Steel drum body "three-in-one" composite molding technology and equipment
Steel drum body "three-in-one" composite molding technology and equipment
Xi'an Machinery Research Institute Jing Zhiping
The barrel "three-in-one" composite molding technology and equipment can be used for the production of closed or open steel barrels of any size from 18 to 200 liters. In one feeding, the machine can automatically complete the three processes of pressing the hem, corrugation and ring ribs, or complete two or one of the processes as needed. The Xi'an Machinery Research Institute first developed this technology in 1987, thus filling the gap in the field of composite molding technology in China. The prototype of the project---XJY44 barrel joint forming machine was put into use in the Huayin City barrel factory in Shaanxi in September 1989, and has been running for two years. The machine tool passed the provincial technical appraisal organized by Xi'an Science and Technology Commission in May 1990, and was put into use in barrel factories in Baoji, Wenjiang, Qingdao, Shanhaiguan, Beijing, Sanming, Tongliao, Kunming and Shanghai.
First, the necessity of researching the composite forming technology and equipment of the barrel body
Since the late 1980s, China's steel barrel industry equipment and technology progress has been significantly improved. The steel drum industry has implemented the International Maritime Dangerous Regulations, revised the national standards for steel drums, promoted triple round crimping technology, and introduced US and European welding machines and mid-section equipment to promote the development of China's steel barrel industry.
However, the status quo of processing technology and equipment in China's steel barrel industry is not optimistic. The vast majority of enterprises that account for more than 90% of the industry are still still using the traditional crafts and equipment of the domestic fifties, which is far from the international modern level.
At present, the three forming processes of the barrel folding, corrugation and ring ribs generally use three forming machine tools to complete one process separately. Decentralized processing, of course, requires several times more equipment, manpower, power consumption, and land occupation than centralized processing. At the same time, since the three processes each have their own positioning standards, positioning errors are easily generated in the three processes, and the improvement in the size and positional accuracy of the barrel molding is limited.
In general, the quality of the triple round bead is affected to varying degrees by the size of the bottom cover forming die, the bottom cover pre-crimping, the crimping core disk, the crimping wheel, the feed speed of the crimping wheel, and the sealing packing. The impact of factors. However, for the barrel molding process, it can be said that the quality of the barrel folding is the most important prerequisite for achieving the triple crimping. The quality of the body of the barrel includes the accuracy of the size and shape of the flange (referring to the width of the flange, the angle of the angle and the radius of the arc), and the accuracy of the position of the flange (mainly the radial and outer diameter of the flange and the end of the flange respectively) Axial runout), repeatability of the hemming edge (refers to the difference in size, shape and position of the different flanges of the barrel), and the flatness and smoothness of the hemming. The rolling process of the barrel in the traditional domestic processing method is generally adopted. The precision of the barrel folded by the process is low (for example, the repeating precision can only reach 0.5 to 1 mm), and cracking and wrinkling are prone to occur.
Another major drawback of conventional processing methods is the singularity of their processing. When the size of the processed barrel needs to be changed, such as from 200 liters to 100 liters, or from closed to open barrels, three sets of molds, positioning devices, main drive and feed stroke control devices on three devices In particular, the relevant links of the three-station conveyor must be adjusted accordingly. If the enterprise produces several different sizes of barrels in small and medium batches according to the needs of the market, and the above adjustments are made, the traditional equipment is very difficult.
Obviously, China's steel drum industry lacks a kind of modern industrial production mode, which can be denatured with high flexibility. It can greatly improve the processing precision of the barrel and reduce the cost of barrel processing, saving personnel and equipment investment, and reducing electricity. Consumption and equipment footprint, close to or catch up with the advanced level of barrel molding processing technology and equipment in the United States and Europe. Xi'an Machinery Research Institute timely recognized this necessity, and in order to meet the urgent needs of the steel barrel industry, it took no time to develop the "three-in-one" composite molding technology and equipment.
Second, the main technical characteristics of "three in one" composite molding technology and equipment
The most notable feature of the "three-in-one" technology and equipment is that it can automatically complete the forming process of the three steps of the barrel folding, corrugation and ring ribs after one machine is loaded. In this way, a three-in-one barrel machine replaces three machine tools (folding machine, corrugating machine, expansion machine), and saves the barrel conveyor of three machine tools, saving tens of square meters of floor space. Save dozens of energy consumption and several operators.
Another notable feature of the "three-in-one" technology and equipment is its wide range of uses. The “three-in-one†machine can process any size from 18 liters to 200 liters by replacing only one die (eg 1, 8, 20, 25, 30, 35, 50. 60. 80. 100. 135. 150 160. 200 liters, etc.) Closed or open steel drum body. Practice has proved that the "three-in-one" machine tool only needs one hour to replace a mold, and immediately converts another barrel to another. The three-in-one device has a uniform mold centering mounting size for easy replacement of molds of different specifications. Stepless adjustment can be made to the machine's movement stroke and the barrel centering diameter and the pressing force, and the pressure and speed. In this way, the machine tool can meet one-time forming process of folding, corrugating and ring-forming of any closed or open barrel from 18 to 200 liters, or one-time forming of two or one process.
The operation of the "three-in-one" machine tool is automated. When the barrel rolls over the loading and unloading raceway and presses a stroke switch on the raceway, the machine automatically completes the following cycle:
The robot positions the barrel → the two sides of the mold slowly enter the barrel → after entering the barrel mouth, the mold moves quickly to the working position → when the position is close to the hemming position, the mold is slowly fed to squeeze the hemming → expansion pressure ripple → expansion pressure ring → mold shrinkage Return to the original radial position → the mold quickly withdraws from the barrel → the positioning robot is opened to make the barrel automatically roll out the loading and unloading track → the barrel is pressed down the stroke switch on the raceway to start the next automatic cycle.
Some users prefer to process the barrel one by one. At this time, each time the automatic cycle start button on the electrical cabinet of the bed machine is pressed, the machine automatically completes the above cycle once and processes a barrel.
It can be said that the quality of the barrel flange is the most important prerequisite for achieving the seven-layer crimp. The "three-in-one" machine tool adopts the extrusion hemming technology that has appeared in foreign countries in recent years, which makes the repeating precision of the hemming edge stable to ±0.1 mm, which is 5-10 times higher than the ±0.5-±1 mm of the conventional rolling hemming. This provides a reliable guarantee for achieving a seven-layer crimp. The "three-in-one" extrusion hemming technology also effectively solves the problems of wrinkles and cracking which are likely to occur in the conventional rolling and hemming process of the domestic hot-rolled sheet. The production practice of more than ten domestic steel drum enterprises applying “three-in-one†technology proves that the “three-in-one†technology can increase the first-class product rate of steel drums by more than 5%, and the finished product rate can reach 100%. After the introduction of “three-in-one†technology, many users quickly became the top in the industry (such as the first inspection of the Inner Mongolia Tongliao Hardware No. 3 Factory in September 1991).
The “three-in-one†fuselage adopts a four-column frame-type overall layout to improve the rigidity of the machine tool support guiding system and improve the system stress. The guide rail adopts a molded nylon guide sleeve with adjustable clearance. The "three-in-one" forming tool adopts the rolling wedge iron expansion mechanism and the extrusion hemming die design with high mechanical efficiency and high coefficient of force to realize the continuous expansion pressure of multiple corrugations of the barrel without interference. The hydraulic system of the machine tool adopts ISO4401 international standard series superposition valve and DC wet reversing valve to form a multi-power component anti-interference centralized control system; variable-variable constant-power control system design using quantitative pump; automatic timing full-load unloading to reduce system heating .
I. Technical and economic benefits of “three-in-one†composite molding technology and equipment
The "three-in-one" machine tools are divided into XJY44 type (2 pieces/min), XJY44A type (4 pieces/min) and XJY44B type (6 pieces/min) according to the production efficiency. The analysis is now performed on the XJYA44 type with a productivity of 4 pieces/min.
1. According to the 200-liter barrel, the output value of a single piece is 80 yuan, and the machine load rate is 70%. The annual output value of the computer bed linen system is 32.256 million yuan. The annual profit calculated by the minimum profit margin of 5% in the steel drum industry is 1.612 million yuan. That is to say, after purchasing the production profit of 40 days after purchasing an XJY44A machine tool, the equipment investment can be recovered.
2. Compared with the three-machine linkage traditional equipment, the use of "three-in-one" machine tool can save two machine tools and supporting facilities, 30 square meters of floor space and 15? power consumption. A total of about 200,000 yuan in fixed asset purchase costs were saved. The annual management fee for personnel and equipment is 20,000 yuan.
3. The user can produce four kinds of barrel specifications. The "three-in-one" machine tool saves three sets of machine tools, conveying devices, personnel and equipment management costs, etc., and saves fixed assets purchase cost of about 500,000 yuan and management fee of about 50,000 yuan. .
The social benefits of applying the XJY44 series of “three-in-one†machine tools are not included in the above direct economic benefits.
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