1. Project background
The 12 meters press brake bending machine mainly produces automobile longitudinal beam, auxiliary beam, thickened crossbeam of connecting plate and some new products, trial products, special-shaped parts and super long and ultra-thick connectors.
There are 8 different thicknesses from 3mm to 10mm.
There are 263 specifications and 554 varieties and 272 varieties are produced every month.
Due to the increasing market demand for heavy-duty vehicles, small batch and multi-batch production is gradually increasing.
However, the production cycle of large-scale press brake machine can not meet the production requirements, so the supply cycle is prolonged due to frequent adjustment.
2. The main deficiencies
2.1 Poor adjustment accuracy
The fixed dead positioning block is used in the adjustment and positioning device of the system.
When the positioning block has deteriorated, deformed and worn, the four positioning points of the single machine will shift.
It is necessary to add gasket and insert plate for repeated adjustment and trial molding.
2.2 Poor reliability
First of all, the impact force of large bending parts on the positioning block is large, which makes the fastening bolts of the positioning block loose, the inserting plate move, and the positioning deviation deviates with a forming dimension deviation over 2 mm.
In order to ensure the bending size, it is necessary to adjust and fasten the positioning point twice.
2.3 Extended production cycle
As the adjustment of gasket insert plate is troublesome, and the adjustment frequency is more, the batch production cycle is prolonged, which can not meet the delivery needs.
For the above problems, we put forward the transformation scheme of the positioning system of the large-scale press brake machine.
3. Modification scheme
The position adjusting device of inserting plate is changed into screw type.
Three holes are drilled on the original positioning block plate, two of which are tapped and installed with adjusting bolts, which is convenient for debugging and installation.
3.1 Working principle of the system
This device is a typical precision feed adjustment device, namely thread adjustment.
As shown in the figure below: the accuracy adjustment of the system is completed by adjusting the upper and lower bolts.
Adjustment process and method of positioning block: (one person operation)
1) Loosen the fastening bolt of the locating block with the hexagon wrench.
2) Hold the positioning block with one hand to prevent side rotation.
3) Use a wrench to rotate the upper or lower adjusting bolts, and adjust the positioning block to move forward or backward.
4) After in place, use the hexagon wrench to tighten the bolt of the positioning block.
The above is a major advantage of the thread adjusting device.
System simplified block diagram
3.2 Work plan and technical solutions
|NO.||Scheme||Project||Take on||Plan implement (August)||Confirm|
|1||Design, manufacture and installation|
1. Bolt type positioning adjustment device
2. Bolt limit device
|2||Installation and debugging||____||08.09||OK|
We use spare time to improve the positioning accuracy of the large bending machine, which can not affect the production.
In this short period of time, we should first be familiar with and master the positioning structure of the equipment, remove all the devices to be replaced, install new positioning block adjustment device, and then complete the debugging task.
We adopt the method of technical preparation in advance, multi-channel parallel operation and cross operation. It only takes one week to complete the installation and debugging work, which makes the equipment put into operation, shortens the transformation time and ensures the production.
4. Economic benefit and effect after use
The adjustment time of the positioning block has been reduced from 64 minutes per day to 22 minutes now.
Average daily decrease of 42 minutes.
It is calculated by 23 working days per month.
Shorten time: 966 minutes
Equivalent to increase work shifts: 2.01 shifts
The number of varieties completed can be increased: 26 species
It can ensure that the delivery of parts will not be affected.
5. Final thoughts
The application of new technology, new material and new technology to transform old equipment has a good prospect.
Our company is facing the global economic cooperation, a large number of equipment need to be updated, which can save a lot of money for the enterprise, improve the production conditions of workers, improve the processing accuracy and efficiency, save energy and reduce the failure rate of equipment