Adjustable machining scheme of the hottest cube pa

2022-08-16
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Adjustable processing scheme for cube parts

heller uses a new scheme to meet the requirements of the automotive industry for more flexible industrial systems. The automated workflow included in the new "modulelinesystem" allows for higher productivity

as long as you spread your legs enough, you can sit on the floor steadily - Manfred Maier, general manager of Heller company, vividly explained the starting point of the new scheme of flexible machining system "MLS (modulelinesystem)", which is used to process cube parts in engines and gearboxes

one leg represents customers in the automotive manufacturing industry, that is, these OEM companies and primary suppliers have abandoned multi station automatic machine tools and chose the so-called hybrid solution since the 1990s; The other leg represents the general machine tool market in independent machine tools

based on the machining center (modular system), Heller successfully located in the above two areas, but it should avoid more and more complaints and lead to increasing internal packaging costs

"customers' requirements on the technical side are always diverse," Maier said, "On the one hand, they require cutting units to be highly available and provide good automation performance for mass production, so as to achieve the purpose of lower single piece cost; on the other hand, they require a large number of tool libraries, provide good preparation for mass production, and their processing range should fully cover all kinds of parts. In the future, we should go all out to provide solutions without complaints for the application of these two aspects. ”

the starting point of MLS system comes from the changing framework conditions of the automotive industry, the increasingly frequent innovation cycle, the expanding product range, and the increasing cost pressure. The smaller the planning vision of the automotive industry, the lower the safety of the planning. How can the equipment planned today meet the production demand in 8 to 10 years? How can we maximize the safety of investment

"adjustability" is the panacea

generally, multiple special machine tools are used to process cube parts in engines and gearboxes, so as to achieve the low single piece cost so far. However, due to the changing total number of workpieces originally planned, the profitability of the equipment has become a problem. The side effects caused by the changes of part geometry and workpiece processing flow are becoming more and more obvious. The production process is often disturbed. In the worst case, it even needs to add a new production line, or the existing production line cannot be used at all

"who is willing to continue working on a pile of unusable machines? Even though the hybrid solution of previous years is based on assembly line equipment, although this bear equipment has been optimized as much as possible according to the needs of the automotive industry, it can not solve the coming problems well. Therefore, we decided to develop a new solution to unify the requirements of users in terms of production efficiency and flexibility." Maior said

however, at the end of the continuous material flow in Figure 1, depending on the new automation system, the workpiece and cutter can be arranged in the center of the MLS system in the processing module

automation system and become its core part (Figure 1); The workpiece and cutter are arranged on both sides of the processing module and can be transported freely. The control system of MLS system (Figure 2) can automatically judge and accurately convey the workpiece to the machine tool. The workpiece library and smoother conveyor integrated in the MLS system can ensure that every machine tool (even if it is still processing workpiece) is ready to receive the next workpiece at all times. Since the machine tool and the automation system are separated from each other, the processing module can determine the feeding time point by itself and work continuously

the inherent flexibility of the system

this feature enables users to realize that Jinan new era Gold Testing Instrument Co., Ltd. is an enterprise specializing in the production of various types of mechanical experimental machines all year round. There are three changes: the number of planned workpieces can be increased or reduced, or the processing content can be automatically changed according to the change of workpiece conditions. In the first case, the function of MLS system can be expanded by adding additional machine tools. Workpiece management can also meet greater production requirements by further expanding the linear module. The more demanding, but more frequent, situation is the decreasing number of workpieces. In this case, a certain amount of processing content needs to be stripped from the system and then used to process other workpieces. For example, under the current situation, MLS system is arranged to process the cylinder head of four cylinder gasoline engine, and the production task predicts the growth of demand for diesel engine processing in the next step; The equipment in the system will select diesel engine components that meet its own working capacity for processing. Finally, the operation sequence is changed according to the logistics sequence of workpieces with different sizes. In MLS system, system scalability and workpiece scalability are combined: the system can be extended to the variant of conveying workpieces in sequence or in parallel. With this adjustability (Figure 3), the effectiveness of future investment will conditionally depend on whether the predicted number of workpieces is consistent with the number of workpieces of a single contract in the actual situation, and to what extent. At the same time, production capacity will no longer be reserved for flexibility in the future. The price of a single workpiece will directly and positively affect the core scale of the batch production line

ten suggestions on the optimization of life cycle benefits

settable flexibility

the MLS system can meet various needs through the integration of solid and durable machining centers that have been proved by practice, such as integrating the single axis machining centers mc-10 and mc-20 into the double axis machining center mct1o, or combining the modules of MC200, mpc200 and mp200 into a new system with special functions. The modular design of the machine tool enables the MLS system to comprehensively adopt various tool and workpiece converters, tool libraries, bases, machining center units and single axis machine tools. Even processes such as cleaning the workpiece, measuring the workpiece and laser engraving on the workpiece can be flexibly integrated into the MLS system

consolidated machine tool structure

the upper structure and servo motor of the machine tool need to be thermally isolated from the lower high hardness cast iron bed. The stepped design of the column guide takes into account the stiffness in the z-axis direction. It also takes into account the constant condition that the cutter and workpiece have the same lifting height in the z-axis direction. The fixed arrangement of the spindle and the fixture for feeding ensure the repeatability of the processing quality. Ball screws or linear motors can be selectively used for all axial feeding modes

less space requirements

compared with the automatic feeding mechanism or hybrid equipment linked through the conveyor belt and gantry, the space required by the MLS system to achieve the same processing capacity is significantly reduced. The reason is that the area of the machining center is small, and the automation system can be arranged in the center with 2mm on both sides of the module

five sided machining process and dry machining process

five sided machining process puts forward a relatively economic framework condition for cutting power and cutting dynamic characteristics: when the maximum speed is 16000 rpm, the maximum power can not exceed 40kW (hsk-100), the maximum starting time can not exceed 0.3 seconds, the fastest fast travel in all linear axes can not exceed 60 meters/minute, and the maximum acceleration can not exceed 8 meters/second 2, The linear drive in the direction of a-axis and b-axis must also meet future requirements. The equipment of the dry processing process must be locked in harmony to keep the free fall of chips. The external Z uranium, riser processing, chip container and metal covering parts with an inclination of more than 60 degrees must ensure the smooth chip removal, and there must be no chip entanglement

tool management system

when the tool clamping time is getting shorter and shorter, it is necessary to reduce the tool change time in order to improve the overall productivity of the equipment. The MLS system no longer uses the double jaw chuck, but directly arranges the tool magazine above the workpiece, and uses the fast track chain to transport the tools to the spindle (Fig. 5). The separate installation process of the tool is less than 3 seconds, which reduces the work preparation time, so that the cutting interval can reach 2.4 seconds. The tool switching system replaces some of the auxiliary functions, such as tool cleaning, tool coding and tool defect control. The basic arrangement of the spindle of the machine tool allows the free length of the tool to be combined with the optional tool library, so that the maximum length of the drill used by the MLS system can reach 800 mm, and the maximum diameter of the milling cutter can reach 330 mm

tool management system

when the tool clamping time is getting shorter and shorter, it is necessary to reduce the tool change time in order to improve the overall productivity of the equipment. The MLS system no longer uses the double jaw chuck, but directly arranges the tool magazine above the workpiece, and uses the fast track chain to transport the tools to the spindle (Fig. 5). The separate installation process of the tool is less than 3 seconds, which reduces the work preparation time, so that the cutting interval can reach 2.4 seconds. The tool switching system replaces some of the auxiliary functions, such as tool cleaning, tool coding and tool defect control. The basic arrangement of the spindle of the machine tool allows the free length of the tool to be combined with the optional tool library, so that the maximum length of the drill used by the MLS system can reach 800 mm, and the maximum diameter of the milling cutter can reach 330 mm

workpiece management system - flexflow

mls system has a perfect and diverse workpiece management system. Instead of using hard connection between machining centers, a flexible workpiece feeding and workpiece distribution mechanism is adopted. The linear module realizes the workpiece switching speed within 10 seconds, including taking out the workpiece from the workpiece library, feeding along the guide rail (Fig. 4), and then transporting it to the conversion table that works like a "silent servant" (Fig. 6). The central feeding system realizes the workpiece feeding of a single device. 1.5 million tons

Figure 6 workpiece access gate: the connecting mechanism between the processing module and the central workpiece memory

- "silent servant", the conversion time is less than 10 seconds

therefore, the maximum value of repeatability uncertainty in the three calibration points is taken as the repeatability weight (1000N): u4=0.032% simple operation

complex equipment requires simple operation. All production strategies and countermeasures are stored in the control system, and the whole equipment can be operated easily with only eight buttons. The "IPM" process monitoring system integrates the functions of workpiece monitoring (including workpiece damage monitoring and workpiece overload monitoring), machine tool collision monitoring, belt wear monitoring, ball screw function monitoring, and adjusting the actual power of the spindle according to the processing process and workpiece conditions. The video camera in the MLS system can even monitor the process that is not visible at ordinary times in real time. The configuration management function of the central control system can also clearly display the status of the equipment

convenient maintenance

the selection of mechanical and electrical components takes into account the future wear. The spindle in the automatic control system adopts a newly developed direct drive mode. All sensors and actuators, control and automation systems (Siemens "solution line") in the drive system named "help" (including hydraulic part, electric part, lubrication part and pneumatic part)

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