"Full-automatic steel double-sided edge milling machine production line" won the Science and Technology Award
Wen/Hou Bin
The "Automatic Steel Plate Double Side Milling Machine Production Line" jointly researched and developed by Xi'an Zhongyou Electromechanical Automation Engineering Co., Ltd. and Xi'an Productivity Promotion Center won a high evaluation at the China Packaging Federation 2016 Science and Technology Awards Review Meeting. , was awarded the second prize.
The research goal of this project is to develop a steel plate milling machine production line, which is used to process galvanized steel sheets and pre-coated coils as raw materials for the production of steel drums. The special equipment for pre-treating the barrel edges is used for milling. The galvanized steel plate coating and the pre-coated coil coated plate are simultaneously processed on both sides of the upper edge to eliminate the galvanized layer or the coating layer at the seam welding joint, thereby providing a smooth surface for the next process-seam welding. The steel plate milling machine is an indispensable equipment for galvanized steel sheets and pre-coated coiled barrels. It provides an effective guarantee for the use of this new process material in the industry, and solves the industrialization of galvanized steel sheets and pre-coated coils. The production of steel drums has been a bottleneck that has plagued industry companies.
The implementation of the project has promoted the application of galvanized steel sheets and pre-coated coils in the metal packaging industry, and the use of galvanized steel sheets and pre-coated coils to achieve zero pollution of waste gas and waste water produced by the production, thereby protecting the environment.
First, the milling machine production line
The main research and development contents of the project include: 1 basic parameter design: calculation of main parameters such as milling force, milling head rotation speed, steel plate feed feed speed and milling power head installation offset angle; 2 high-speed milling power head and configuration mode; 3 automatic Feeding robot suction cup technology; 4 single-chip control detection technology and PLC electronic control technology of machine tool; 5 main engine transmission device, pressing device, guiding device and feeding device; 6 automatic product stacking device; 7 milling tool; 8 milling head wind Cold system; 9 milling cleaning system, etc.
The composition of the production line: the production line mainly consists of automatic loading robot, bed parts, milling power head parts, feeding system, pressing parts, automatic discharging device, automatic stacking device, milling cleaning system, deburring device, air cooling system , displacement measurement system and control system. Table 1 shows the main technical parameters of the production line.
Table 1 Main technical parameters of the production line
Serial numbername
parameter
Remarks
1
Milling edge width
5~12mm
Adjustable
2
Milling depth
0.06~0.1mm
Adjustable
3
Processing range (board length)
1200~1900mm
Adjustable
4
Adjustment accuracy
0.05mm / circle
5
measurement accuracy
0.01mm
6
Productivity
5m/min
7
Feeding height
890mm
8
Motor Power
Milling head motor
4×1.1kw (level 2)
Feed motor
3kw
Frequency
Feeding robot motor
0.75kw
servo motor
Automatic stacking motor
0.75kw
Stepper motor
9
Dimensions
Host (length × width × height)
7.5×3.16×2(m)
Control cabinet (length × width × height)
0.8×0.7×1.5(m)
The project has been granted a utility model patent: Project Name: Steel Milling Machine Patent No.: ZL2013 20521130.0. The project has been well promoted with the support of the China Packaging Federation Steel Bar Professional Committee. In the steel drum industry, 11 companies have purchased 12 milling machines or production lines; in the container manufacturing industry, 2 companies have also purchased milling machines. Side machine. It is estimated that by 2020, with the maturity of the new process materials market for paint-free barrels, the increase in the number of paint-free steel drums will be 6-8 times that of 2015. It is expected that the products of this project can sell 50-60 units or more. The promotion of economic and social benefits. The implementation of this project will play an active role in promoting the promotion and application of new paint-free barrels in the industry.
Second, the advanced nature of the milling machine production line
Nowadays, more and more steel drum manufacturers use galvanized steel sheets as raw material sheets. Pre-coated sheets are also a new process-free material for domestic paint-free barrels. Their popular use will completely eliminate plating in steel barrels. Environmental pollution caused by phosphating, painting, drying and other processes greatly shortens the work flow and achieves the goal of energy saving and emission reduction. The automatic steel plate milling machine is a special equipment for processing the electroplating and painting-free steel barrel body welding process. It is an indispensable equipment for making steel drums with electroless plating and paint-free sheet. It adopts this new technology for the industry. Process materials provide an effective guarantee.
1. Key innovations
1 Milling precision technology based on thin steel plate; 2 simultaneous double-sided milling technology based on thin steel plate; 3 based on realization of milling power head visibility fine-tuning technology; 4 based on preventing plate from tearing when cutting or cutting in the milling process The technology of the steel plate appears to be angled; 5 based on the realization of various product widths and plate thicknesses; 6 vertical milling cutter technology based on milling head cooling and increasing blade life; 7 fully automated production technology
2, the main innovation content
1 automatic feeding robot suction cup technology
It adopts the vacuum suction type manipulator commonly used in the industry for the piece conveying of steel plates on the steel drum production line. Its principle is to extract the air in the inner cavity of the suction cup by vacuum pump to generate negative pressure and hold the steel plate.
The vacuum chuck robot integrates all vacuum system components, including vacuum transmitters. The variable size adjustment device can be quickly adjusted according to the size of different workpieces or the special surface of the object being sucked to ensure that the suction cup can be placed in a suitable position. The integrated vacuum generator and control valve block ensure rapid system vacuum (short cycle time, dynamic loading and unloading and transportation), ensuring high energy efficiency.
2 single-chip control detection technology, PLC electronic control technology of machine tools
The electrical control of the project adopts mature control technology, and adopts PLC programmable controller to control the behavior of "Automatic Steel Plate Double Side Milling Machine Production Line". The single-chip microprocessor is used to test the "Automatic Steel Plate Double Side Milling Machine Production Line". Control with digital graphic display and remote control.
3 basic parameter selection
Calculation of milling force: Milling edge belongs to metal milling. The experimental radial force can't be more than twice the tangential force. The larger radial force will make the process system composed of frame, steel plate and milling head have greater elasticity. Deformation, which affects milling accuracy. How to reduce one of the directions considered by the radial force in the design of the milling head tool.
Milling head speed: high speed of milling cutter, high production efficiency, smooth surface of steel plate, but the speed is too high, the steel plate is prone to defects such as milling burn. Through trial and error, it is feasible to set the milling cutter speed to 2800r/min.
Feeding speed of milled edge steel plate: The feed rate of milled edge steel plate is related to the quality of milling edge and production efficiency, but the feed speed is too fast, not only the surface finish of the milled surface is small, but also the steel plate is prone to cornering. In order to solve this problem better, the machine adopts the feeding speed to reduce the cutting and cutting, to prevent the cutter from cutting or cutting, and the feeding drive motor is selected as the variable frequency speed regulating motor, combined with photoelectric switch and PLC program. Control to achieve the feed rate of the milled steel plate.
Milling power head mounting offset angle: Milling power head mounting offset angle is one of the key directions of this project. The center axis of the milling head has an offset angle from the feeding direction of the steel plate. This offset angle setting has three functions: one is to improve the stability of the milling edge; the other is to facilitate the feeding of the steel plate; the third is the need for milling the edge shape. The steel plate is made of thin steel plate with poor rigidity, and the milling force of the milling edge is large. The conveying steel plate is only fed by the two rollers of the feeding device. If there is no offset angle, like the plane milling, the milling force is better. The assembly is a steel plate with a large conveying resistance. The setting of the offset angle of the milling power head is also convenient for feeding the steel plate. Therefore, the choice of the offset angle must be comprehensively considered according to the properties of the steel plate, the conveying capacity and the width of the milling edge, and reasonable selection.
4 high speed milling power head design
With three pairs of cylindrical roller bearings and sliding bushings, the motor and the power head are connected through a coupling to ensure sufficient rigidity of the power head. The sliding sleeve is sleeved with the lifting sleeve to adjust the gap, which is not easy to generate vibration during cutting, improves the movement precision and overall rigidity of the milling head, improves the machining precision, and has low noise during high-speed rotation; the overall speed rotates smoothly. Big.
5 press device design
The machine tool is provided with a plate pressing device on the body frame near the milling device, and the plate pressing device comprises a pressing roller and a pressing plate. Five sets of press rolls are arranged along the feeding direction of the guide plate, three of which are connected to the fuselage frame body, and the other two are connected at both ends of the front nip roll and the rear nip roll.
6 guide design
The guiding device is composed of a pressing plate, a backing plate, a guiding plate and a plate baffle. In order to prevent the material plate from deviating during the feeding process, guiding devices are arranged on both ends of the fuselage frame body, the discharging table and the loading table, and the milling cutter is located above the two end edges of the guiding plate, the inner side of the milling cutter and the upper side of the guiding plate The pressure plate is arranged, the pressure plate can further prevent the material from being torn when the milling cutter is cut in and cut out, and the pad plate is arranged between the pressure plate and the guide plate, and the thickness of the gasket is determined according to the thickness of the material plate to ensure The sheet can pass between the binder plate and the guide plate.
7 feeding device design
The feeding device comprises a front nip roll, a rear nip roll and a guide plate. The front nip roll and the rear nip roll are fixed on the fuselage frame body and connected with the feeding drive motor through a transmission device, and the guide plate is arranged. At the two side edges of the fuselage frame body, a front discharge nip is provided at the front part of the front nip roll, and a rear loading stage is provided at the rear part of the rear nip roll, and a front nip roll and a rear nip roll are arranged along the edge. The vertical direction is misaligned against a pair of milling power heads.
8 tool design
The designed 8-blade 45° face milling cutter head has a large front angle but a small load. The four-faced end face milling cutter is designed with a blade positioning platen to ensure that 8 milling inserts are on the same plane, and the empty chip space is large, and the chip removal is good.
3. The composition of the production line:
Automatic loading robot, bed parts, feeding system, pressing parts, guiding parts, automatic discharging device, automatic stacking device, milling cleaning system, deburring device, milling power head components, displacement measuring system and control System composition.
4. Technical patents and papers
1 Process innovation: The subject of this innovation is classified into metal cutting processing technology; the patent authorization number is: ZL2013 2 0521130.0.
Paper: China Packaging Industry 2015, 7th issue "Review of thin steel double-sided milling machine". The use of a milling process is a new process innovation relative to chemical methods and edging processes. The milling process has no chemical pollution, no dust pollution, no noise pollution, and can realize automatic production.
2 Innovation based on intelligent control technology for fully automatic production. The subject of this innovation is classified into automation technology application; the patent authorization number is: ZL2013 2 0521130.0.
Paper: China Packaging Industry 2015, 7th issue "Review of thin steel double-sided milling machine". The production line control mode adopts the time series centralized control mode, which controls the process sequence and duration of each power component of the power tool from loading, feeding, pressing, guiding, milling, discharging and stacking, and sensing and transmitting. The processing, control, execution, and driving mechanisms work in an orderly manner under the control of the PLC processing unit, and organically combine these independent parts to achieve fully automated control of production.
3 The subject of this innovation point is classified into metal cutting processing technology; the patent authorization number is: ZL2013 20521130.0.
Paper: China Packaging Industry 2015, 7th issue "Review of thin steel double-sided milling machine". Process innovation based on double-sided and high-speed milling at both ends of the steel sheet: four two-pair rotary, high-speed, air-cooled milling power heads are installed; the power head mounting offset angle is set; the milling cutter disc is 45° octahedron End face cutter head, large front angle, self-contained air-cooling system; power head can be adjusted horizontally as a whole, which can meet the milling work of various specifications.
4 The subject of this innovation point is classified into sensor technology; the patent authorization number is: ZL2013 2 0521130.0.
Paper: China Packaging Industry 2015, 7th issue "Review of thin steel double-sided milling machine". Accurate technical innovation based on milling precision: set four-way displacement measurement and precise micro-adjustment system, visually display the adjustment of the milling head; achieve precise adjustment of the milling head.
Third, comparative analysis with leading levels at home and abroad
Since the technology of eliminating the galvanized sheet plating layer and the pre-coated coil coating layer by milling method has not been found in the country, the double-sided edge milling machine for milling thin steel sheets (0.7-1.5 mm) has not been found.
Table 2 Full-automatic steel double-sided edge milling machine production line of the same type abroad comparison table
Performance parameterunit
Project product
Similar foreign products
Remarks
Processing product variety
One
6
7
Sudronik
Product delivery form
Roller
Roller
Sudronik
Automatic loading form
Robotic suction cup
Robotic suction cup
Sudronik
Automatic discharge form
Mechanical stacking
Mechanical stacking
Sudronik
Total power
Kw
9
17
Sudronik
productivity
m/min
5
8
Sudronik
Length processing range
Mm
1200~1900
1200~2200
Sudronik
Thickness processing range
Mm
0.7 to 1.5
0.6 to 1.5
Sudronik
Number of operators
One
1
1
Sudronik
Milling edge width
Mm
5~13
4~15
Sudronic
Milling depth
Mm
0.06~0.10
0.05~0.10
Sudronic
Adjustment accuracy
Mm/ring
0.05
0.05
Sudronic
measurement accuracy
Mm
0.01
0.01
Sudronik
Equipment purchase cost
Ten thousand yuan
38
90
Sudronik
Equipment maintenance cost
Ten thousand yuan / year
0.8
2.4
Sudronic
Through the above comparison of the parameters of the performance table, the products of this project have higher product performance, lower energy consumption, lower procurement cost and equipment maintenance cost, and its technological advancement, innovation and practicality are listed in the domestic leading level. .
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