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CN1199363A - 制造定向塑料管用的控制方法 - Google Patents

制造定向塑料管用的控制方法 Download PDF

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CN1199363A
CN1199363A CN96197479A CN96197479A CN1199363A CN 1199363 A CN1199363 A CN 1199363A CN 96197479 A CN96197479 A CN 96197479A CN 96197479 A CN96197479 A CN 96197479A CN 1199363 A CN1199363 A CN 1199363A
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expansion
pipe
tube
diameter
downstream
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CN1064587C (zh
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P·G·查普曼
A·K·瓦拉克
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Vinidex Pty Ltd
Uponor Innovation AB
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UPONOR BV
Vinidex Tubemakers Pty Ltd
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Abstract

公开了一种膨胀塑料管子的方法,其中一个沿纵向行进的管子(10)在上游插塞(24)和可膨胀的下游插塞(26)之间的膨胀区(20)内利用内部流体压力逐渐地沿直径膨胀。管子的膨胀根据参数来控制,这些参数直接或间接地指示将材料传说达到膨胀区或从膨胀区移出的相对速度的变化,例如检测上游管子速度(38)、初期膨胀直径(36)、定径装置(28)上的轴向力(39)或刚巧在膨胀区前面的管子直径(41)。

Description

制造定向塑料管用的控制方法
发明背景
本发明涉及制造定向塑料管，特别涉及制造沿圆周方向具有高度定向的管子。
国际专利申请No.WO 90/02644描述一种制造热塑性管子如未塑化的聚氯乙烯(uPVC)的工艺方法，后者具有一定程度的沿圆周方向定向，这改善了诸如抵抗环向应力之类的性能，并使管子特别适合于输送水。该专利申请中描述的工艺过程包括：
(i)挤压一根塑料管子；
(ii)调节该受挤压管子的温度，使其达到适于管子膨胀的围绕管子的稳定温度分布，以形成聚合物的分子定向，对uPVC优选采用85-115℃的温度，最好为90-100℃。
(iii)通过对管子施加内部压力来使管子径向膨胀，该管子在其下游端部受一插塞的限制，该插塞可以充气膨胀或可以其它方式膨胀，以便在膨胀区内保持压力；
(iV)冷却该受膨胀的管子，使该管子在其沿径向膨胀的构形中硬化。
在膨胀区的下游端部该受膨胀的管子行进通过定径装置中的圆形通道，后者限制管子径向膨胀到允许该膨胀管子滑过该定径装置的直径。在管子通过膨胀区后当它受到冷却时，由于内部压力减小，管子的直径可能收缩一个小的量，如几毫米或更小(所谓“急速返回”)，使管子得到最终膨胀的直径。
在预定用作水管并因此必须端部对端部地相接合的管子的情况下，必须控制膨胀的管子直径特别其外径，以便管子能够精确而紧密地配合在联接装置内或相邻管子的附加的膨胀端部区段内，从而防止泄漏。但是，我们发现，使用普通的反馈控制方法即通过测量管子的最终膨胀直径和壁厚来控制膨胀工艺过程，既不能足够精确地控制成品管子的性能，也不能使工艺本身的操作稳定。
发明概要
本发明提供一种膨胀塑料管子的方法，其中一个沿纵向行进的管子在上游插塞和下游插塞之间的膨胀区内利用内部流体的压力逐渐地沿径向进行膨胀，该上游插塞紧密地配合在基本上没有膨胀的管子的孔内，而该下游插塞紧密地配合在膨胀步骤之后的管子的孔内，其中管子的膨胀根据一个或多个参数受到控制，这些参数直接或间接地指示将材料传送到膨胀区或从膨胀区移出的相对速度的变化。
根据相对速度的变化来控制工艺过程最好通过改变膨胀区中的流体压力来达到。在一种优选形式中，这通过改变可膨胀的插塞的直径来控制通过可膨胀的下游插塞的膨胀流体的泄漏。在下游活塞可以膨胀的最优选情况下，通过控制插塞内膨胀流体的压力来控制泄漏。
进出膨胀区的相对速度的变化最好间接测量，并可由下述方法中任何一种或几种来测量：
(a)可以测量和比较膨胀区上游的未膨胀管和下游的已膨胀管的绝对速度。最好上游测量是在基本上紧接膨胀区之前的一个点上进行的。该测量将检测到管子在膨胀区的膨胀的增大，因为这将伴随着进入膨胀区的材料的速度的增大，因为向外鼓胀将开始从上游插塞的上游侧拉伸材料。实际上可以认为该下游速度由离开速率已足够精确地知道，因为在膨胀区的管子下游的冷却区段中没有再出现拉伸。因此可以通过单独检测上游速度来确定合理的相对速度近似值，而上游速度的独自变化可以用作控制参数，因为离开速度受下游引出牵引机支配而通常不会波动，除了引出速率故意变化。
(b)部分膨胀管的直径可以在膨胀区内的一个位置上测量，最好在上游插塞下游的小于预膨胀管直径约三倍的距离的一个位置上。该直径反映大致截锥形的膨胀区的精密构形。例如，如果管子离开膨胀区的速度相对于传送到膨胀区的速度是减小了，那么管子的截锥形膨胀区将向外鼓出到一定程度从而增大测到的直径，但如果管子离开膨胀区的速度相对于传送到膨胀区的速度是增大了，那么管子的截锥形膨胀区将沿轴向更加伸长而测到的直径将减小。
(c)可以测量由膨胀管沿轴向施加在定径装置上的力。在第一工作方式中，管子膨胀而配合定径装置，并由于其对定径装置内表面产生剪切作用，沿下游方向在定径装置上施加一个轴向力。该轴向力的大小将取决于受膨胀管子接触定径装置的轴向长度和/或取决于该管子施加在该装置上的径向压力，因此合适的反馈控制可以保持该管子在设定点处首次接触定径装置的那个点。在第二工作方式中，该管子先稍许过度膨胀，然后经定径套管拉细直径。在定径套管上的轴向力将反映进入定径装置的过度膨胀管子的变形和对内表面的剪切作用。在任何一种工作方式中，测到的力都与膨胀区的形状有关，因此与上述相对速度有关。
(d)可以测量刚巧在膨胀区之前的未膨胀管子的直径，例如上游插塞上游的小于预膨胀管直径约10倍的距离处。该读数反映进入膨胀区的速度的长期平均值，因为一定时间的太高的进入速度将使材料从预膨胀区被拉伸，造成管子材料变薄，并减小膨胀区上游的直径。
附图简述
现在将参照附图进一步描述优选实施例，其中：
图1是管子制造和膨胀工艺的示意图；
图2A和2B分别是第一和第二工作方式中进入定径套管的受膨胀管子的示意细节图。
优选实施例的描述
参照图1，塑料管10由挤压机12生产，并在第一冷却喷水箱14内用定径装置如定径套管13硬化到正确的直径。管10通过第一引出牵引机16从挤压机引出。
管10然后前进至温度调节区18，在该区中管子受到处理而得到一个围绕管壁的均匀的特定温度轮廓分布，使得管子随后的膨胀导致聚合物分子主要沿圆周方向定向，从而增强物理性能特别是增大对环向应力的抵抗。然后管子进入一对插塞24和26之间的膨胀区20，这一对插塞通过检修管22保持在管子内，该检修管22通过挤压头往回连接到推力限制件上(未示出)
第一插塞24(相对于管子10的行进方向的上游插塞)的尺寸做成紧配合在未膨胀的管子10内。一系列围绕管子周面的控制轮25将管子紧紧地推到插塞24上，使得存在足够的密封以维持膨胀区中的压力。下游插塞26是可以充气膨胀的，使其直径可从非膨胀状态改变到膨胀状态，以便开始该工艺。
插塞26最好如我们共同而未决的国际专利申请No.PCT/AU94/00784中描述的。插塞充分地充气，以保持膨胀区中的压力而同时允许一些膨胀流体流过插塞并润滑运动管子内的插塞。检修管22有一对同心管，其中之一继续向前将充气流体(如空气)带到下游插塞，而另一将膨胀流体(最好是热水)供给上游插塞，而后经过出口27进入膨胀区。
在两个插塞之间，塑料管10由于不受外部限制的内部压力而经受到径向膨胀。面向膨胀区的下游端部，有一个定径套管28或其它定径装置和一个冷却喷水箱30，用于硬化膨胀管32的最终直径。这后随第二引出牵引机34和切割设备(未示出)，如果需要管子沿轴向定向，可以将第二引出牵引机34的速度调整到高于第一牵引机。
图2A和2B图示该工艺的膨胀部分和定径部分的操作方式。在图2A所示的第一方式中，在可膨胀插塞之后的膨胀区内保持的压力较小，而膨胀管的截锥形状较平缓。管子10逐渐膨胀到在其入口或在一下游点处第一次接触定径套管28。通过变更插塞充气压力来调整膨胀区内的压力，将使管子和定径套管之间的第一接触点移向上游或下游。
在图2B所示的第二方式中，膨胀压力足以使管子的膨胀稍许超出定径套管直径。然后向下拉伸过度膨胀的管子，以进入定径套管。
如果充气式插塞26充分充气以膨胀管子，使其以上述两种方式之一接触定径套管，那么除了由于“急速返回”或定径套管和下游插塞之间的某些轻度蠕变之外，管子的最终外径将主要由定径套管决定。但是，这是最小的，因为膨胀管子固定其直径的冷却已经在该点开始。
因此，可膨胀插塞的精确膨胀程度对最终直径仅有微小影响。相反，本发明人发现，插塞的膨胀不足或过度膨胀的结果是要改变进出膨胀区的速度，因而改变在膨胀区中出现的轴向拉伸量和该工艺线本身的稳定运行。
管子的平均轴向拉伸由第一和第二引出牵引机的比例固定。在膨胀区本身和在第一引出机构16与上游插塞之间的预膨胀区中采用轴向拉伸。在膨胀区之后基本上采用轴向拉伸，因为管子已被冷却。这样，在任何时候，在膨胀区和预膨胀区中采用的轴向拉伸之和将等于该引出比并因此是恒定的。本发明人发现，在每个区中控制多大程度上出现这种情况对于产品的一致性和该工艺本身的操作来说是重要的。
本发明提供许多装置，用于测量管子10在膨胀之前或膨胀期间的不同参数，以指示管子材料进入和离开膨胀区20时的速率。
在膨胀区中可以设置测量管子直径用的机构36，优选安置在上游插塞的下游小于管子直径三倍处，最好是小于管子一个直径的距离处。在这个膨胀的早期阶段处管子的直径与膨胀区的形状从而与相对速度惊人地精确相关，此外还立即提供足以充分控制的信息。
管子的过度膨胀可能开始从上游插塞的上游侧拉伸材料，因此刚巧安置在上游的速度测量机构可以提供工艺控制用的信息。此外，即使相对速度的长期平均值偏离检查点的轻微不一致也会引起由装置41测量的预膨胀直径的变化。
定径装置28上由管子产生的前进推力可以用机构39测量并用于工艺控制，因为此种测量对膨胀区形状的变化非常敏感。
除上述以外，本发明人发现，决定膨胀行为的重要因素是受挤压管子10的壁厚，而由安置在膨胀区之前的壁厚测量装置40获得的这种测量，对于工艺的向前进料控制是有用的。
增大进入膨胀区的壁厚使锥形变窄，因为它强度更大，所以能抵抗膨胀压力。这转过来拖拉较少的上游材料进入膨胀区，减小上游速度，因此按照质量流动部分地自动校正。但是，发明人发现，这会改变整个生产线的平衡。本发明的控制系统检测进入膨胀区的速度的这种变化(或者直接或者间接)并提高膨胀压力。这会颠倒上游速度的坡度，虽然这会进一步增大质量流动。
整个线上的轴向拉伸由两个引出之比来决定并因此是恒定的。本发明控制这种情况在膨胀区中和在上游发生多少。实际上在膨胀管离开定径套管28之后并不发生，因为管子由于冷却而固定。
实际上，将来自测量装置36、38、39、40和41的信号输入处理器42。如果这些信号指示进出膨胀区的速度之间的相对性移离工艺设定点。那么处理器会转而通过检修管22控制供给可膨胀插塞26的膨胀流体。因此，例如，如果初期直径检测器36读数信号太高，或者如果从38得到的速度测量值大于比第一牵引机16的速度大的一个预定量，那么将从可膨胀插塞释放压力。这转过来会由于允许过量的膨胀流体通过可膨胀插塞逸走而减小留在插塞26后的膨胀流体压力。
发明人已经发现，插塞的膨胀压力和通过插塞的压力降之间的关系可按照下述方程式预测：
Pp＝ΔP+Pd式中Pp＝施加在插塞上的压力
ΔP＝通过插塞的压力差
Pd＝将插塞不受限制地膨胀到直径d的压力(自由膨胀压力)
虽然本发明人已经发现，通过改变插塞压力来控制膨胀是非常方便的并且是优选的，但可以理解，此外可以使用其它的控制动作或作为替代方案。例如，通过改变牵引机34上的引出速率可以更直接地控制进出膨胀区的相对速度。
检测到的参数最好综合用于控制工艺。例如，定径套筒上的推力和未膨胀管的壁厚可以用于粗略调整，而精细调整可以根据从38读得到的线性速度的变化和从36得到的初期膨胀直径大小来进行。综合使用控制参数的一个优选方法是利用定径套管推力测量中的变化来改变初期膨胀直径的控制设定点。
虽然已经描述了本发明的特定实施例，但该技术的专业人员显然知道，本发明可以以其它特定形式实施而并不偏离其基本特征。因此现有实施例和例子在一切方面都被看作是例示性的而非限制性的，发明的范围由附属的权利要求书指示而非由上面的描述指示，因此要使所有落入这些权利要求的等效和含义范围内的变化包括在内。

Claims (9)

1.一种使塑料管子膨胀的方法，其中一个沿纵向行进的管子在上游插塞和下游插塞之间的膨胀区内利用内部流体的压力逐渐地沿径向经受膨胀，该上游插塞紧密地配合在基本上设有膨胀的管子的孔内，而该下游插塞紧密地配合在膨胀步骤之后的管子的孔内，其中管子的膨胀根据一个或多个参数受到控制，这些参数直接或间接地指示将材料传送到膨胀区或从膨胀区移出的相对速度的变化。
2.一种如权利要求1所述的方法，其特征在于，所述参数包括膨胀区上下游管子速度的比较。
3.一种如权利要求1所述的方法，其特征在于，所述参数包括未膨胀管进入膨胀区的速度。
4.一种如权利要求1所述的方法，其特征在于，所述参数包括在上游插塞的下游的小于预膨胀管直径三倍的膨胀区内的一个点上的部分膨胀管的直径。
5.一种如权利要求4所述的方法，其特征在于，所述点处在上游插塞的下游小于预膨胀管一个直径的距离处。
6.一种如权利要求1所述的方法，其特征在于，所述参数是由膨胀管施加在定径装置上的轴向力。
7.一种如权利要求1所述的方法，其特征在于，所述膨胀是通过改变膨胀区内的内部流体压力来控制的。
8.一种如权利要求7所述的方法，其特征在于，所述膨胀是通过控制自膨胀区流径下游插塞的流体的泄漏来控制的。
9.一种如权利要求8所述的方法，其特征在于，所述下游插塞是可以通过一种在该下游插塞内的膨胀流线的内部流体压力来膨胀的，而所述泄漏是通过改变所述膨胀流体的压力来控制的。
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