Analysis and modification measures of spring washer production line

Analysis and Reform of Spring Washer Production Line Chen Tangxian School of Electrical and Information, Three Gorges University, Yichang, Hubei 443002, China: A comprehensive analysis of the problems existing in the spring washer production line of Hubei Yichang Hengchang Standard Parts Co., Ltd., in line with energy conservation, consumption reduction, environmental protection, and increase The principle of effectiveness, the transformation plan is given, and the feasibility of the program is demonstrated.

Spring washer production line laser cutting AC frequency conversion soft switching technology 1. Introduction At present, China's standard parts production industry is basically a small workshop-style enterprise, the degree of automation is not high, energy consumption is large, environmental pollution is serious, material utilization rate is low, product quality and Foreign countries are far apart. Using computer management and control, making full use of laser technology and power electronics technology is the fundamental solution to the problem. Based on this development idea, this paper analyzes the spring washer production line of Hubei Yichang Hengchang Standard Parts Co., Ltd. in detail and finds out Problems and proposed transformation measures.

2. Problems existing in the current production line 2.1 Volume cutting section There are forty-four coil spring machines and cutting spring machines of various specifications in this section. The equipment is simple, cold cut by alloy knife and manual operation. The proficiency of workers' technology determines the quality of the products, the noise is extremely more than 100dB, and the oil pollution is serious, which greatly pollutes the environment and harms the workers' body, especially the hearing. The equipment of the section is simple to control, the AC motor drives the speed reducer, the energy consumption is large, the maintenance cost is high, the work is unreliable, and the quality of the product cannot be guaranteed.

2.2 Annealing, quenching and tempering sections There are six annealing furnaces in this section, single power 100KW, resistance wire heating, relay control, simple control and low efficiency. Due to the backward control method, the product decarburization is caused from time to time, which increases the consumption of raw materials and increases energy consumption.

There are two quenching furnaces and two tempering furnaces in the section, single power 90KW, vibration bottom type, relay control, transformer low voltage and high current power supply, resistance band heating, fan temperature adjustment.

The production efficiency is low and the energy waste is serious. Because the feeding amount is controlled by the vibration frequency, the vibration frequency control is manually adjusted, the human factor component is heavy, and the product quality control is difficult.

2.3 Surface treatment and packaging section There are three lines of blackening, phosphating and electroplating in this section. The power supply of each line is 45KW, 45KW, 20KW, resistance wire heating, small driving assistance, manual operation and simple control. People have high labor intensity, poor production environment, low efficiency, high energy consumption, and no environmental protection.

The packaging of the section is fully manual and labor-intensive, especially manual handwriting and pasting trademarks, which reduces the grade of the product, low efficiency and high cost.

In order to change the current status quo, new technologies and new equipment are adopted to ensure energy conservation, consumption reduction and efficiency.

3. Production line transformation plan 3.1 The volume cutting section adopts the combined volume cutting equipment to combine the original independent coil spring machine and the cutting spring machine into one. It is expected that the eight transformation equipments can realize the workload of the current 44 equipments and improve the working environment.

The control part adopts high-speed digital processor DSP TI's TMSF series, which is flexible in control. It can be set by computer parameters and meets the needs of various specifications. It can change the defects of the original specification of single equipment, and can realize various operation strategies through software. The process strategy ensures that the quality of the product is not determined by the proficiency of the worker and improves the pass rate of the product. In order to improve the grade of the product, the DSP can realize the market competitiveness of the laser marking products, improve the market share of the products, and at the same time, can make the anti-counterfeiting marks of the products.

The cutting part uses high-power laser rapid cutting technology to solve environmental pollution problems. Laser cutting can also solve the product's large incision, burr and other quality defects, which have been plaguing the product, and many methods have not been well solved.

The drag motor adopts the crossover frequency conversion technology to adjust the speed, removes the speed reduction mechanism with high maintenance cost, energy saving, efficiency increase, and the frequency conversion technology is the hot technology of current AC speed regulation.

3.2 Annealing, quenching, tempering section annealing furnace, quenching furnace, tempering furnace adopts the principle of electromagnetic induction heating, eddy current heating of the heating product, the process is that the mains is converted into direct current by the bridge rectifier, and then converted into a DC resonant converter. AC with a frequency of 20 to 30 kHz. The voltage resonant converter is a low-voltage-loss zero-voltage ZVS converter that is controlled by a computer. The eddy current heating is carried out by using the heating product itself, the thermal efficiency is high and the thermal efficiency is 90, and there is no pollution, and the specific heat efficiency of the resistance heating is increased by 35. The technology is mature and is the main development direction of current energy conservation.

At the same time, the heating method forms a three-dimensional heating, the heating is uniform, and the fan is not required to be tempered, thereby avoiding quality problems such as decarburization due to uneven heating.

The feeding mode of quenching furnace and tempering furnace adopts the track conveying mode, and the drag motor adopts the crossover frequency conversion technology and computer control. The computer software can be used to prepare the transmission amount, heating time, temperature and other strategies of various product specifications to ensure the quality of the product.

3.3 Surface treatment and packaging section The heating of this section adopts two-way SCR high-power devices to realize the size of controllable rectification power, avoiding big horse-drawn cars and small horse-drawn carts, and achieving energy saving.

The control equipment of this section adopts programmable controller PLC Siemens S7 series, which realizes sequential control from product loading, rust removal, surface treatment to product cleaning, oiling, transportation, metering, etc., fully automated, greatly reducing the labor intensity of workers. .

The product packaging adopts spring washer intelligent quantitative packaging machine. Its control adopts single-chip control, and adopts intelligent sampling and fuzzy control to realize adaptive less beat and no ripple control. It can better solve the problem of stable control of spring washer automatic packaging system and ensure packaging. Precision.

4. Feasibility analysis From the technical point of view, the transformation task of this production line belongs to the application of typical computer control technology and power electronic technology. At present, related hardware equipment and software technology at home and abroad are very mature.

Economically speaking, energy saving: At present, the total power of the above equipment is 0KW, 10 hours/day, then 11,000 kWh per day, 25 days in January, 275,000 degrees, 3.3 million degrees per year, 0.5 yuan/degree, then used annually. The electricity consumption is 1.65 million yuan. After the transformation, according to the efficiency increase of 30, the total power of 0KW is reduced by 30, that is, 770KW can meet the current production demand, and the annual electricity cost can also be calculated. 50,000 yuan, it can be seen that the annual energy saving is 495,000 yuan.

Reduced consumption: Now 10 shifts are required for each shift (4 units per person). Calculated according to the annual salary of 10,000 yuan / person, the annual light wages need 100,000 yuan. After the transformation operation, 2 people are required for each class (4 devices per person), and the annual salary is 40,000 yuan. The annual consumption of this year is 60,000 yuan. If the transformation plan is fully implemented, it will take about 20 people to meet the operational requirements (60 existing operators). Then the equipment investment of this system can be saved in three years and the economic benefits of production are self-evident.

Social benefits: Due to the use of computer control, the experience control of many people is eliminated, the quality of products is greatly improved, and laser marking and anti-counterfeiting treatment, the competitiveness of products and market share will be significantly improved, and customer satisfaction will be enhanced. The quality of the product in the automotive and other related products is guaranteed, and the social benefits are remarkable.

From the implementation point of view, the transformation of the entire production line can be modified and controlled by the step furnace heating method, and at the same time provides a good platform for the transformation of the later production line. Then we implemented the transformation of the entire production line step by step according to the actual situation.

5. Functions after the completion of the transformation of the production line The annual production capacity of spring washers and related products is 5,000 tons/year, with a growth rate of 2,000 tons/year.

¤With the combined roll cutting function, laser cutting, laser marking or anti-counterfeiting mark ¤ reduces the noise to less than 45 dB, basically achieving no environmental pollution.

¤ Annealing, quenching and tempering heating realize the eddy current heating and stereo uniform heating of the product itself.

¤Quenching and tempering feeding adopts crawler belt and frequency conversion speed regulation technology.

¤ Surface treatment adopts PLC control technology to realize fully automatic sequence control, which can be unattended.

¤ Use intelligent packaging machine to replace manual packaging, reduce the labor intensity of workers and reduce consumption.

¤Computer control adopts the control mode of upper computer and lower computer, and the whole production line adopts DCS distributed control for monitoring.

数据 Monitoring the data storage requirements of the production line requires the use of a standard database system to facilitate the addition of new equipment in the future.

The management of the production line data is implemented as a database engine using a standard database to ensure the transparency of the data and the manageability of the data by the user. Since the database itself provides a variety of functions for managing data, a standard database is used to manage the data. For the user, the data is completely transparent, and the user can complete various functions not provided by the system software, such as curve generation, report summary, and data. Query, etc.

¤ Achieving a truly meaningful network of production and distribution control.

6. Conclusion The transformation plan fully utilizes computer control technology and power electronic technology, which can achieve the purpose of energy saving, consumption reduction, environmental protection and efficiency improvement, and shorten the gap between the industry and foreign countries.

Optoelectronic Technology Application 2005.8 (12) Power Electronics Technology 2001.12 Mechanical Industry Press, 2004

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