I. Operating Procedures
1. Chemical Mixing and Feeding
Dyes must be thoroughly dissolved and stirred in the mixing tank before being fed into the machine cylinder to avoid color deposits or stains on the fabric surface.
When feeding, add the dye evenly from both sides and use a bamboo stick to stir along the edge of the cylinder for 1-2 minutes to ensure thorough mixing.
2. Temperature Control
Keep the machine covered to maintain a consistent temperature throughout the cylinder, both above and below the liquid level.
When heating with steam, do not allow the fabric roll to move, as this can cause temperature differences and color variations.
3. Tension and Speed
Tension control needs to be adjusted according to the fabric type. For example, for synthetic fiber fabrics above 100℃, the tension should be appropriately relaxed to avoid excessive fabric elongation.
The bottom of the dye roll machine should be equipped with both direct and indirect heating devices. Use direct heating during heating and feeding, and switch to indirect heating after feeding is complete.
II. Maintenance and Care
1. Mechanical Structure Maintenance
Regularly inspect moving parts such as clamps, guide rails, and transmission components to ensure they are free from wear or looseness.
Guide rails and transmission slides require regular lubrication to prevent jamming due to lack of oil.
2. Electrical System Maintenance
Regularly clean the inverter's cooling fan to prevent lint buildup and subsequent burnout.
Check sensor wiring continuity to ensure normal signal transmission.
3. Control System Maintenance
Regularly check the input/output points of the PLC and expansion modules to ensure normal control functions.
Maintain stable temperature and humidity in the workshop to minimize damage to electrical components.
III. Fault Prevention
1. Prevention of Overlap Marks
Seam allowances should not be too wide; make several cuts at the seam to prevent water accumulation; adjust tension appropriately to prevent fabric sagging.
2. Prevention of Darker/Lighter Colors
Keep the dye guide clean; add dyes according to their properties; use a cover during dyeing; strictly control the temperature.
3. Prevention of Dark/Light Edges
Align the fabric width when loading the roll, select dyes with similar dyeing temperatures, and reduce the curvature of the fabric stretcher.
4. Prevention of Wrinkles
Keep seam ends flat, align fabric widths, reduce steam pressure, maintain moderate tension, and keep the fabric stretcher level.
5. Prevention of Color Variation
Increase the outlet water level, dissolve disperse dyes in cold water and filter, and use an appropriate amount of dispersant.
IV. Other Precautions
Number of Tanks: Adjust the number of tanks according to the fabric type. For example, 1300-1500 meters per roll for lightweight fabrics, and less for light-colored fabrics.
Operator Training: Operators must be proficient in the equipment's performance, and machine operators must carefully observe the equipment's operation.
