Process for producing 6.0 Kg twisted yarns through parallel passages by using tank furnace wire drawing method

Abstract

The invention relates to the technical field of tank furnace wire drawing, in particular to a tank furnace wire drawing method parallel passage 6.0 Kg twisted yarn production process, which comprises the following steps of: dissolving raw materials by using a glass solution, performing wire drawing forming, transforming a wire drawing machine, performing twisting treatment, and performing winding and packaging. The tension fluctuation during winding and turning is controlled within + / -5%, the filament flying phenomenon is reduced, the operation efficiency and stability are improved, the precise twisting treatment process is combined with high-quality raw materials and the fine melting process, it is guaranteed that the yarn is excellent in strength, abrasion resistance, flexibility and the like, the quality of glass fiber precursors is guaranteed, and a foundation is laid for producing high-quality yarn; full-automatic equipment and a control system cover the whole production process, manual intervention is reduced from raw material feeding to packaging and warehousing, and the production efficiency and the product quality stability are improved. And data in each link are monitored, regulated and controlled in real time, so that accurate execution of process parameters is ensured, and the consistency and reliability of products are enhanced.

Description

Technical Field

[0001] This invention relates to the field of tank furnace drawing technology, and in particular to the production process of 6.0Kg twisted yarn using the parallel channel method in tank furnace drawing. Background Technology

[0002] The tank furnace drawing process is a mainstream technology for producing glass fibers. This method involves melting raw materials such as pyrophyllite into a glass molten metal in a furnace, then removing air bubbles and conveying it through a channel to a porous stencil, and finally drawing it into glass fiber filaments using a high-speed drawing machine.

[0003] Currently, most mainstream twisted yarn production processes operate in a vertical path (with the spinneret and the path perpendicular to each other). Vertical path production results in relatively stable twisted yarn formation, while parallel path production, due to higher tension, leads to lower efficiency and cannot achieve stable mass production. Through further research, verification, and modification, a parallel path process has been developed to produce small-batch 3.0kg glass fiber twisted yarn. However, existing processes and equipment cannot meet the production requirements for large-batch glass fiber twisted yarn (>6.0kg). Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a process for producing 6.0 kg twisted yarn using a parallel channel in a pool kiln drawing method, thereby solving the technical problems mentioned in the background section.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] 1. A process for producing 6.0 kg twisted yarn using a parallel flow method in a tank kiln, characterized by the following steps:

[0007] Step 1: Raw material selection

[0008] The raw materials are mixed in a ratio of 60% pyrophyllite, 20% soda ash, 15% limestone and 5% borax by weight, and then put into a kiln and melted at 1400℃ to form a uniform glass melt.

[0009] Step 2, Melting of glass melt: The furnace is equipped with a temperature monitoring system and an automatic adjustment device, which can monitor the temperature of the glass melt in real time and automatically adjust the fuel supply according to the set temperature curve to ensure that the temperature of the glass melt is stable within the range of 1400℃±5℃, thereby ensuring the quality stability and composition uniformity of the glass melt. After being fully melted and clarified, the glass melt flows into the channel through the flow hole, ready for the subsequent wire drawing process.

[0010] Step 3, drawing and forming: The tension of the glass fiber filament is monitored and precisely controlled in real time through a high-precision tension detection device and an automatic control system to ensure that the tension is stable within the range of 50-80N, thus ensuring the quality stability and consistency of the glass fiber filament.

[0011] Step 4, Fiber Drawing Machine Modification: During the movement of the bundling nozzle, the glass fiber filaments are consistently guided by the nozzle, preventing filament fly-off caused by sudden tension changes. Simultaneously, the special design of the bundling nozzle ensures the integrity of the glass fiber filaments during the bundling process, improving yarn quality and strength. After winding and turning, the hydraulic drive system drives the bundling nozzle assembly back to its initial position to continue normal fiber drawing and winding operations.

[0012] Step 5, Twisting treatment: When the glass fiber filament passes through the twisting roller, the high-speed rotation of the twisting roller causes the filament to twist and deform, forming a uniform spiral structure, thus completing the twisting process. Through precise control of the twisting tension and twist degree, the twisted glass fiber yarn not only has excellent strength and abrasion resistance, but also good flexibility and weaving performance, which can meet the needs of various application scenarios.

[0013] Step 6, Winding and Packaging: The process can be flexibly adjusted according to the specifications of the yarn spindle and production needs. The yarn spindle is made of high-strength plastic material, and the inner wall is treated with anti-static agents to reduce static electricity generated by friction between the yarn and the yarn spindle during winding. The winding capacity of the yarn spindle is designed to be 6.0Kg. It is equipped with a high-sensitivity tension sensor to monitor the winding tension in real time. The speed of the winding roller is automatically adjusted by the PLC control system to ensure that the tension is stable within the range of (65±5)N.

[0014] In one possible implementation, during the melting of the glass solution, pyrophyllite blocks are first crushed to a particle size of less than 5 mm to increase their specific surface area, facilitating chemical reactions and uniform heating during subsequent melting. Soda ash, limestone, and borax are each sieved through a 200-mesh sieve to ensure uniform and fine particle size, preventing incomplete dissolution of large particles or localized overheating during melting. The treated pyrophyllite, soda ash, limestone, and borax are then precisely mixed on a high-precision electronic batching scale. The mixing process uses a three-dimensional motion mixer at a speed of 60 rpm for 30 minutes to ensure thorough and uniform dispersion of the raw materials and uniformity of their chemical composition. The uniformly mixed raw materials are then slowly fed into a tank kiln through an automatic feeding system. A 300 mm thick layer of heat-insulating refractory material is pre-laid at the bottom of the tank kiln to reduce heat loss and protect the kiln structure. The kiln's heating system is ignited, using natural gas as fuel, and the temperature inside the kiln is gradually raised to 1400°C at a rate of 100°C per hour through an automatic combustion control system.

[0015] In one possible implementation, during the melting of the glass molten glass, the stirring device inside the furnace is turned on during the heating process, and the glass is slowly stirred at a low speed of 30 rpm to promote uniform heating and melting of the raw materials and prevent local overheating that could cause segregation of glass components. When the temperature inside the furnace reaches 1400°C, this temperature is maintained and heated continuously for 6 hours, allowing the raw materials to fully melt at high temperatures and undergo complex chemical reactions to form a uniform and transparent glass molten glass. During the melting process, an appropriate amount of compressed air is introduced into the glass molten glass through the feeding port at the top of the furnace to generate bubbles. These bubbles can effectively carry out impurities and volatile components in the glass molten glass as they rise, thus refining and clarifying the glass molten glass.

[0016] In one possible implementation, after the glass melt is melted, the glass melt, with its temperature strictly controlled between 1380-1400℃, is fed into the flow path system of the wire drawing machine in a stable and continuous flow state through a flow channel. At this time, the viscosity of the glass melt is maintained at 20-25 Pa·s to ensure good fluidity and provide an ideal state for subsequent wire drawing processes. The flow rate of the stencil is precisely controlled to keep it stably below 70 kg. This process uses a 2400-hole stencil made of high-purity platinum-rhodium alloy, wherein the platinum content is... With a purity exceeding 95% and a rhodium content of approximately 5%, this type of stencil possesses excellent high-temperature resistance and corrosion resistance, maintaining stable performance even under prolonged high-temperature operation. This ensures uniform flow and stable wire drawing of the molten glass within the stencil. As the molten glass flows into the stencil, it flows evenly through 2400 micro-pores, forming nascent fibers. These nascent fibers, with a diameter between 15-20 μm, are relatively fragile at this stage and require immediate cooling to rapidly solidify and enhance their mechanical strength. In the cooling zone, multiple... The cooling process involves a multi-stage cooling system. First, a high-efficiency centrifugal fan blows cooling air at a temperature controlled at 10-15℃ and a speed of 5-8m / s evenly onto the surface of the nascent glass fibers, rapidly reducing the temperature to 600-700℃ for initial cooling. Next, a spray cooling device evenly sprays ultrafine water mist with a particle size of 5-10μm onto the glass fiber surface. The water mist rapidly vaporizes upon contact with the high-temperature glass fibers, absorbing a large amount of heat and further reducing the temperature to 200-300℃, completing deep cooling. During the cooling process, the temperature of the cooling area is monitored and precisely controlled in real time by a precision temperature sensor and an automatic control system to ensure the consistency and stability of the cooling effect. After cooling, the glass fiber enters the sizing agent coating device. The sizing agent is carefully formulated and mainly contains silane coupling agent, film-forming agent and lubricant. The content of silane coupling agent is 15-20%, the content of film-forming agent is 30-35%, and the content of lubricant is 45-50%. The components work synergistically to significantly improve the surface properties and processing performance of the glass fiber.

[0017] In one possible implementation, the coating device in the fiber drawing process employs an advanced electrostatic atomizing nozzle to uniformly spray the sizing agent onto the surface of the glass fiber. This allows the sizing agent to quickly and evenly cover each fiber, forming a uniform protective film. Through precise control, the coating amount of the sizing agent is stabilized within the range of 0.8-1.2%, ensuring good bundleability and lubrication of the glass fiber during subsequent bundling and processing. After the sizing agent coating is completed, the glass fiber enters the bundling stage, where a high-precision bundling device uniformly bundles multiple glass fibers together to form glass fiber filaments of a certain thickness. The bundling device adopts an advanced servo motor drive system, which can automatically adjust the bundling force and speed according to the running speed of the drawing machine and the tension of the glass fiber, ensuring the forming quality of the glass fiber filaments. During the bundling process, by applying appropriate tension to the glass fiber, the diameter of the glass fiber filaments is stabilized within the range of 10-15μm, ensuring that it has good mechanical properties and processing performance. The glass fiber filaments are introduced into the high-speed winding system of the drawing machine. Under the high-speed traction and winding action of the drawing machine, the glass fiber filaments are evenly wound on the winding drum to form a glass fiber filament roll with specifications of 264cm×φ300cm×2cm.

[0018] In one possible implementation, during the wire drawing process, when a winding and turning operation is required, the control system of the wire drawing machine sends a command to the hydraulic drive system. The hydraulic drive system responds quickly and pushes the bundle nozzle assembly on the telescopic guide rail to a preset telescopic position.

[0019] In one possible implementation, the twisting process involves introducing the glass fiber filaments obtained through the drawing and forming process into a specially designed twisting device. This device mainly consists of a twisting roller driven by a high-performance servo motor, a high-precision tension controller, and an intelligent twist adjuster. The twisting roller is made of high-quality alloy steel with a special surface hardening treatment, exhibiting extremely high wear resistance and deformation resistance. This ensures that the twisting effect remains accurate even during long-term high-speed operation. The roller has a diameter of 120mm and a length of 300mm, and its surface is covered with fine anti-slip textures, which effectively enhances the friction between the roller and the glass fiber filaments, making the twisting process more stable and reliable.

[0020] In one possible implementation, a high-precision tension controller is installed at a critical position before the glass fiber filament enters the twisting roller during the twisting process. Its core component is a high-sensitivity strain gauge sensor, which can monitor the tension changes of the glass fiber filament in real time and feed the data back to the control system at a frequency of 100 times per second. Based on the preset tension value of 65N, the control system quickly calculates and adjusts the damper in the tension controller through a precise algorithm to strictly control the tension fluctuation range within ±3N, ensuring that the glass fiber filament is always in an ideal tension state during the twisting process. This precise tension control can not only effectively prevent yarn loosening due to insufficient tension, but also avoid yarn breakage caused by excessive tension, greatly improving production efficiency and yarn quality.

[0021] In one possible implementation, the twisting process precisely controls the twist by changing the rotation speed of the twisting roller. During production, the target twist is set to 160 twists / m. The intelligent twist adjuster calculates and adjusts the roller speed in real time based on the linear density of the glass fiber filament and the rotation speed of the twisting roller, ensuring that the twist accuracy error is controlled within ±2 twists / m. At the same time, the adjuster has self-learning and adaptive functions, and can automatically optimize the twist control parameters according to different production conditions to achieve the best twisting effect.

[0022] In one possible implementation, after the glass fiber filaments have been twisted, they are introduced into the winding system. The core component of the winding system is the winding roller, whose surface is treated with high-precision polishing to achieve a roughness of Ra0.8, ensuring that the yarn is wound smoothly. The speed of the winding roller is steplessly regulated by a frequency converter, ranging from 300 to 500 r / min.

[0023] Beneficial effects compared to existing technologies:

[0024] 1. In this solution, the TTS device of the wire drawing machine, through the movable and retractable bundle nozzle assembly and the hydraulic drive system, controls the tension fluctuation during winding and turning within ±5%, reduces wire flying, and improves work efficiency and stability.

[0025] 2. In this solution, the precise twisting process, combined with high-quality raw materials and refined melting technology, ensures excellent yarn strength, abrasion resistance, flexibility, and other properties, meeting the needs of various applications. Strict control over glass melt melting and fiber drawing parameters guarantees the quality of the glass fiber filaments, laying the foundation for producing high-quality yarn.

[0026] 3. In this solution, fully automated equipment and control systems cover the entire production process, from raw material feeding to packaging and warehousing, reducing manual intervention and improving production efficiency and product quality stability. Real-time monitoring and control of data at each stage ensures precise execution of process parameters, enhancing product consistency and reliability. Attached Figure Description

[0027] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention and to implement it in accordance with the contents of the specification, the preferred embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0028] Figure 1 This is a schematic diagram of the method flow of the present invention;

[0029] Figure 2 This is a schematic diagram of the yarn and oiling roller coating device of the present invention;

[0030] Figure 3 This is a schematic diagram of the wire drawing machine bundling device of the present invention;

[0031] Figure 4 This is a schematic diagram of the winding drum position of the wire drawing head of the present invention;

[0032] Figure 5 This is a schematic diagram showing the distance and angle between the yarn and the spray center of the present invention. Detailed Implementation

[0033] Preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. However, the present invention can also be implemented in various different forms, and therefore the present invention is not limited to the embodiments described below.

[0034] The technical solution in this application embodiment is to solve the problems mentioned in the background art, and the overall idea is as follows:

[0035] Example:

[0036] Please refer to Figures 1 to 5 As shown, this embodiment introduces the production process of 6.0Kg twisted yarn using the tank kiln drawing method with parallel channels, including the following steps:

[0037] Step 1: Raw material selection

[0038] The raw materials are mixed in a ratio of 60% pyrophyllite, 20% soda ash, 15% limestone and 5% borax by weight, and then put into a kiln and melted at 1400℃ to form a uniform glass melt.

[0039] Step 2: Preparation of glass solution

[0040] Step 2.1: First, crush the pyrophyllite blocks to a particle size of less than 5mm to increase their specific surface area, which facilitates the chemical reaction and uniform heating in the subsequent melting process. Soda ash, limestone and borax are passed through a 200-mesh sieve to ensure uniform and fine particle size, and to avoid large particles from being incompletely dissolved or causing local overheating during the melting process.

[0041] Step 2.2: Add the treated pyrophyllite, soda ash, limestone and borax together into a high-precision electronic batching scale for precise mixing. The mixing process uses a three-dimensional motion mixer, which mixes at a speed of 60 rpm for 30 minutes to ensure that the raw materials are fully and evenly dispersed and to ensure the uniformity of their chemical composition.

[0042] Step 2.3: The uniformly mixed raw materials are slowly fed into the tank kiln through an automatic feeding system. A 300mm thick layer of heat-insulating refractory material is pre-laid at the bottom of the tank kiln to reduce heat loss and protect the kiln structure. The kiln's heating system is ignited, using natural gas as fuel. The temperature inside the kiln is gradually raised to 1400℃ at a rate of 100℃ per hour through an automatic combustion control system.

[0043] Step 2.4: During the heating process, turn on the stirring device in the furnace and stir slowly at a low speed of 30 rpm to promote uniform heating and melting of the raw materials and prevent local overheating that could cause segregation of glass components.

[0044] Step 2.5: When the temperature inside the kiln reaches 1400℃, maintain this temperature and continue heating for 6 hours to allow the raw materials to fully melt at high temperature and undergo complex chemical reactions to form a uniform and transparent glass melt.

[0045] Step 2.6: During the melting process, an appropriate amount of compressed air is introduced into the molten glass through the feeding port at the top of the furnace to generate bubbles. As these bubbles rise, they can effectively carry out impurities and volatile components in the molten glass, thus refining and clarifying the molten glass.

[0046] Step 2.7: The furnace is equipped with a temperature monitoring system and an automatic adjustment device, which can monitor the temperature of the molten glass in real time and automatically adjust the fuel supply according to the set temperature curve to ensure that the temperature of the molten glass is stable within the range of 1400℃±5℃, thereby ensuring the quality stability and compositional uniformity of the molten glass. After being fully melted and clarified, the molten glass flows into the channel through the flow hole, ready for the subsequent wire drawing process.

[0047] Step 3, wire drawing and shaping

[0048] Step 3.1: After the glass melt is melted, the glass melt, with its temperature strictly controlled between 1380-1400℃, is fed into the flow path system of the wire drawing machine in a stable and continuous flow state through the flow channel. At this time, the viscosity of the glass melt is maintained at 20-25 Pa·s to ensure good fluidity and provide an ideal state for subsequent wire drawing processes. Simultaneously, the flow rate of the stencil is precisely controlled to keep it stably below 70 kg. This process uses a 2400-hole stencil made of high-purity platinum-rhodium alloy, with a platinum content of over 95% and a rhodium content of approximately 5%. This type of stencil has excellent high-temperature resistance and corrosion resistance, maintaining stable performance under prolonged high-temperature operating conditions, ensuring uniform flow of the glass melt in the stencil and stable wire drawing.

[0049] Step 3.2: After the molten glass flows into the baffle plate, it will flow evenly from the 2400 tiny holes in the baffle plate, forming nascent fibers. These nascent fibers have a diameter between 15-20 μm. At this stage, the nascent fibers are relatively fragile and require immediate cooling to rapidly solidify them and enhance their mechanical strength. In the cooling zone, a multi-stage cooling device is used for cooling operations. First, a high-efficiency centrifugal fan is used to evenly blow cooling air at a temperature controlled at 10-15℃ and a wind speed of 5-8 m / s onto the surface of the nascent fibers, rapidly reducing the temperature of the glass fibers to 600-700℃, completing the initial cooling. Next, a spray cooling device is used to uniformly spray ultrafine water mist with a particle size of 5-10μm onto the surface of the glass fiber. The water mist vaporizes rapidly upon contact with the high-temperature glass fiber, absorbing a large amount of heat and further reducing the temperature of the glass fiber to 200-300℃, thus completing deep cooling. Throughout the cooling process, a precise temperature sensor and an automatic control system monitor and precisely control the temperature of the cooling area in real time to ensure the consistency and stability of the cooling effect.

[0050] Step 3.3: After cooling, the glass fiber enters the sizing agent coating device. The sizing agent is carefully formulated and mainly contains silane coupling agent, film-forming agent and lubricant. The content of silane coupling agent is 15-20%, the content of film-forming agent is 30-35%, and the content of lubricant is 45-50%. The components work synergistically to significantly improve the surface properties and processing performance of the glass fiber.

[0051] Step 3.4: The coating device uses an advanced electrostatic atomizing nozzle to evenly spray the sizing agent onto the surface of the glass fiber, so that the sizing agent can quickly and evenly cover each fiber to form a uniform protective film. Through precise control, the coating amount of sizing agent is stabilized within the range of 0.8-1.2%, ensuring that the glass fiber has good bundle and lubrication properties in the subsequent bundling and processing.

[0052] Step 3.5: After the sizing agent coating is completed, the glass fibers enter the bundling stage. Multiple glass fibers are uniformly bundled together using a high-precision bundling device to form glass fiber filaments of a certain thickness. The bundling device employs an advanced servo motor drive system, which can automatically adjust the bundling force and speed according to the drawing machine's operating speed and the tension of the glass fibers, ensuring the forming quality of the glass fiber filaments. During the bundling process, by applying appropriate tension to the glass fibers, the diameter of the glass fiber filaments is stabilized within the range of 10-15 μm, ensuring good mechanical and processing properties.

[0053] Step 3.6: The fiberglass filaments are introduced into the high-speed winding system of the drawing machine. Under the high-speed traction and winding action of the drawing machine, the fiberglass filaments are evenly wound on the winding drum to form a fiberglass filament roll with specifications of 264cm×φ300cm×2cm.

[0054] Step 3.7: The traction speed of the drawing machine is precisely controlled and stabilized within the range of 3000-4000 m / min to ensure uniform tension and density of the glass fiber filaments during winding. The winding bobbin is made of high-strength, high-wear-resistant aluminum alloy with a finely anodized surface, providing excellent corrosion resistance and friction resistance. This effectively prevents quality problems such as loose strands and kinks in the glass fiber filaments during winding. During winding, a high-precision tension detection device and an automatic control system monitor and precisely control the tension of the glass fiber filaments in real time to ensure that the tension remains stable within the range of 50-80 N, guaranteeing the quality stability and consistency of the glass fiber filaments.

[0055] Step 4: Modification of the wire drawing machine

[0056] Step 4.1: During the wire drawing process, when a winding and turning operation is required, the control system of the wire drawing machine will send a command to the hydraulic drive system. The hydraulic drive system will respond quickly and push the bundle nozzle assembly on the telescopic guide rail to the preset telescopic position.

[0057] Step 4.2: During the movement of the bundling nozzle, the glass fiber filaments are always stably guided by the bundling nozzle, avoiding the phenomenon of flying filaments caused by sudden tension changes. At the same time, the special design of the bundling nozzle ensures the integrity of the glass fiber filaments during the bundling process, improving the quality and strength of the yarn. After the winding and turning is completed, the hydraulic drive system drives the bundling nozzle assembly to return to the initial position and continue the normal drawing and winding operation.

[0058] Step 5: Twisting treatment

[0059] Step 5.1: The glass fiber filaments obtained through the drawing and forming process are introduced into a specially designed twisting device. This device mainly consists of a twisting roller driven by a high-performance servo motor, a high-precision tension controller, and an intelligent twist adjuster. The twisting roller is made of high-quality alloy steel and its surface has undergone special hardening treatment, which has extremely high wear resistance and deformation resistance, ensuring that it can maintain a precise twisting effect during long-term high-speed operation. The roller has a diameter of 120mm and a length of 300mm, and its surface has fine anti-slip texture, which can effectively enhance the friction between the roller and the glass fiber filaments, making the twisting process more stable and reliable.

[0060] Step 5.2: The high-precision tension controller is installed at a critical position before the glass fiber filament enters the twisting roller. Its core component uses a high-sensitivity strain gauge sensor, which can monitor the tension change of the glass fiber filament in real time and feed the data back to the control system at a frequency of 100 times per second. Based on the preset tension value of 65N, the control system quickly calculates and adjusts the damper in the tension controller through a precise algorithm to strictly control the tension fluctuation range within ±3N, ensuring that the glass fiber filament is always in an ideal tension state during the twisting process. This precise tension control can not only effectively prevent yarn loosening due to insufficient tension, but also avoid yarn breakage due to excessive tension, which greatly improves production efficiency and yarn quality.

[0061] Step 5.3: The twist is precisely controlled by changing the rotation speed of the twisting roller. During the production process, the target twist is set to 160 twists / m. The intelligent twist adjuster will calculate and adjust the rotation speed of the roller in real time according to the linear density of the glass fiber filament and the rotation speed of the twisting roller to ensure that the twist accuracy error is controlled within ±2 twists / m. At the same time, the adjuster has a self-learning and adaptation function, and can automatically optimize the twist control parameters according to different production conditions to achieve the best twisting effect.

[0062] Step 5.4: When the glass fiber filament passes through the twisting roller, the high-speed rotation of the twisting roller causes the filament to twist and deform, forming a uniform spiral structure, thus completing the twisting process. Through precise control of the twisting tension and twist degree, the twisted glass fiber yarn not only has excellent strength and abrasion resistance, but also good flexibility and weaving performance, which can meet the needs of various application scenarios.

[0063] Step 6: Wrapping

[0064] After the glass fiber filaments are twisted, they are introduced into the winding system. The core component of this system is the winding roller, whose surface is treated with high-precision polishing to a roughness of Ra0.8, ensuring smooth yarn winding. The winding roller speed is steplessly regulated by a frequency converter, ranging from 300-500 r / min, and can be flexibly adjusted according to the spindle specifications and production needs. The spindle is made of high-strength plastic material, and the inner wall is treated with anti-static agents to reduce static electricity generated by friction between the yarn and the spindle during winding. The spindle winding capacity is designed to be 6.0 kg, and it is equipped with a high-sensitivity tension sensor to monitor the winding tension in real time. The PLC control system automatically adjusts the winding roller speed to ensure that the tension is stable within the range of (65±5) N.

[0065] Finally, it should be noted that the above embodiments are merely examples for clearly illustrating the present invention and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. A process for producing 6.0 kg twisted yarn using a parallel-path production method in a tank kiln, characterized in that: Includes the following steps: Step 1: Raw material selection The raw materials are mixed in a ratio of 60% pyrophyllite, 20% soda ash, 15% limestone and 5% borax by weight, and then put into a kiln and melted at 1400℃ to form a uniform glass melt. Step 2, Melting of glass melt: The furnace is equipped with a temperature monitoring system and an automatic adjustment device, which can monitor the temperature of the glass melt in real time and automatically adjust the fuel supply according to the set temperature curve to ensure that the temperature of the glass melt is stable within the range of 1400℃±5℃, thereby ensuring the quality stability and composition uniformity of the glass melt. After being fully melted and clarified, the glass melt flows into the channel through the flow hole, ready for the subsequent wire drawing process. Step 3, drawing and forming: The tension of the glass fiber filament is monitored and precisely controlled in real time through a high-precision tension detection device and an automatic control system to ensure that the tension is stable within the range of 50-80N, thus ensuring the quality stability and consistency of the glass fiber filament. Step 4, Fiber Drawing Machine Modification: During the movement of the bundling nozzle, the glass fiber filaments are consistently guided by the nozzle, preventing filament fly-off caused by sudden tension changes. Simultaneously, the special design of the bundling nozzle ensures the integrity of the glass fiber filaments during the bundling process, improving yarn quality and strength. After winding and turning, the hydraulic drive system drives the bundling nozzle assembly back to its initial position to continue normal fiber drawing and winding operations. Step 5, Twisting treatment: When the glass fiber filament passes through the twisting roller, the high-speed rotation of the twisting roller causes the filament to twist and deform, forming a uniform spiral structure, thus completing the twisting process. Through precise control of the twisting tension and twist degree, the twisted glass fiber yarn not only has excellent strength and abrasion resistance, but also good flexibility and weaving performance, which can meet the needs of various application scenarios. Step 6, Winding and Packaging: The process can be flexibly adjusted according to the specifications of the yarn spindle and production needs. The yarn spindle is made of high-strength plastic material, and the inner wall is treated with anti-static agents to reduce static electricity generated by friction between the yarn and the yarn spindle during winding. The winding capacity of the yarn spindle is designed to be 6.0Kg. It is equipped with a high-sensitivity tension sensor to monitor the winding tension in real time. The speed of the winding roller is automatically adjusted by the PLC control system to ensure that the tension is stable within the range of (65±5)N.

2. The process for producing 6.0 kg twisted yarn using the parallel channel method in a pool furnace as described in claim 1, characterized in that, In the melting of the glass solution, pyrophyllite blocks are first crushed to a particle size of less than 5 mm to increase their specific surface area, facilitating chemical reactions and uniform heating during subsequent melting. Soda ash, limestone, and borax are each sieved through a 200-mesh sieve to ensure uniform and fine particle size, preventing incomplete dissolution of large particles or localized overheating during melting. The treated pyrophyllite, soda ash, limestone, and borax are then precisely mixed on a high-precision electronic batching scale. The mixing process uses a three-dimensional motion mixer at a speed of 60 rpm for 30 minutes to ensure thorough and uniform dispersion of the raw materials and uniformity of their chemical composition. The uniformly mixed raw materials are then slowly fed into the tank kiln through an automatic feeding system. A 300 mm thick layer of heat-insulating refractory material is pre-laid at the bottom of the tank kiln to reduce heat loss and protect the kiln structure. The kiln's heating system is ignited, using natural gas as fuel. The temperature inside the kiln is gradually raised to 1400°C at a rate of 100°C per hour through an automatic combustion control system.

3. The process for producing 6.0 kg twisted yarn using the parallel path method in a pool kiln as described in claim 2, characterized in that... During the melting of the glass molten glass, the stirring device inside the furnace is turned on during the heating process, and the glass is slowly stirred at a low speed of 30 rpm to promote uniform heating and melting of the raw materials and prevent local overheating that could cause segregation of glass components. When the temperature inside the furnace reaches 1400℃, this temperature is maintained and heated continuously for 6 hours to allow the raw materials to fully melt at high temperatures and undergo complex chemical reactions, forming a uniform and transparent glass molten glass. During the melting process, an appropriate amount of compressed air is introduced into the glass molten glass through the feeding port at the top of the furnace to generate bubbles. These bubbles can effectively carry out impurities and volatile components in the glass molten glass as they rise, thus refining and clarifying the glass molten glass.

4. The process for producing 6.0 kg twisted yarn using the parallel path method in a tank furnace as described in claim 1, characterized in that, In the wire drawing process, after the glass melt is melted, the glass melt, with its temperature strictly controlled between 1380-1400℃, is fed into the wire drawing machine's flow path system in a stable and continuous flow state through a flow channel. At this time, the viscosity of the glass melt is maintained at 20-25 Pa·s to ensure good fluidity and provide an ideal state for subsequent wire drawing processes. The flow rate of the stencil is precisely controlled to keep it stably below 70 kg. This process uses a 2400-hole stencil made of high-purity platinum-rhodium alloy, with a platinum content of over 95% and rhodium content of [missing information]. With a content of approximately 5%, this material's stencil possesses excellent high-temperature resistance and corrosion resistance, maintaining stable performance even under prolonged high-temperature operation. This ensures uniform flow and stable wire drawing of the molten glass within the stencil. When the molten glass flows into the stencil, it flows evenly through 2400 micro-pores, forming nascent fibers. These nascent fibers have a diameter between 15-20 μm. At this stage, the nascent fibers are relatively fragile and require immediate cooling to rapidly solidify them and enhance their mechanical strength. A multi-stage cooling system is used in the cooling zone. The cooling process begins with a high-efficiency centrifugal fan blowing cooling air at a temperature controlled at 10-15℃ and a speed of 5-8m / s evenly onto the surface of the nascent glass fibers. This rapidly lowers the temperature of the glass fibers to 600-700℃, completing the initial cooling. Next, a spray cooling device evenly sprays ultrafine water mist with a particle size of 5-10μm onto the glass fiber surface. The water mist rapidly vaporizes upon contact with the high-temperature glass fibers, absorbing a large amount of heat and further reducing the temperature to 200-300℃, completing the deep cooling process. During the process, the temperature of the cooling zone is monitored and precisely controlled in real time through a sophisticated temperature sensor and an automatic control system to ensure the consistency and stability of the cooling effect. After cooling, the glass fiber enters the sizing agent coating device. The sizing agent is carefully formulated and mainly contains silane coupling agent, film-forming agent and lubricant. The content of silane coupling agent is 15-20%, the content of film-forming agent is 30-35%, and the content of lubricant is 45-50%. The components work synergistically to significantly improve the surface properties and processing performance of the glass fiber.

5. The process for producing 6.0 kg twisted yarn using the parallel passage method in a pool kiln as described in claim 4, characterized in that, The coating device in the fiber drawing process employs an advanced electrostatic atomizing nozzle to uniformly spray the sizing agent onto the surface of the glass fiber. This allows the sizing agent to quickly and evenly cover each fiber, forming a uniform protective film. Through precise control, the coating amount of sizing agent is stabilized within the range of 0.8-1.2%, ensuring good bundleability and lubrication of the glass fiber during subsequent bundling and processing. After the sizing agent coating is completed, the glass fiber enters the bundling stage. A high-precision bundling device evenly bundles multiple glass fibers together to form glass fiber filaments of a certain thickness. The bundling device uses... An advanced servo motor drive system can automatically adjust the bundling force and speed according to the running speed of the drawing machine and the tension of the glass fiber, ensuring the forming quality of the glass fiber filaments. During the bundling process, by applying appropriate tension to the glass fiber, the diameter of the glass fiber filaments is stabilized within the range of 10-15μm, ensuring that they have good mechanical and processing properties. The glass fiber filaments are introduced into the high-speed winding system of the drawing machine. Under the high-speed traction and winding action of the drawing machine, the glass fiber filaments are evenly wound on the winding drum to form a glass fiber filament roll with specifications of 264cm×φ300cm×2cm.

6. The process for producing 6.0 kg twisted yarn using the parallel path method in a pool kiln as described in claim 1, characterized in that, In the wire drawing machine modification, when a winding and turning operation is required during the wire drawing production process, the wire drawing machine's control system sends a command to the hydraulic drive system. The hydraulic drive system responds quickly and pushes the bundle nozzle assembly on the telescopic guide rail to the preset telescopic position.

7. The process for producing 6.0 kg twisted yarn using the parallel path method in a tank kiln as described in claim 1, characterized in that, In the twisting process, the glass fiber filaments obtained through the drawing and forming process are introduced into a specially designed twisting device. This device mainly consists of a twisting roller driven by a high-performance servo motor, a high-precision tension controller, and an intelligent twist adjuster. The twisting roller is made of high-quality alloy steel with a special surface hardening treatment, which has extremely high wear resistance and deformation resistance, ensuring that it can maintain a precise twisting effect during long-term high-speed operation. The roller has a diameter of 120mm and a length of 300mm, and its surface has fine anti-slip texture, which can effectively enhance the friction between the roller and the glass fiber filaments, making the twisting process more stable and reliable.

8. The process for producing 6.0 kg twisted yarn using the parallel path method in a pool kiln as described in claim 7, characterized in that, In the twisting process, a high-precision tension controller is installed at a critical position before the glass fiber filament enters the twisting roller. Its core component uses a high-sensitivity strain gauge sensor, which can monitor the tension changes of the glass fiber filament in real time and feed the data back to the control system at a frequency of 100 times per second. Based on the preset tension value of 65N, the control system quickly calculates and adjusts the damper in the tension controller through a precise algorithm, strictly controlling the tension fluctuation range within ±3N. This ensures that the glass fiber filament is always in an ideal tension state during the twisting process. This precise tension control can not only effectively prevent yarn loosening due to insufficient tension, but also avoid yarn breakage caused by excessive tension, greatly improving production efficiency and yarn quality.

9. The process for producing 6.0 kg twisted yarn using the parallel path method in a pool kiln as described in claim 8, characterized in that, In the twisting process, the twist is precisely controlled by changing the rotation speed of the twisting roller. During production, the target twist is set to 160 twists / m. The intelligent twist adjuster calculates and adjusts the roller speed in real time based on the linear density of the glass fiber filament and the rotation speed of the twisting roller to ensure that the twist accuracy error is controlled within ±2 twists / m. At the same time, the adjuster has a self-learning and adaptive function, which can automatically optimize the twist control parameters according to different production conditions to achieve the best twisting effect.

10. The process for producing 6.0 kg twisted yarn using the parallel path method in a pool furnace as described in claim 1, characterized in that, In the winding packaging process, after the glass fiber filaments have been twisted, they are introduced into the winding system. The core component of the system is the winding roller, whose surface is treated with high-precision polishing, with a roughness of Ra0.8, to ensure that the yarn is wound flat. The speed of the winding roller is steplessly regulated by a frequency converter, ranging from 300 to 500 r / min.

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