Throughout the development of manufacturing industry at home and abroad, automation transformation plays an important role in its production process.With the automation equipment taking over the labor market, more and more enterprises are engaged in the automation transformation, and realize the benefits of automation transformation for enterprises.It is an inevitable trend for labor-intensive enterprises to transform to automation. China has a long way to go on the road of automation. Following beigang union, we will analyze five classic solutions of automation transformation.
The scene of a
Industry: nuclear test
Item: automatic sample changing test equipment
A unit of China national nuclear power group, focusing on nuclear physics research, has always kept a mystery to the outside world. Thanks to the development strategy of national military-civilian integration and the military qualification of beigang united, this enterprise finally opened its door and took the first step of automatic transformation.
As we all know, nuclear material test itself is dangerous, radioactive elements, complex space environment, precise and accurate operation, etc., have extremely high requirements for personnel.In order to change the sample changing testing process operated by scientists in the glove box and reduce the risk, inefficiency and inaccuracy of manual experiments, an automatic testing solution is proposed for manual testing process:
Use the mechanical arm to place the required workpiece on the workpiece frame placement board, through the horizontal movement of the left and right movement and upgrade the mechanism up and down operation to achieve automatic detection of the workpiece (accuracy ±0.05) and parts replacement.After the workpiece is tested, the cutting arm will remove the workpiece and replace the next batch of workpiece to be tested.And the whole set of equipment has: workpiece in place detection, missing parts alarm and personnel rushed into the test area by mistake, and other emergency treatment systems.
The delivery of this set of equipment reduced the original 5 inspectors responsible for implementation, supervision and statistics to 2 for monitoring, greatly saving valuable human resources, enhancing the reliability of inspection results, and playing a typical demonstration role in building a world-class advanced laboratory.
Scenario 2
Industry: refractory materials
Project: automatic production line of finished firebrick
A large domestic refractory company is one of the leading companies in the fire brick industry, with high quality aluminum magnesium brick occupied a large number of market share.Due to the good situation in recent years, the market demand is huge, but the production cannot meet the growing demand.According to the strategy of promoting development through reform and seeking progress through innovation, the semi-automatic production line of finalizing aluminum-magnesia brick has been transformed into full automatic production line.
The existing manual production process is as follows: powder loading weighing -- powder pouring into press mold -- press work -- mold taking -- mold cleaning -- finished product testing. Relying on the experience of beigang steel co., LTD. 's fully automatic production line designed for the same type of magnesia-carbon firebrick, the solution is customized for the existing process.
Line the success of the reform, the realization of the original series of five production lines, the number of workers from 30 people to 6 people, the automatic weighing and loading to ensure the consistency of raw material, improve the quality of the brick shape, output more than three times higher than before renovation, and increase the product competitiveness of aluminium magnesium shape brick, strengthened the market position of the enterprise, won the praise of the top.
Scenario 3
Industry: sensor manufacturing
Project: automatic assembly line of smoke sensor
SOLOON group is a new high-tech enterprise mainly engaged in fire alarm system and gas fire extinguishing system.The company's main products fire sensor is set to detect smoke, dust, light, electricity in one of the ultra-new sensor, with precision, fragile, expensive and other characteristics.
Affected by this, the previous production needs to be carefully inserted in the small circuit board according to the hole position, spot welding, flip, shear, low efficiency, and the existence of welding mouth is not strong, assembly errors, is also a great test of the human body, easy to cause visual fatigue.With the help of beigang's case study in automated assembly, SOLOON group sought their help.
The overall layout design of the assembly line, fully consider the rationality of the process system, advanced equipment.Welding adopts 5-axis welding robot;All electronic components and accessories are accurately output by vibration disk;A 3-axis grasping robot is used for grasping assembly.The whole production line only needs one person to monitor.
The production of smoke sensing automatic assembly line increases the tempo from 115s/ s to 85s/ s, saves 65% of labor, and enables frequent switching of sensor assembly of different specifications.This technology is suitable for the discrete production of small batch and many varieties, and has potential development value, which can be applied to the assembly and production of PCBA circuit board, electrical and electronic accessories, small precision parts.
Scenario 4
Industry: chemical industry
Project: automatic transformation of calcium carbide furnace
Calcium carbide is widely used in industry, agriculture, medicine and other aspects, generally using electric heating method 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 produce calcium carbide.
In the original production process, operators wear self-suction filter dust masks, wear chemical safety protection glasses, wear chemical protective clothing, wear rubber gloves, discharge in front of calcium carbide furnace, which poses a great threat to artificial safety.In order to create a human-friendly win-win production mode, mechanical and electrical improvements are made to the discharging structure of carbide furnace.
Before mechanical transformation:
The up-and-down swing mechanism of the burners is composed of extension rod hinged support and carbon rod fixed extension rod.The worker manually swings the carbon rod up and down to fix the tail of the extension rod and rotate it around the hinge shaft of the extension rod hinged bearing to achieve up and down swing.
After mechanical transformation:
Remove the original manual rotation and up-down swing mechanism, and determine the action implementation device according to the actual process.The rotary motion is realized by electric rotary disc, and the back and forth swing is realized by servo electric cylinder.
Before electrical transformation:
All parts of the oven are operated manually by operators on the site through buttons, remote controls, and close to the source of danger.
After electrical transformation:
The remote operation function of oven is added, which can be used in parallel with the original field operation function.The system integrates remote control and remote video monitoring in the central control room, and the operator can complete the operation by controlling the rocker and monitoring video screen in real time.
The solution is mainly aimed at the safety of workers and the improvement of production environment. Based on the original furnace, the modification can meet the requirements of remote centralized operation and remote monitoring of the current operation of the furnace by the central control room, and no one is on duty at the discharging site, so that front-line workers are far from the source of danger and create a good working environment.
Scene five
Industry: elevator manufacturing
Project: automatic production line of elevator car door system
XIZI UHC is a high-tech enterprise dedicated to elevator research and development. It occupies a relatively high share in elevator production industry, but the production mode of elevator parts is mainly labor-intensive mode, which is contrary to the increasingly developed intelligent manufacturing strategy.
In order to change the traditional production mode of xizi elevator, beigang united, as the strategic consultant of intelligent manufacturing, strives to improve the assembly efficiency and production line output while pursuing to build the benchmark production line of elevator car door according to the current production process and technology.
The AGV trolley for raw material transportation and the automatic suction cup device are used to complete the automatic feeding, the servo arm is used for automatic tapping, and the vibration plate is used for the feeding of the roller.In order to ensure the flatness of assembly, a calibration instrument is set up on the production line structure.The assembly line USES a set of positioning fixture to hold the same type of hanging board, so the switching time of the car door for different OP values of the same type is 2 minutes;Different types of car door replacement time is 3 minutes.
This scheme not only realizes the demonstration function of benchmarking production line of elevator car door, but also improves the efficiency to 12 seconds/group, saves 23 labor, and achieves the ROI (input-output ratio) of 1:5.
Based on the above series of cases, it is not difficult to see that the automation equipment consists of some standard equipment: all kinds of hardware, conveying system, industrial control machine, pneumatic components, hydraulic system, mechanical arm, etc.Also includes non-standard equipment: automation special aircraft, automation custom equipment, automatic control equipment.Combine the standard equipment and non-standard equipment organically to form a complete set of production system. According to the established procedures, all parts move in harmony to achieve the purpose of production, which is automatic transformation.
As we all know, the risk of enterprise automation upgrading is very high. If the research and development fails, the enterprise will lose not only the research and development expense, but also the opportunity cost caused by the shutdown.So how to ensure the high success rate of reconstruction?Many practical cases tell us that the key to the success of enterprise automation upgrading and transformation is to find suppliers qualified to develop complex non-standard equipment, and to find suppliers capable of system integration of standard and non-standard equipment.If you can find a supplier with the above two qualifications and capabilities, then the success of enterprise automation upgrade will be a natural course, twice the result with half the effort.
Automated transformation is not a "fancy" for others to see, nor is it a copycat industry 4.0.It costs a lot of money to improve the quality of products, reduce the cost of raw materials and labor, or change the poor operating environment of workers. In the end, real benefits are needed.
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