Ta Yaya Injin Toshe Na Zamani Ya Inganta Haɓaka Haɓaka?

Wadanne Mabuɗin Fasaha Ke Haɓaka Ingantacciyar Na'urar Yin Toshe Na Zamani?

Juyin Halitta daga injunan toshewa na yau da kullun zuwa na zamani, cikakken tsarin sarrafa kansa yana rataye akan haɗuwar ci gaban aikin injiniya. Masana'antarmu ta shafe shekaru tana tace waɗannan fasahohin don tabbatar da cewa kowane injin yin toshe QGM yana ba da fa'idodin ingantaccen aunawa. A ƙasa mun rushe ginshiƙan ginshiƙan fasaha waɗanda ke sake fasalta yawan aiki.

1. Tsarukan Jijjiga Mai Girma

Ba kamar a tsaye ko ƙaramar girgiza ba, injunan zamani suna amfani da servo-driven eccentric vibrators waɗanda ke haifar da mitoci sama da 85 Hz. Wannan yana samun haɗin kai kai tsaye tare da ƙarancin abun ciki na siminti yayin da yake riƙe mafi girman ƙarfin kore. Sakamakon: Ana iya tara tubalan da wuri, rage buƙatun yanki da haɓaka kayan aiki gabaɗaya. A masana'antar mu, sigogin rawar jiki suna daidaitawa ta hanyar HMI, ba da damar masu aiki su canza tsakanin ƙwararrun tubalan, ɓangarorin fashe, da pavers ba tare da sake fasalin injin ba.

2. Rufe-Madauki na Gine-ginen Ruwa

Ingantaccen na'ura mai aiki da karfin ruwa yana daidaita kai tsaye tare da amfani da makamashi da saurin zagayowar. Tsarin zamani yana amfani da bawul ɗin daidaitawa, famfo mai ɗaukar nauyi, da da'irori masu tarawa waɗanda ke rage kuzari mara amfani da kusan 35%. Injin ɗin mu na toshe QGM ya haɗa da tsarin hydraulic mai famfo dual-pump wanda ke aiki tare da rawar jiki da ƙarfi, kashe lokutan sake zagayowar zuwa ƙasan 12-15 seconds kowane pallet don daidaitattun tubalan.

3. Smart PLC tare da Shirye-shiryen IoT

Daidaituwar masana'antu 4.0 yana canza bayanai zuwa abubuwan da ake iya aiwatarwa. Tsarin mu ya ƙunshi masu sarrafa Siemens ko Beckhoff waɗanda ke saka idanu kan sigogi na ainihin lokaci - girman girgiza, zafin mai na ruwa, danshi mai ɗanɗano - da daidaitawa ta atomatik don kiyaye daidaito. Bincike mai nisa yana ba ƙungiyar sabis ɗinmu damar tsara gazawa, tabbatar da lokacin aiki ya kasance sama da 95% koda a cikin ayyukan 24/7.

4. Modular Mold & Saurin Canjin Tsarin

Lalacewar lokaci tsakanin sauye-sauyen samfur yana kashe inganci. Na'urori masu tasowa sun haɗa nau'ikan nau'ikan nau'ikan ruwa na ruwa tare da hanyoyin sakin sauri. Canza daga toshe 6-inch zuwa toshe 8-inch yana ɗaukar ƙasa da mintuna 8 idan aka kwatanta da canje-canje na al'ada na mintuna 45. Wannan sassauci yana ƙarfafa masu kera don gudanar da ƙananan batches ba tare da sadaukar da OEE (Ingantacciyar Kayan Aiki ba).

Don misalta fifikon fasaha, anan akwai cikakkun sigogin jerin mashin ɗin mu na QGM block yin inji. Waɗannan ƙayyadaddun bayanai sune sakamakon sama da shekaru ashirin na bayanan filin da ci gaba da R&D aAbubuwan da aka bayar na Abubuwan da aka bayar na Quangong Machinery Co., Ltd.

Waɗannan alkaluma ba kawai na ka'ida ba ne. A masana'antar mu, muna gudanar da gwaje-gwajen juriya mai ƙarfi don tabbatar da kowane na'ura mai toshe QGM yana ba da ingantaccen aiki ko da a cikin yanayin da ake buƙata. Ta hanyar haɗa waɗannan fasahohin, masu kera suna rage farashin wutar lantarki da kashi 22 cikin ɗari kuma farashin ma'aikata da kusan kashi 50% idan aka kwatanta da madadin atomatik.

Ta Yaya Haɓaka Lokacin Zagayowar Aiki Automa da Zagayowar Zagayowar Ƙarfafa Fitowa?

Lokacin zagayowar—lokacin daga ciyarwar ɗanyen abu zuwa ƙarewar toshewar-shine bugun zuciya na ingancin samarwa. Injin ƙera katanga na zamani suna yin amfani da cikakkun sarƙoƙi na atomatik waɗanda ke aiki tare da kowane ƙaramin tsari, kawar da shisshigin hannu da rage tazara marasa aiki. Kwarewarmu a Quangong Machinery Co., Ltd. tana nuna cewa ingantaccen tsarin sarrafa kansa zai iya haɓaka fitarwa da kashi 70% idan aka kwatanta da layukan hannu ko Semi-atomatik, yayin da lokaci guda ke haɓaka daidaiton samfur.

Ƙarshe-zuwa-Ƙarshe Ƙarshen Gine-gine na Automation

Haƙiƙa na gaskiya yana zuwa daga cikakkiyar hanya. Tsarin mu sun haɗa da:

• Jumla ta atomatik da haɗawa:Na'urori masu auna nauyi da binciken danshi suna tabbatar da daidaituwar haɗuwa kafin abu ya shiga cikin injin, yana rage ƙin yarda.
• Zazzagewar pallet na PLC:Masu isar da saƙon da ke sarrafa Servo suna aiki tare da babban injin, yana tabbatar da lokacin jira na sifili tsakanin kekuna.
• Tsige Layer Robotic & Cubing:Ana sarrafa sarrafa bayan samarwa ta atomatik, yana ba da damar injin yin toshe don ci gaba da gudana ba tare da jinkirin forklift ba.
• Ciyarwar kayan tsinkaya:Sa ido kan amfani na ainihi yana haifar da cikawa ta atomatik daga silos, yana hana yunwa.

Ma'aikatarmu tana tsara kowane layin samarwa a matsayin tsarin yanayin haɗin gwiwa. AQGM block yin injiyana haɗawa ba tare da wani lahani ba tare da tsarin sarrafa kayan aikin sarrafa kansa da kuma layukan marufi, wanda ke nufin cewa ko da lokacin samar da hadaddun kayayyaki kamar fakitin shiga tsakani, jimillar abubuwan da aka samu ya kasance mai girma.

Rage Lokacin Zagayowar Ta Hanyar Daidaita Ayyuka

Na'urorin gargajiya suna aiki a jere: ciyarwa, girgiza, latsawa, fitarwa, sannan jira dawowar pallet. Kayan aikin zamani, duk da haka, sun mamaye ayyukan. Yayin da babban latsa ke tattara tsari, mai ciyarwa ya riga ya rigaya ya gama hadawa na gaba, kuma mai kula da pallet yana shirya allo na gaba. Wannan yana rage ingantaccen lokacin zagayowar har zuwa 40%. A ƙasa akwai ɓarna na inganta zagayowar:

• Cajin albarkatun kasa: 3 sec (madaidaicin adadin kuzari)
• Vibration & compaction: 5-7 sec (sabis mai sarrafa amplitude modulation)
• Na'ura mai aiki da karfin ruwa latsa & rike: 2 sc (bawul masu aiki daidai gwargwado)
• Cirewa & Fitar pallet: 2 s (a daidaita tare da mai ɗaukar kaya)
• Jimlar bushewar zagayowar:12-16 sec (gami da interlocks)

Haka kuma, injinan zamani sun haɗa da girke-girke masu zaɓin zaɓi. Injin ƙera toshe QGM ɗin mu na iya adana girke-girke na samfur har zuwa 200, yana ba masu aiki damar canzawa tsakanin ɓangarorin ɓatanci, ƙwanƙwasa masu ƙarfi, da hana duwatsu a cikin daƙiƙa ba tare da gyare-gyare na inji ba. Wannan ƙarfin aiki yana rage raguwar lokaci kuma yana ba da damar samar da lokaci-lokaci, rage farashin kaya.

A Zenith, mun aiwatar da dashboards na Masana'antu 4.0 waɗanda ke ba da ma'auni na OEE (Ingancin Kayan Aikin Gabaɗaya). Abokan ciniki sau da yawa suna ba da rahoton cewa bayan haɓakawa zuwa tsarin mu masu sarrafa kansa, aikin canjin su ya ƙaru daga tubalan 6,000 zuwa sama da 15,000 tare da ma'aikata iri ɗaya. Haɗin rage lokutan sake zagayowar, rage girman kuskuren ɗan adam, da ci gaba da aiki yana sa sarrafa kansa ya zama babban mai ba da gudummawa guda ɗaya ga ingantaccen samarwa na zamani.

Me yasa Tsarin Tsarin Na'ura na Hydraulic Yayi Mahimmanci don daidaiton Samfura?

Hydraulics tsokoki ne na kowane injin yin toshe, amma tsarin da ba a tsara shi ba yana haifar da sharar makamashi, rashin daidaituwa, da rufewar kulawa akai-akai. Sabanin haka, madaidaicin da'irar injin hydraulic yana tabbatar da cewa kowane toshe yana karɓar ƙarfin latsa iri ɗaya, ba tare da la'akari da saurin samarwa ko yanayin yanayi ba. Domin shekaru biyu, mu factory ya mai ladabi na'ura mai aiki da karfin ruwa gine-gine don cimma masana'antu-manyan daidaito da aminci. Ga dalilin da ya sa yana da mahimmanci don dacewa.

Ingantaccen Makamashi & Gudanar da Zafi

Tsarin na'ura mai aiki da karfin ruwa na al'ada yana gudana a ƙayyadaddun famfun matsuguni, yana haifar da asarar kuzari yayin lokutan aiki. Na'ura mai toshe toshe na QGM na zamani yana amfani da famfunan bututun piston axial-masu-masu-wuri hade tare da fasahar jin nauyi. Wannan yana rage amfani da wutar lantarki har zuwa 38% idan aka kwatanta da tsofaffin samfura. Bugu da ƙari, manyan masu sanyaya mai tare da sarrafa zafin jiki suna ci gaba da aiki da yanayin zafi tsakanin 45-55 ° C, suna kiyaye rayuwar hatimi da dankon mai. Ƙirƙirar ƙarancin zafi kuma yana rage ƙarfin sanyaya, ƙirƙirar haɓakar haɓakar haɓaka.

Daidaitaccen Ƙarfafawa = Ƙananan Ƙimar ƙima

Daidaitaccen toshe mai yawa da daidaiton girma ya dogara da matsa lamba na hydraulic mai maimaitawa. Tsarin mu na latsa silinda mai dual-cylinder yana aiki har zuwa 25 MPa tare da ra'ayoyin matsayi (masu fassarar layi) wanda ke tabbatar da naushi na sama yana tsayawa daidai tsayi iri ɗaya kowane zagayowar. Wannan yana kawar da bambance-bambance a tsayin toshe kuma yana rage sharar gida. Ƙin ƙima a kan rukunin yanar gizo na yau da kullun suna raguwa daga 3-5% zuwa ƙasa da 0.8% bayan ɗaukar tsarin injin mu.

Maintenance-Friendly Design

Lokacin da aka rage don gyaran hydraulic na iya gurgunta samarwa. Ƙirar mu ta ƙunshi nau'ikan nau'ikan samun sauƙin shiga, tashar jiragen ruwa mai sauri, da abubuwan da ba su iya jurewa (ISO 4406 class 18/16/13). Har ila yau, muna ba da faɗakarwar tabbatarwa na tsinkaya-lokacin da tace bambance-bambancen matsa lamba ya tashi, tsarin sarrafawa yana sanar da masu aiki. A masana'antar mu, muna gwada kowace rukunin wutar lantarki na tsawon awanni 72 a ƙarƙashin nauyin da aka kwaikwayi don ba da garantin aiki mara ƙyalƙyali. Abokan cinikinmu sun ba da rahoton cewa raguwar lokaci mai alaƙa da hydraulic yana da ƙasa da 1% na jimlar lokacin samarwa kowace shekara.

Don kwatancen sauri, a nan ne duba mahimmin sigogin hydraulic a cikin tsararraki na inji:

• Na'ura na gargajiya: Kafaffen famfo, da'irar matsa lamba ɗaya, 12-15 MPa, 45 sec sake zagayowar, 55 kWh/ton
• Na'ura mai toshe QGM na zamani: famfo mai ɗaukar nauyi, da'irar matsa lamba biyu, har zuwa 25 MPa, sake zagayowar 14 sec, 32 kWh/ton

Tare da waɗannan ci gaban, masu kera suna samun ba kawai mafi girma fitarwa ba har ma da raguwar farashin aiki. Yana da bayyananniyar kwatanci na yadda sophistication na hydraulic ke fassara kai tsaye zuwa riba.

Menene Ribar Ingantaccen Aunawa Tare da Tsarin Kula da Smart?

A zamanin masana'antu masu kaifin basira, injin yin toshe ba tare da kulawar hankali ba kamar wayowin komai da ruwan da ba shi da aikace-aikace-mai aiki amma nesa da mafi kyau. A Quangong Machinery Co., Ltd., mun shigar da masu sarrafa wayo waɗanda ke yin fiye da kawai gudanar da jeri; suna nazari, daidaitawa, da tsinkaya. Wannan sashe yana ƙididdige nasarorin da aka samu ta hanyar ingantaccen tsarin gine-ginen sarrafa mu, wanda ke goyan bayan ainihin bayanai daga shigarwa a duk duniya.

Haɓaka Daidaitaccen Lokaci na Gaskiya

Injin ɗinmu na toshe QGM yana amfani da algorithm na taimakon AI wanda ke lura da mitar girgiza, matsa lamba na hydraulic, da danshin kayan a ainihin lokacin. Idan mahaɗin ya ɗan ɗanɗana ruwa saboda yanayin, tsarin yana daidaita lokacin girgiza ta atomatik don kiyaye cikakkiyar haɗakarwa. Wannan dabarar daidaitawa tana tabbatar da daidaiton ƙarfin toshe (yawanci 10-15% mafi girman ƙarfin C28) kuma yana rage yawan amfani da siminti. Abokan ciniki sukan adana 8-12% akan farashin albarkatun ƙasa a cikin watanni uku na farko.

Kulawa Mai Nisa & Gudanar da Jirgin Ruwa Tsakanin

Har ila yau, inganci yana fitowa daga raguwar lokacin raguwa. Dandalin iQGM na tushen girgije yana bawa masu sarrafa shuka damar saka idanu akan samarwa KPIs-kamar hawan keke a kowace awa, amfani da makamashi kowane toshe, da tarihin ƙararrawa-daga kowace na'ura. Lokacin da aka gano wani abu mara kyau, tsarin yana samar da rahoton bincike, kuma injiniyoyin sabis ɗinmu na iya daidaita sigogin nesa nesa. Wannan yana rage ma'anar lokacin gyara (MTTR) daga matsakaicin masana'antu na sa'o'i 8 zuwa ƙasa da awanni 2.

Ilimin Amfani da Makamashi

Ƙwararrun sarrafawa suna ba da saƙon kuzari na granular. Misali, za mu iya keɓance yawan amfani da injina na girgiza, famfo na ruwa, da masu jigilar kaya. Abokan cinikinmu suna amfani da wannan bayanan don tsara samarwa a lokacin farashin wutar lantarki mafi tsada, yana ƙara rage farashin da kusan 18%. A ƙasa akwai kwatancen nazarin makamashi:

• Injin Legacy: 2.1 kWh kowace daidaitaccen toshe (400x200x200mm)
• QGM mai sarrafa kansa mai wayo: 1.35 kWh kowace daidaitaccen toshe
• Ajiye na shekara-shekara don aiki na sau biyu: ≈ 85,000 USD (dangane da 0.12 USD/kWh)

Haka kuma, tsarin sarrafawa yana yin rajistar tazarar kiyayewa na rigakafi-mai mai, sauye-sauyen tacewa, da daidaita rawar jiki-don kada wani sabis ɗin da aka tsara ya ɓace. Masana'antar mu tana horar da ƙwararrun masu fasaha ta hanyar AR-taimakon littafan, yana tabbatar da masaniyar babban tsarin da saurin matsala. Sakamakon shine yanayin samar da kayan aiki inda ba'a samun ingantaccen aiki ba kawai amma yana dawwama tsawon shekaru.

Tare da waɗannan fasalulluka masu wayo, QGM block yin inji ya zama fiye da kayan aiki; ya zama kadara mai mahimmanci wanda ya dace da buƙatun kasuwa yayin inganta kowane albarkatu. Ga masu kera da ke da niyyar yin ƙima, haɗewar aiki da kai, daidaitaccen ruwa, da sarrafawa mai wayo yana haifar da gasa mai gasa wanda tsarin gado kawai ba zai iya daidaitawa ba.

Ƙarshe: Ƙirƙirar Ƙwararrun Ƙwararrun Ƙwararrun Ƙwararrun Ƙwararrun Ƙwararrun Ƙwararrun Ƙwararrun Ƙwararrun Ƙwararru na gaba

Kamar yadda muka bincika, amsar "yaya na'urar kera na'ura ta zamani ke inganta ingantaccen samarwa" ta ta'allaka ne a cikin haɗin kai na girgiza mai ƙarfi, na'urorin lantarki masu hankali, sarrafa kansa, da sarrafa bayanai. Waɗannan fasahohin suna aiki tare don yanke lokutan sake zagayowar, rage sharar gida, rage yawan amfani da makamashi, da haɓaka tasirin kayan aiki gabaɗaya. A Quangong Machinery Co., Ltd., mun sadaukar da sama da shekaru 20 don samar da hanyoyin injiniya waɗanda ke ƙarfafa masu kera don biyan buƙatun gine-gine ba tare da ƙimar ƙimar kuɗi ko aiki ba.

Ma'aikatarmu ta ci gaba da haɓaka-haɓaka tsinkayar ingancin AI-kore da tsarin dawo da makamashi mai dorewa-tabbatar da cewa kowane na'ura mai toshe QGM ya kasance a kan gaba a matsayin masana'antu. Ko kuna neman haɓaka layin da ke akwai ko gina cikakken shuka mai sarrafa kansa daga karce, ƙungiyarmu tana ba da tallafi na ƙarshe zuwa ƙarshe: daga ƙirar shimfidar wuri zuwa horon tallace-tallace. Sakamako shine haɓakar aunawa a cikin layin ƙasa da raguwa mai mahimmanci a cikin sawun carbon da aka samar.

Shirya don canza ingancin samarwa ku? Abubuwan da aka bayar na Quongong Machinery Co., Ltddon tsara shawarwari. Kwararrunmu za su bincika saitin ku na yanzu, samar da keɓaɓɓen hasashen ROI, kuma su nuna yadda injin ɗin mu na toshe QGM zai iya haɓaka ƙarfin masana'anta. Mu gina makoma mai inganci tare.

Tambayoyin da ake Yi akai-akai (FAQ) - Inganci, Kulawa & ROI