卧式丁基胶涂布机作为中空玻璃、光伏组件等精密制造领域的关键设备，其操作安全性与工艺稳定性直接影响产品质量与生产效率。本文从设备启停、工艺控制、安全防护、日常维护四个维度，系统梳理操作核心要点。

　　The horizontal butyl rubber coating machine, as a key equipment in precision manufacturing fields such as insulating glass and photovoltaic modules, directly affects product quality and production efficiency in terms of operational safety and process stability. This article systematically outlines the core operational points from four dimensions: equipment start stop, process control, safety protection, and daily maintenance.

　　一、操作前准备规范

　　1、 Preparation standards before operation

　　设备状态核查

　　Equipment status verification

　　开机前需执行三重检查：首先确认电源电压稳定在380V±10%范围内，接地电阻≤4Ω，避免电气故障；其次检查气路压力是否达标，压缩空气需经干燥过滤，压力维持在0.6-0.8MPa，防止气动元件动作异常；最后验证液压系统油位，确保液压油清洁度达NAS 7级以上，避免油泵卡滞。

　　Before starting up, perform a triple check: first, confirm that the power supply voltage is stable within the range of 380V ± 10%, and the grounding resistance is ≤ 4 Ω to avoid electrical faults; Next, check if the air path pressure meets the standard. Compressed air needs to be dried and filtered, and the pressure should be maintained at 0.6-0.8MPa to prevent abnormal operation of pneumatic components; Finally, verify the oil level of the hydraulic system to ensure that the cleanliness of the hydraulic oil reaches NAS level 7 or above, and avoid oil pump jamming.

　　温度校准与预热

　　Temperature calibration and preheating

　　丁基胶需在110-150℃环境下充分融化，设备配备的双温区控制系统需分别设定胶缸与挤胶头温度。以某型设备为例，其加热系统采用PID算法，升温阶段需观察温度曲线，确保胶缸温度达到设定值后保温20分钟，使胶体粘度均匀。严禁在温度未达标时启动液压装置，否则可能导致胶体流动性不足引发堵料。

　　Butyl rubber needs to be fully melted in an environment of 110-150 ℃, and the dual temperature zone control system equipped with the equipment needs to set the temperature of the rubber cylinder and extrusion head separately. Taking a certain type of equipment as an example, its heating system adopts PID algorithm. During the heating stage, the temperature curve needs to be observed to ensure that the temperature of the rubber cylinder reaches the set value and is kept warm for 20 minutes to make the viscosity of the colloid uniform. It is strictly prohibited to start the hydraulic device when the temperature does not meet the standard, otherwise it may cause insufficient fluidity of the colloid and lead to material blockage.

　　机械部件调试

　　Mechanical component debugging

　　调整两挤胶头间距时，需使用千分尺测量，确保间距误差≤0.05mm，并保持挤胶嘴、小压轮、间隔框三点共线。传送带速度需根据基材厚度动态调节，例如处理2mm铝条时，速度应控制在8-12m/min，避免因速度不匹配导致涂胶重叠或断胶。

　　When adjusting the spacing between the two extrusion heads, a micrometer should be used to measure, ensuring that the spacing error is ≤ 0.05mm, and keeping the extrusion nozzle, small pressure wheel, and spacing frame in line. The speed of the conveyor belt needs to be dynamically adjusted according to the thickness of the substrate. For example, when processing 2mm aluminum strips, the speed should be controlled at 8-12m/min to avoid overlapping or breaking of the adhesive due to mismatched speeds.

　　二、运行中关键控制

　　2、 Key controls during operation

　　工艺参数监控

　　Process parameter monitoring

　　实时监测三项核心指标：挤胶压力需稳定在8-18MPa，压力波动超过±1MPa时需检查胶路密封性；涂布厚度采用激光测厚仪在线检测，允许偏差为设定值的±5%；传送带张力通过张力控制器维持180-280N，防止基材跑偏。

　　Real time monitoring of three core indicators: the extrusion pressure should be stable at 8-18MPa, and the sealing of the rubber path should be checked when the pressure fluctuation exceeds ± 1MPa; The coating thickness is measured online using a laser thickness gauge, with an allowable deviation of ± 5% of the set value; The tension of the conveyor belt is maintained at 180-280N through a tension controller to prevent substrate deviation.

　　安全防护执行

　　Safety protection execution

　　操作人员必须佩戴防烫手套、护目镜及防尘口罩，严禁在设备运行中触碰挤胶嘴，其表面温度可达150℃。当检测到压轮振动幅度超过0.1mm或轴承温升至65℃时，系统将自动触发急停，此时需排查机械卡滞或润滑不良问题。

　　Operators must wear heat-resistant gloves, goggles, and dust masks. It is strictly prohibited to touch the extrusion nozzle during equipment operation, as its surface temperature can reach 150 ℃. When the vibration amplitude of the pressure roller exceeds 0.1mm or the bearing temperature rises to 65 ℃, the system will automatically trigger an emergency stop. At this time, mechanical jamming or poor lubrication problems need to be investigated.

　　异常处理流程

　　Exception handling process

　　若遇胶头不出胶，应立即检查胶温及胶路电磁阀状态；发生断胶时，需在10秒内暂停设备并清理胶嘴，避免残胶固化堵塞喷孔。某企业实践数据显示，85%的工艺故障可通过标准化处置流程在5分钟内解决。

　　If the glue head does not release glue, immediately check the glue temperature and the status of the glue circuit solenoid valve; When glue breakage occurs, the equipment should be paused within 10 seconds and the glue nozzle should be cleaned to avoid residual glue solidifying and blocking the spray hole. Practical data from a certain enterprise shows that 85% of process failures can be resolved within 5 minutes through standardized disposal processes.

　　三、停机维护要点

　　3、 Key points for shutdown maintenance

　　清洁与保养

　　Cleaning and maintenance

　　每日生产结束后，需用60℃热风枪配合专用清洗剂清理胶嘴、光眼及皮带残留，避免胶体碳化。每周对气泵液压油进行取样检测，当粘度变化超过15%时需更换，确保动力传输效率。

　　After daily production, it is necessary to use a 60 ℃ hot air gun combined with a special cleaning agent to clean the glue nozzle, light eye, and belt residue to avoid colloid carbonization. Sample and test the hydraulic oil of the air pump every week, and replace it when the viscosity changes by more than 15% to ensure power transmission efficiency.

　　易损件管理

　　Management of vulnerable parts

　　建立易损件寿命台账，例如密封圈更换周期为500-800小时，皮带张紧度需每日检查，当伸长率超过3%时需调整或更换。某企业通过实施预防性维护，使设备故障率降低62%。

　　Establish a service life ledger for vulnerable parts, such as a seal replacement cycle of 500-800 hours, daily inspection of belt tension, and adjustment or replacement when elongation exceeds 3%. A certain enterprise reduced the equipment failure rate by 62% by implementing preventive maintenance.

　　长期停用保护

　　Long term disuse protection

　　若设备停机超过72小时，需将胶缸活塞提升至高位，涂抹防锈油并覆盖防尘罩。再次启用前，需执行完整加热循环并验证所有安全联锁功能。

　　If the equipment is shut down for more than 72 hours, the rubber cylinder piston should be raised to a high position, coated with anti rust oil, and covered with a dust cover. Before enabling again, a complete heating cycle must be performed and all safety interlock functions verified.

　　四、安全风险管控

　　4、 Security risk control

　　人员培训制度

　　Personnel training system

　　操作人员需通过三级安全教育，考核内容包括设备原理、应急处置及防护用品使用。某企业实施“理论+实操”双认证后，人为事故率下降89%。

　　Operators need to undergo three-level safety education, which includes assessment of equipment principles, emergency response, and the use of protective equipment. After implementing the dual certification of "theory+practice" in a certain enterprise, the human accident rate decreased by 89%.

　　环境要求

　　Environmental requirements

　　作业区域需保持通风，可燃气体浓度控制在爆炸下限的25%以下。夜间作业时，工作面照度需≥500lx，避免视觉误差导致操作失误。

　　The work area should be kept ventilated, and the concentration of combustible gases should be controlled below 25% of the lower explosive limit. When working at night, the illumination of the work surface should be ≥ 500lx to avoid visual errors that may cause operational errors.

　　应急预案

　　Emergency plan

　　制定专项应急预案，明确胶体泄漏、机械伤害、电气火灾等场景的处置流程，并每季度组织演练，确保全员掌握急停按钮位置及灭火器材使用方法。

　　Develop a special emergency plan, clarify the disposal process for scenarios such as colloid leakage, mechanical injury, and electrical fires, and organize quarterly drills to ensure that all personnel are familiar with the location of emergency stop buttons and the use of firefighting equipment.

　　通过严格执行上述操作规范，企业可使卧式丁基胶涂布机运行稳定性提升至99.5%以上，涂胶合格率达99.8%，同时延长设备使用寿命至10年以上。标准化作业不仅是质量保障的基础，更是生产安全的生命线。

　　By strictly implementing the above operating standards, enterprises can improve the stability of the horizontal butyl rubber coating machine to over 99.5%, achieve a coating qualification rate of 99.8%, and extend the equipment's service life to over 10 years. Standardized operations are not only the foundation of quality assurance, but also the lifeline of production safety.

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