Throughout the development of domestic and foreign manufacturing industry, automation transformation plays an important role in its production process. As automation equipment takes over the labor market, more and more companies are engaged in automation and transformation, and they are aware of the benefits that automation can bring to the enterprise. The transformation of labor-intensive enterprises into automation is an inevitable trend. China has a long way to go on the road of automation. The following follows the North Steel Group to analyze the classic solutions of five automation transformations.
scene oneIndustry: Nuclear Experiment
Project: Automated sample testing equipment
A unit of China National Nuclear Corporation, which focuses on nuclear physics research, has always maintained its mystery to the outside world. Thanks to the development strategy of the national military-civilian integration and the quality of the military of the North Steel Federation, the company has finally opened its doors and took the initiative of automation transformation. step.
As we all know, the nuclear raw material test itself is dangerous, radioactive elements, complex space environment, precise and accurate operation, etc., which have extremely high requirements for personnel. In order to change the process of sample change detection performed by scientists in the glove box and reduce the risk, inefficiency and inaccuracy of manual experiments, a solution for automatic detection is proposed for the manual detection process:
The robot is used to place the required workpiece on the workpiece frame placement plate, and the workpiece is automatically detected (accuracy ± 0.05) and replaced by the horizontal movement mechanism and the up and down operation of the upgrade mechanism. After the workpiece is detected, the blanking arm removes the workpiece and replaces the next batch of workpieces to be inspected. And the whole set of equipment has: various types of emergency processing systems such as workpiece in-position detection, missing parts and small parts alarms and personnel mistakes in the test area.
Figure 1 Overall schematic of the device
The delivery of the equipment reduced the original five inspectors responsible for implementation, supervision and statistics to two people, greatly saving valuable human resources, enhancing the reliability of inspection results, and creating a world-class advanced experiment. The room played a typical demonstration role.
Scene twoIndustry: Refractory
Project: Automated production line for shaped refractory bricks
A large domestic refractory company is one of the leaders in the refractory brick industry, with a large market share of high-quality aluminum-magnesium bricks. Due to the good situation in recent years, the market demand is huge, but the output cannot meet the growing demand. The company's senior management put forward: transforming the semi-automatic production line of stereotyped aluminum-magnesium brick into a fully automated production line with the strategy of promoting development through reform and making progress with innovation.
The existing manual production process is: powder feeding weighing - powder pouring into the press mold - press work - taking the mold - cleaning the mold - finished product testing, relying on the North Steel Union for the same type of magnesium carbon refractory brick design Automated production line experience, customizing solutions for existing processes.
Figure 2 Process diagram of the automated production line
The successful transformation of the line has realized the series connection of the original five production lines, reducing the number of workers from 30 to 6. The automatic weighing and loading and unloading ensure the consistency of raw materials, improve the quality of bricks, and the output ratio is not modified. It has increased by more than 3 times, and has enhanced the competitiveness of aluminum-magnesium styling bricks, consolidated the market position of the company, and won high praise from the company's top management.
Scene threeIndustry: Sensor Manufacturing
Project: Smoke sensor automatic assembly production line
SOLOON Group is a new high-tech enterprise mainly engaged in fire alarm systems and gas fire extinguishing systems. The company's main product fire sensor is a super-new sensor that integrates smoke, dust, light and electricity. It is characterized by precision, fragility and high cost.
Affected by this, in the past production, manual and careful insertion, spot welding, turning, shearing, etc. on the small circuit board according to the hole position are required, and the efficiency is low, and the welding port is not strong and the assembly error occurs. Physical fitness is also a great test, and it is easy to cause visual fatigue. With the case experience of VAI in automated assembly, the SOLOON Group sought their help.
Figure 3 Schematic diagram of the automatic assembly line of smoke
The overall layout design of the assembly line fully considers the rationality of the process system and the advanced nature of the equipment. The welding adopts 5-axis welding robot; all electronic components and accessories are accurately output by vibrating plate; the 3-axis grab robot is used for grab assembly; the entire production line only needs one person to monitor.
The commissioning of the automatic assembly line of smoke has increased the beat from 115s/bar to 85s/piece, and eliminated 65% of the labor. It also enables frequent switching of sensor assemblies of different specifications. This technology is suitable for small-volume, multi-variety discrete production, and also has potential development value, which can be applied to, for example, PCBA circuit boards, electrical and electronic accessories, assembly and production of small precision parts.
Scene fourIndustry: Chemical
Project: Automation transformation of calcium carbide furnace
Calcium carbide is widely used in industry, agriculture, medicine, etc. Generally, electro-thermal method is used to produce calcium carbide, that is, quicklime and carbonaceous raw materials (coke, anthracite or petroleum coke) in the calcium carbide furnace, relying on arc high temperature melting reaction to form calcium carbide.
In the original production process, operators wear self-priming filter dust masks, chemical safety glasses, chemical protective clothing, rubber gloves, and discharge operations in front of the calcium carbide furnace, which poses a great threat to artificial safety. In order to create a human-machine-friendly win-win production model, the mechanical and electrical improvement of the calcium carbide furnace discharge structure is carried out.
Before mechanical transformation:
The upper and lower swinging mechanism of the original burner is composed of an elongated rod hinge support and a carbon rod fixed extension rod. The worker manually swings the carbon rod up and down to fix the tail of the extension rod to rotate the hinge shaft of the extension rod hinge support to realize the up and down swing.
After mechanical transformation:
The original manual rotation and the up and down swing mechanism are removed, and the action execution device is determined according to the actual process. The turning motion is realized by the electric rotary disc, and the front and rear swing is realized by the servo electric cylinder. The swing and swing can be precisely controlled remotely by the remote control handle, and the swing is stable without impact and the response speed is fast.
Figure 4 Schematic diagram of automated discharge structure
Before the electrical transformation:
All the components of the tapping machine are operated by the operator through the button, remote control and manual operation. They are close to the danger source and are in danger of burns and burns.
After electrical renovation:
Increase the remote operation function of the furnace and use it in parallel with the original on-site operation function. The system integrates remote control and remote video monitoring into the central control room. The operator can control the video display by real-time monitoring of the video screen.
Figure 5 Outer furnace control network topology
The solution is mainly aimed at worker safety and improvement of the production environment. It is carried out on the basis of the original tapping machine. After the transformation, it can meet the existing actions of the tapping machine, and the remote control and remote monitoring of the central control room, and the unloading site is unattended. Frontline workers are far from dangerous sources and create a good working environment.
Scene fiveIndustry: Elevator Manufacturing
Project: Fully automated production line for elevator car door system
XIZI UHC is a high-tech enterprise dedicated to the development of elevators. It has a high share in the elevator production industry, but the production methods of elevator components remain in the labor-intensive mode dominated by labor, and the increasingly intelligent manufacturing strategy. Related information.
In order to change the traditional production mode of Xizi Elevator, Beigang, as a strategic consultant for enterprise intelligent manufacturing, strives to improve assembly efficiency and production line production while pursuing the production line of elevator car door standard according to current production processes and processes.
Figure 6 Schematic diagram of the fully automated production line of the elevator car door system
The automatic feeding is completed by the cooperative operation of the raw material transportation AGV trolley and the automatic suction cup device, and the servo robot arm is used for automatic tapping, and the roller is loaded with the vibration plate. In order to ensure the flatness of the assembly, a calibrator is provided on the production line structure. The assembly line uses a set of positioning fixtures to clamp the same type of hanging plate, so the door switching time for different OP values ​​of the same model is 2 minutes; the replacement time of different types of car doors is 3 minutes.
The program not only realizes the demonstration role of the elevator car door benchmark production line, but also increases the efficiency to 12 seconds/group, saves 23 laborers, and the ROI (input-output ratio) reaches 1:5.
It is not difficult to see the above series of cases, the automation equipment contains nothing standard equipment: all kinds of hardware, conveyor system, industrial computer, pneumatic components, hydraulic system, mechanical arm, etc.; also includes non-standard equipment: automatic plane, automation customization Equipment, automation control equipment, etc. The standard equipment is combined with the non-standard equipment to form a complete production system. According to the established procedure, all the components coordinate movement and achieve the purpose required for production, which is the automation transformation.
As we all know, the risk of enterprise automation upgrade is very high. If the research and development fails, the enterprise will not only lose the research and development expenses, but also the opportunity cost caused by the stoppage loss. So how can we guarantee the high success rate of the transformation? Numerous practical case experiences tell us that the key to the success of enterprise automation upgrades is to find suppliers with the qualification to develop complex non-standard equipment and find suppliers with standard and non-standard equipment system integration capabilities. If you can find a supplier with both of the above qualifications and capabilities, then the success of the enterprise automation upgrade will be a success, with half the effort.
Automated transformation is not a "flower shelf" for others to see, but it is not a follow-up industry. Expensive capital, either to improve product quality, or to reduce raw materials and labor costs, or to change the harsh operating environment of workers, ultimately requires tangible benefits.
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