can make the melt flow rate more uniform, reduce quality problems caused by uneven flow rate, ensure fiber consistency and high-quality output, improve the overall stability of fiber molding, and avoid molding defects caused by uneven melt flow rate under different working conditions.

[0030] The dynamic adjustment of the geometric parameter set depends on the design of the etching depth and melt flow rate distribution in the previous step. The precise design of the microstructure provides physical support for flow rate regulation and temperature control.

[0031] Based on the disturbance results and melt flow state, the system calculates the flow velocity uniformity index, which reflects the flow velocity uniformity at the spinneret outlet, ensuring that the flow velocity of the melt does not fluctuate significantly during the forming process.

[0032] If the flow rate uniformity index is lower than the set threshold, the system will initiate additional disturbance control to further optimize the flow rate. By calculating the flow rate uniformity index, the system can dynamically monitor and optimize the melt flow rate distribution. In actual operation, if unevenness occurs, the system will adjust in time to ensure that the melt flow rate always remains in a stable state. This step helps optimize fiber forming quality, reduce defect rates, and ensure product consistency and high strength properties. This step combines the design results from the first two steps with the actual melt flow state. By calculating the flow rate uniformity index in real time and adjusting the system based on the feedback, the interaction between disturbance control and microstructure design ensures the stability and consistency of the final fiber quality.

[0033] Based on the directional temperature compensation result output by the temperature determination module, the fish scale-like microstructure receives the trigger signal, adjusts the disturbance amplitude, and outputs an adjustable disturbance result. The system adjusts the flow rate uniformity according to the disturbance result and temperature compensation, so that the melt flow rate matches the target set value, thereby further improving the quality of the fiber.

[0034] It can coordinate the adjustment of temperature and flow rate according to the actual working conditions, effectively improve the orientation of fiber molecular chains, and thus improve the mechanical properties of fibers, such as strength and modulus. Through precise flow rate and temperature adjustment, the stability of the molding process is greatly enhanced, and production efficiency and quality are improved. This step enables the coordinated regulation of flow rate and temperature. The close cooperation between the temperature compensation and flow rate regulation modules ensures high-quality output during the fiber forming process. The synergistic effect of disturbance results and temperature compensation ultimately achieves high-quality fiber forming through the flow rate uniformity index.

[0035] Example 4: Figure 1 As shown, specifically: the temperature determination module first collects the actual temperature data at the spinneret outlet and calculates the difference with the target temperature parameter to obtain the temperature deviation value ΔT. Next, the temperature determination module compares the temperature deviation value ΔT with the allowable critical temperature deviation to determine whether the current temperature deviation is within the allowable range. If the ratio of the temperature deviation value ΔT to the critical temperature deviation exceeds a preset threshold, the subsequent temperature adjustment mechanism is triggered.

[0036] By accurately calculating temperature deviations and comparing them with the allowable temperature fluctuation range, the system can monitor temperature stability in real time and promptly determine whether adjustments are needed, thus avoiding fiber quality instability caused by temperatures exceeding the tolerance range. This temperature determination method based on difference calculation and ratio comparison greatly improves the system's response sensitivity, enabling rapid response to environmental changes and ensuring temperature stability during the molding process.

[0037] After performing difference calculation and ratio comparison, the temperature determination module generates a temperature level determination result. If the result exceeds the preset temperature stability threshold, a threshold over-limit detection action is performed, and a trigger signal is output. This trigger signal is sent to the fish-scale-like microstructure control module to activate the disturbance regulation mechanism and adjust the melt flow rate and molecular chain orientation.

[0038] Threshold over-limit detection automatically initiates subsequent control measures when temperature fluctuations exceed a predetermined range. Through this real-time monitoring and triggering mechanism, the system can promptly activate disturbance control, ensuring the fiber forming quality remains stable in the face of environmental fluctuations. This effectively avoids problems such as uneven flow rate and poor molecular chain orientation caused by abnormal temperatures, thereby improving fiber strength and modulus.

[0039] When the temperature determination module outputs a trigger signal, the fish scale-like microstructure control module receives the signal and initiates a disturbance control action. This action includes adjusting the amplitude of the microstructure and dynamically adjusting the disturbance intensity according to the state of the melt flow. The microstructure generates micro-disturbances around the spinneret outlet, thereby affecting the flow velocity distribution, making the flow velocity more uniform, and ensuring that the melt flow is more stable during the fiber forming process.

[0040] By manipulating the microstructure, not only can flow rate be homogenized, but turbulence or inhomogeneity in melt flow can also be eliminated, thereby improving the uniformity of fiber molecular chain orientation and enhancing the fiber's mechanical properties. This effectively improves the control precision during the molding process, ensuring the stability and high quality of the final product.

[0041] The integrated control module generates comprehensive control indicators based on the temperature level determination and flow rate uniformity index. This module then jointly adjusts the workload of the temperature compensation module and the flow rate control module according to these indicators, ultimately outputting a dual-gradient control signal. This dual-gradient control signal regulates both temperature and flow rate, thereby optimizing the polyethylene fiber molding process and ensuring the high strength and high modulus properties of the fibers.

[0042] Through intelligent adjustment by the integrated control module, the system can automatically adjust temperature and flow rate under different operating conditions, ensuring temperature stability and flow rate uniformity during fiber forming. This linkage control mechanism can quickly respond to temperature changes and flow rate disturbances during forming, ensuring that the molecular chain structure of the fiber reaches optimal orientation, thereby improving the physical properties of the fiber. Ultimately, this optimizes the forming effect and improves the fiber's strength, modulus, and overall stability.

[0043] The temperature and flow rate dual-gradient control system in this embodiment ensures the temperature stability and flow rate uniformity of polyethylene fibers during the molding process through precise temperature monitoring and flow rate disturbance control, combined with disturbance adjustment based on the fish-scale microstructure. Through the coordinated adjustment of the integrated control module, the system can automatically optimize operating conditions in response to changes in temperature and flow rate, improving fiber performance and production efficiency, ultimately achieving high-strength, high-modulus polyethylene fiber molding results.

[0044] Example 5: Figure 1 As shown, specifically: the temperature determination module monitors the actual temperature of the spinneret in real time and calculates the temperature deviation by comparing it with the target temperature, thereby determining whether temperature adjustment is needed. When the temperature deviation exceeds a preset threshold, the module triggers the flow rate control module to adjust the melt flow rate and further optimize the quality during the fiber forming process.

[0045] The temperature determination module obtains the actual outlet temperature of the spinneret through the temperature acquisition module, and at the same time, the system compares it with the preset target temperature.

[0046] The temperature deviation ΔT is calculated based on the difference between the actual temperature and the target temperature. If the actual temperature is higher than the target temperature, ΔT is positive; if the actual temperature is lower than the target temperature, ΔT is negative.

[0047] The calculated temperature deviation ΔT is compared with the preset allowable temperature deviation threshold, and the ratio is used to assess the severity of the temperature deviation.

[0048] Based on the ratio calculation, the system determines whether the temperature deviation is within the allowable range. If ΔT exceeds the preset threshold, it indicates that the temperature deviation is too large, and temperature compensation is required.

[0049] Based on the ratio calculation or grading results, the temperature determination module generates a temperature level determination result. If the temperature deviation ΔT exceeds the set allowable range, a corresponding trigger signal is output.

[0050] Once the temperature level determination result shows that the temperature deviation exceeds the threshold, the temperature determination module will output a trigger signal to the flow rate control module; After receiving the trigger signal, the flow rate control module will activate the corresponding adjustment mechanism, such as adjusting the flow rate at the spinneret outlet or other related parameters, to ensure that the polyethylene melt flow rate is uniform, thereby optimizing the fiber forming process.

[0051] In this embodiment, the introduction of the temperature determination module and its linkage with the flow rate control module effectively improve the system's automated adjustment capability. During the fiber forming process, the system can automatically determine whether to trigger flow rate adjustment based on the deviation between the spinneret temperature and the target temperature, ensuring stable fiber quality and efficient production.

[0052] Example 6: As Figure 1 As shown, specifically, the integrated control module generates integrated control indicators based on the temperature level determination results and flow rate uniformity index. It then coordinates the temperature compensation module and flow rate control module through dual-gradient regulation signals to ultimately optimize the molding quality of polyethylene fibers, ensuring stable spinneret outlet temperature and uniform flow rate. This process involves the joint regulation of temperature and flow rate, and achieves high strength and high modulus of the fibers through synchronous coupling control of the melt's molecular chain orientation.

[0053] The temperature determination module calculates the temperature deviation at the spinneret and generates a temperature level determination result. If the temperature deviation exceeds a preset threshold, temperature compensation measures are triggered. The flow rate control module calculates the flow rate uniformity index based on the flow rate disturbance and microstructure adjustment at the spinneret. If there is flow rate non-uniformity, the system will activate flow rate control optimization measures. The integrated control module combines the temperature level determination result with the flow rate uniformity index to form integrated input data. This data integrates two key performance parameters, namely temperature stability and flow rate uniformity, and provides a joint adjustment input for the system. The integrated control module generates integrated control indicators based on the integrated input data. These indicators reflect the stability and efficiency of the current system operation. When the comprehensive control index is greater than or equal to the preset stability threshold, the comprehensive control module generates a full-power command, which indicates that the system is in a stable operating state and can perform full-power temperature compensation and flow rate homogenization operations.

[0054] The full-power command is simultaneously input to the environmental compensation module and the fish-scale-like microstructure control module, initiating the temperature regulation and flow rate regulation processes.

[0055] According to the full power command, the environmental compensation module performs temperature compensation to ensure that the spinneret temperature is stable. The compensation process uses phase change materials to absorb or release heat to regulate the spinneret temperature and keep it within the target range.

[0056] The fish-scale microstructure control module adjusts the flow rate disturbance according to the full power command, optimizes the uniformity of the melt flow rate, and enhances the uniform flow of the melt by adjusting the microstructure on the surface of the spinneret, thereby reducing flow rate fluctuations.

[0057] The temperature stabilization results and flow rate homogenization results are integrated and processed in the comprehensive control module to generate the final dual-gradient control result. This result simultaneously adjusts the workload of the environmental compensation module and the fish scale microstructure control module to ensure the stability and uniformity of the spinneret temperature and flow rate.

[0058] The resulting dual-gradient regulation affects the molecular chain orientation process of polyethylene melt. By simultaneously coupling and controlling temperature stability and flow rate homogenization, uniform molecular chain orientation in the melt is ensured, improving fiber tensile strength. With the optimization of molecular chain orientation, crystallinity evolution is effectively controlled, further enhancing fiber mechanical properties such as modulus and tensile strength.

[0059] By synchronously controlling temperature, flow rate, molecular chain orientation, and crystallinity, the system can ultimately produce polyethylene fibers with high strength and high modulus. These fibers not only meet molding requirements but also possess excellent physical properties, satisfying the needs of high-end applications.

[0060] This embodiment utilizes intelligent adjustment by a comprehensive control module to ensure stable operation of the ship fiber forming system under various working conditions, while effectively improving the mechanical properties of polyethylene fibers. By precisely controlling temperature, flow rate, molecular chain orientation, and crystallinity, the system can ultimately produce high-strength, high-modulus polyethylene fibers efficiently.

[0061] like Figure 2 As shown, this application provides a high-strength, high-modulus polyethylene spinneret temperature-flow-rate dual-gradient fiber forming system, the specific steps of which include: The outlet temperature of the spinneret is detected at the spinneret outlet, and the actual temperature is compared with the preset target temperature to calculate the temperature deviation value. The temperature deviation value is used as the input reference for subsequent control and adjustment.

[0062] Based on the magnitude of the temperature deviation, the system determines whether the temperature is within the normal range. When the temperature deviation exceeds a preset threshold, the system generates tiered temperature adjustment commands. Different deviation ranges correspond to different control levels, achieving tiered control from coarse to fine adjustment.

[0063] Under the action of the graded regulation command, the system synchronously regulates temperature and flow rate through a dual-path approach: On the one hand, the phase change material layer integrated into the spinneret is used for heat absorption or release compensation to achieve stable temperature control; On the other hand, activating the biomimetic microstructure disturbance channel circumferentially etched at the spinneret improves the uniformity of the flow velocity distribution by locally disturbing the melt flow velocity.

[0064] The dual-path collaborative execution ensures that flow rate uniformity is improved while temperature control is achieved.

[0065] After completing the dual-path adjustment, the system again collects the temperature and flow rate at the spinneret outlet using sensors, compares the actual operating data with the target setpoint, and generates new deviation information. This deviation information is fed back to the control module to dynamically optimize the hierarchical control commands and the dual-path adjustment strategy, forming a closed-loop control.

[0066] Through the above steps, this embodiment can simultaneously achieve dual-gradient control of temperature stability and flow rate uniformity during the polyethylene fiber molding process, ensuring high orientation and high crystallinity of melt molecular chains, thereby significantly improving the strength and modulus of the fiber.

[0067] The foregoing has shown and described the basic principles, main features, and advantages of this application. Those skilled in the art should understand that this application is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of this application. Various changes and modifications can be made to this application without departing from the spirit and scope thereof, and all such changes and modifications fall within the scope of this application as claimed. The scope of protection of this application is defined by the appended claims and their equivalents.

Claims

1. A high-strength, high-modulus polyethylene spinneret temperature-flow-rate dual-gradient fiber forming system, characterized in that, The system includes: The temperature acquisition module is used to acquire the spinneret outlet temperature parameters and compare them with the target temperature parameters to generate a temperature deviation value ΔT. The environmental compensation module is used to perform heat absorption or heat release actions based on the temperature deviation value ΔT and output the temperature compensation result. The temperature determination module is used to receive the temperature compensation result, generate a temperature level determination result based on the temperature compensation result, and output a trigger signal when the temperature level determination result exceeds a preset threshold. The flow rate control module is used to receive the trigger signal output by the temperature determination module. When the trigger signal exceeds the preset disturbance threshold, it performs an amplitude adjustable action, adjusts the amplitude of the disturbance based on the disturbance coefficient, generates a disturbance result, and calculates the flow rate uniformity index based on the disturbance result. The integrated control module receives the temperature level determination result and the flow rate uniformity index, generates an integrated control index based on the temperature level determination result and the flow rate uniformity index, and adjusts the working intensity of the environmental compensation module and the flow rate regulation module according to the integrated control index, thereby outputting a dual-gradient regulation result.

2. The system according to claim 1, characterized in that, The flow rate control module includes a fish-scale-like microstructure at the spinneret outlet, specifically used for: The fish-scale-like microstructure is etched on the circumferential surface of the spinneret outlet, and the etching depth parameter corresponds to the melt flow velocity distribution parameter. The melt flow rate distribution parameters and the etching depth parameters are used to geometrically map the fish-scale-like microstructure to obtain a set of circumferential geometric parameters. The circumferential micro-perturbation action is performed on the spinneret outlet based on the circumferential geometric parameter set and melt flow state to generate perturbation results, and the flow velocity uniformity index is calculated based on the perturbation results.

3. The system according to claim 2, characterized in that, The flow rate control module is specifically used for: The fish-scale-like microstructure receives the directional temperature compensation result output by the temperature determination module as a trigger signal. When the trigger signal exceeds the disturbance threshold, it performs an amplitude-adjustable action and adjusts the disturbance amplitude according to the disturbance coefficient, outputting an adjustable disturbance result. The adjustable perturbation result serves as a perturbation source, and the flow velocity uniformity is adjusted through the geometric mapping and flow state. Based on the disturbance results and velocity distribution parameters, a velocity uniformity index is calculated, and an adjustment signal is output based on this index to optimize the melt velocity distribution.

4. The system according to claim 1, characterized in that, The environmental compensation module specifically includes a phase change material compensation layer integrated into the spinneret: The phase change material compensation layer is provided with a multi-layer encapsulation structure along the thickness direction of the spinneret, and different encapsulation layers have different latent heat parameters. The temperature deviation value ΔT and the multilayer packaging structure parameter set are used to perform threshold matching judgment on the phase change material compensation layer to obtain the layered trigger sequence; The layered trigger sequence and the latent heat parameter set perform a layer-by-layer heat absorption action on the phase change material compensation layer to obtain the layered temperature compensation result.

5. The system according to claim 4, characterized in that, The environmental compensation module is specifically used for: When the phase change material compensation layer performs the layer-by-layer heat absorption action, the sign of the temperature deviation value ΔT determines whether the deviation is positive or negative. When the temperature deviation value ΔT is positive, a directional compensation command is generated, and a directional heat release action is performed based on the directional compensation command; When the temperature deviation value ΔT is negative, a directional compensation command is generated, and a directional heat absorption action is performed based on the directional compensation command; The directional compensation command, combined with the layered temperature compensation result, performs directional heat absorption or release on the phase change material compensation layer and outputs the directional temperature compensation result. The directional temperature compensation result is input to the temperature determination module as the input parameter for subsequent temperature compensation.

6. The system according to claim 5, characterized in that, The temperature determination module is specifically used for: The difference between the directional temperature compensation result and the spinneret target temperature is calculated to generate the temperature deviation ΔT; The temperature level determination result is generated by calculating the ratio of temperature deviation ΔT to a preset allowable deviation threshold or by classifying the temperature level. When the temperature level determination result exceeds the preset threshold, a trigger signal is output to the flow rate control module.

7. The system according to claim 1, characterized in that, The integrated control module is specifically used for: Receive the temperature level determination result and the flow rate uniformity index, and perform parameter combination actions based on the temperature level determination result and the flow rate uniformity index to generate comprehensive input data; The integrated control module generates integrated control indicators based on the integrated input data.

8. The system according to claim 7, characterized in that, The integrated control module is specifically used for: When the comprehensive control index is greater than or equal to the preset stability threshold, a full power command is generated. The full-power command is input to the environmental compensation module and the fish-scale microstructure control module respectively: The environmental compensation module performs temperature compensation based on the full-power command and outputs a temperature stabilization result. The fish-scale-like microstructure control module executes a disturbance action based on the full-power command and outputs a flow velocity uniformization result. The integrated control module integrates the temperature stabilization result and the flow rate homogenization result to generate the final dual-gradient regulation result. The dual-gradient control results are used to coordinate the control environment compensation module and the fish-scale microstructure control module to achieve temperature stability and flow rate uniformity at the spinneret outlet.

9. The system according to claim 8, characterized in that, The integrated control module is specifically used for: After generating the aforementioned dual-gradient modulation results: The temperature stabilization result and the flow rate homogenization result are synchronously coupled and controlled to achieve the molecular chain orientation process of polyethylene melt, thereby obtaining the molecular chain orientation homogenization result. The homogenization of molecular chain orientation and the evolution parameters of crystallinity are used to synergistically optimize the fiber curing process, resulting in high-strength, high-modulus polyethylene fiber molding.

10. The system according to claim 1, characterized in that, The system also includes a status display module, specifically used for: The system receives and displays the temperature parameters acquired by the temperature acquisition module and the dual-gradient control results generated by the integrated control module.

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