Idler shaft CNC automated production line solution
1. Product overview
TSZX-1 idler shaft CNC automatic production line is an intelligent manufacturing system designed for the needs of the domestic idler shaft processing industry, adopting a modular design concept and integrating core functions such as automatic feeding, CNC machining, and intelligent testing. The production line realizes the whole process of automated production through one-person control, the key dimensional error is controlled within ±0.05mm, and the class output exceeds 500 pieces, completely solving the pain points of low efficiency and poor accuracy of traditional processing mode.
2. Core technological innovation
(1) Intelligent control system
The electrical control system is composed of touch screen, PLC, servo drive and frequency converter to realize real-time dynamic adjustment of processing parameters. The original "one-screen intelligent control" technology visualizes equipment status, processing progress, fault warning and other data, and operators can complete complex process programming through the touch screen, greatly lowering the technical threshold.
(2) Precision machining unit
Milling CNC machine tool: 5.5KW frequency conversion speed control saw blade and servo motor linkage technology are used to realize arbitrary feeding within 0-2500mm, hydraulic clamping and pneumatic flipping mechanism to ensure processing stability, and the length error is strictly controlled at ±0.05mm.
Milling flat and groove special machine tools: Innovative use of 4 3KW motors to drive double groove synchronous processing, 2 5.5KW motors to achieve double flat one-time forming, frequency conversion speed feed system to increase processing efficiency by 40%, hydraulic clamping device effectively suppresses workpiece vibration.
Flat head chamfering and grooving CNC machine tool: the country's first full CNC double-head integrated processing technology, through the patented tool magazine system to achieve automatic tool change, using special coating CNC turning tools, the tool life is extended by 3 times, and the processing accuracy reaches IT6.
Double-head flat drilling machine tool: equipped with a 2.2KW motor to drive a three-speed variable speed system, patented anti-iron filing technology to solve industry problems, hydraulic clamping and infinitely regulated speed feed to achieve synchronous drilling at both ends, and the hole diameter accuracy reaches H7 level.
(3) Intelligent logistics system
The translation manipulator assembly adopts 3-coordinate rolling linear guide rails and 4 sets of pneumatic manipulators to work together, and realizes 0.1mm accurate grasping of the workpiece through the laser positioning system. The original "trajectory optimization algorithm" improves handling efficiency by 30%, and the simple and reliable structure reduces maintenance costs by 60%.
3. Industry application value
(1) Quality improvement
Through 12 online inspection processes, 100% of key dimensions are fully inspected, and the product qualification rate has increased from 92% to 99.8% of traditional processing, completely solving quality problems such as coaxiality deviation and surface scratches at both ends of the idler shaft.
(2) Cost optimization
The modular design reduces the equipment footprint by 35% and energy consumption by 28%. Taking the annual production line with an annual output of 200,000 pieces as an example, the annual electricity cost is saved by about 150,000 yuan and the labor cost is reduced by 400,000 yuan.
(3) Flexible production
By changing fixtures and adjusting parameters, the production of workpieces of Φ20-Φ40mm and length 280-2400mm can be quickly switched to meet the customized needs of different industries such as coal mines, ports, and electric power.
4. Service guarantee system
Intelligent O&M platform: Through real-time monitoring of equipment status through IoT technology, the predictive maintenance system can warn of potential faults 72 hours in advance, reducing unplanned downtime by 85%.
Process database: Built-in more than 300 kinds of idler shaft processing process parameters, support one-click call, shorten the trial production cycle of new products from 7 days to 8 hours.
Technical training: Provide "theory + practice" step-by-step training to ensure that operators master equipment operation within 3 days and master process optimization within 7 days.
