高一致性聚酰亚胺纤维制程控制参数优化实践

Practice of Parameter Optimization for Production of PI Fiber with High Consistency

针对高性能聚酰亚胺纤维从研发转入量产阶段初期出现的品质波动大的问题,依托已建立的DCS与SCADA系统所采集的过程数据及工艺工程知识,采用DOE工具进行制程关键参数的优化,采用回归方程分析关键参数与成品指标之间的数量关系,优化关键参数控制标准值;通过关键参数的效应分析,改进了高效应参数相关设备与仪表,提高了制程控制精度。依据不同控制参数的特点,采用合适的控制调节方案,降低控制参数实测值与标准值的离差;尝试将统计过程控制技术应用于关键参数波动分析,建立在线SPC实时监控系统,为提高制程控制精度提供支持。结果表明,关键控制参数的波动得到了显著改善,产品品质一致性大幅提高。

To solve the problem of quality fluctuation of PI fiber at the early stage of mass production,DOE is employed as a tool to optimize the key control parameters of the production based on the collected process data by DCS and SCADA system and the process engineering knowledge.The standard values of the key control parameters are optimized efficiently by employing regression equation to analyze the relations between the key parameters and the product indicators.Based on the analysis of the effects of key parameters,the improvement on equipment and instruments related to the parameters with high effectiveness are obtained,and the control accuracy of the process is improved.Proper control scheme are adopted based on the characteristics of different parameters to reduce the deviations between measured values and standard values of parameters.The statistical process control technology is attempted to apply to the fluctuation analysis of the key parameters and to establish the online SPC real-time monitoring system(RTMS),which provides a strong support for the improvement of process control accuracy.The optimization results show that the fluctuation of key control parameters has been significantly reduced and the consistency of product quality has been greatly improved.