This issue of "Intercontinental casting" takes you into a technology company in Tianjin, where we are together, with high-tech to find the answer. Intelligent robots to replace manual operation, can effectively solve this problem to improve efficiency and quality.
The rapid development of industrial demand has given birth to industrial robots, but also led to the rapid development of artificial intelligence. Industrial robots are able to do numerous extreme industrial records that cannot be reached by human labor, so they are able to greatly increase industrial output and achieve unimaginable work efficiency. The cutting operation of industrial robots, for example, can do a variety of human beings can not reach the accuracy and speed of action.
Jiangsu Wuxi Lihu Pressurization Technology Co., Ltd. was founded in 1994, with two production plants, Huazhuang and Hudai. The main business is the two key parts of the pressurizer shell and turbine shell, with an annual production of more than 3 million pieces. These castings are characterized by high viscosity, high heat and high hardness in the post-casting process. The main difficulties of this kind of casting grinding and cutting are large residual size of sprue and riser, complex casting surface, low efficiency of manual cutting, high labor intensity, many times of transferring the process, and the existence of certain safety hazards. In order to enhance processing efficiency and improve the operating environment, a tandem robot cutting equipment has been purchased, grinding using the existing manual method, the efficiency of the manual has been improved, but for the large pouring risers, there is still a slow sanding speed, the shortcomings of the productivity is not high, and can not meet the production needs.
At the beginning of 2020, the company purchased 1 set of 550 type hybrid robot automatic grinding equipment, the equipment is characterized by high rigidity and precision, and effectively solved the client's large pouring riser cutting and complex surface grinding problems. During the trial production period, the efficiency has been increased from 80 pieces per person per day to 400 pieces per day by a single machine, which is 5 times higher than that of manual labor.
Therefore, Jiangsu Wuxi Lihu Boosting Technology Co., Ltd. unified procurement of a batch (34 sets) of hybrid robot automatic grinding equipment. At present, all the deliveries have been completed, through the production situation in the past six months, the comprehensive benefits are as follows:
34 sets of equipment for three shifts can save labor 150 people / time, annual labor cost savings of about 15 million yuan. In addition, the purchased equipment can complete the efficient cutting of complex castings by simply replacing the cutting tools, realizing the multi-purpose use of one machine.
In addition, other hidden benefits are: small size of the equipment can save a lot of space; hybrid robotic automatic grinding equipment with low energy consumption, no increase in the load on the existing power facilities, the upstream and downstream processes, especially the machining tool to save reduced to 30% of the original.
At present, the above equipment has been in the client's dedicated grinding workshop stable operation for nearly a year, *** total cost savings of more than 20 million yuan, the cumulative output value of 534 million yuan, profits and taxes of more than 30 million yuan. Not only that, the use of the above equipment, in reducing labor intensity at the same time, greatly improve the grinding operating environment, significantly enhance the image of the foundry enterprises.
Grinding is often a lot of product processing must go through the process. The traditional grinding process is often dominated by manual operation. In foreign countries, for example, a single skilled personnel to spend several hours, and the scrap rate is very high. And even more so at home, the scrap rate is much higher compared to abroad.
The disadvantages of manual grinding are obvious, mainly in the lack of efficiency, time-consuming. It is also reflected in the poor grinding environment, accompanied by noise and dust, and often requires the operator to work continuously, for their physical health is undoubtedly also caused harm.
For non-ferrous castings, such as aluminum castings, where the material is softer, articulated robots and standard or non-standard equipment can be used in this process. At the same time, the use of robots to automatically grind, the advantage of stronger controllability, and easy to accurately locate, with a stronger adaptability, and for irregular devices can also be a good deal, thus reducing the difficulty of processing, shortening the duration.
Tianjin Zhongyiming Technology Co., Ltd. has delivered the open type medium to large parts to Jinan Heavy Duty Truck, solving the problem of grinding and cutting large engine cases and replacing the existing four-side grinder in terms of application.
The main advantages of this equipment are:
1. Replacement of four-face grinding: the equipment has high rigidity, and it can complete several whole-face machining in one sequence, as well as surface machining; it avoids production line stoppage caused by equipment maintenance.
2. Alternative to manual labor: no need to manually knock the air hole needle; high precision grinding, no need to manually clean up the residue after four-sided grinding.
3. Replacement of robot: the equipment has high flexibility, can complete the top surface, curved surface, non-planar and hollowing and other grinding; visual function is stable.
4. Saving logistics: the four-sided grinding form requires many times of logistics transfer, long logistics line, occupying the site.
5, cut and grind one: equipment cut and grind one, process cut and grind one.
6, laser detection, to solve the problem of casting deviation.
The company's independent research and development of high rigidity cutting and grinding universal robot base process is perfect, through the force control remote control and spatial positioning, a sequence of cutting and grinding processing, saving logistics transit time. The equipment is not affected by dust, can be adapted to the harsh working conditions of cutting and grinding. It solves the technical difficulties of automated cutting and grinding of castings containing nickel, chromium, molybdenum, silicon, manganese and other special materials with high-viscosity, high-heat and high-hardness characteristics, as well as the automated cutting and grinding of medium-sized and large workpieces in one machine, and it can solve the demand for grinding and cutting of different types of oversized castings!
The application of high rigidity general-purpose robot cutting and grinding and the functional configuration of the force control remote control, spatial origin positioning, won the first prize of Tianjin Science and Technology Invention, which is the world's leading level.
After more than a decade of research and development and market application, in the ordinary cast iron and cast aluminum parts grinding and cutting technology and market share on the basis of a far-leading breakthrough in the industry for many years is difficult to solve the industry with high-viscosity, high-heat, high-hardness characteristics of the casting grinding and cutting; large and medium-sized castings, large castings, castings grinding cutting of casting grinding and cutting in a sequence of the completion of the four technical problems. Products have been widely and successfully used in foundry enterprises, the latest research and development of the successful open-type multi-tool head tool magazine form of equipment to solve the large castings, large castings grinding and cutting problems, such as concave, convex, flat, curved surfaces and so on.
Tianjin Zhongyiming Technology Co., Ltd. is located in Tianjin Binhai Hi-Tech Zone and was founded in 2011. It is a comprehensive intelligent equipment manufacturer integrating production, learning and research, and its main products are casting grinding and cutting general-purpose equipments, and its technology line belongs to the field of high-rigidity robotic machining. The company will continue to work for the foundry industry to develop better, stronger, better quality equipment, let us walk side by side.
Editor's summary:
It has been proved that the high rigidity cutting and grinding general-purpose robots produced by Tianjin Zhongyi Ming Science and Technology Co., Ltd. have been highly evaluated after being applied in the customer's site, and the scientific and technological principles have been fully verified, which has gained wide recognition in the industry. (This article was supplied by Tianjin Zhongyiming Science & Technology Co.