New technology and application of barrel production line (Wang Zhijian)
New technology and application of barrel production line
Yingkou North Barrel Equipment Technology Co., Ltd. Wang Zhijian
Wang Zhijian gave a speech at the 2014 Wuhan Industry Conference
Yingkou North Baking Equipment Technology Co., Ltd. is a joint-stock company established after the restructuring of the former China National Petroleum Corporation Yingkou Co., Ltd. (founded in 1908), covering an area of ​​21,000 square meters. It is the only one in China that produces both barrels. The company specializes in the production of steel drums. It is the only professional company in China that can provide a complete line of barreling equipment in the form of turnkey projects. It is also the only professional company in China that produces high-speed barreling equipment and has core technology with independent intellectual property rights. It is a technical enterprise integrating scientific research, design, production, maintenance, sales and production line integration system. It was once under the former Ministry of Commerce, Sinopec and PetroChina.
The company's barrel equipment series, front barrel equipment, welding equipment, middle barrel equipment, and rear barrel equipment have achieved high, medium and low speed full barrel production lines. The top three international barrel companies: Greif in the United States, Mauser in Germany, Jefferies in Japan, domestic barrel companies: COFCO, Sinopec, PetroChina, and the United Kingdom, Japan, Singapore, Iran, Saudi Arabia, Russia, Kenya, Cameroon, Pakistan and other domestic and foreign companies are using our equipment.
In recent years, the company adheres to the philosophy of “leading technology and leading the development of the industryâ€, taking the road of “high efficiency, energy saving, low carbon and environmental protection†and “achieving quality and speedâ€. Has developed and developed "KJ-1810 new CNC unwinding and leveling offset stamping production line, wafer sheeting machine and bottom cover automatic stamping forming production line, wafer stacking unit, automatic double lock production line, frequency conversion automatic steel barrel seam welding machine, Automatic upper plate manipulator, weld rolling production line, steel barrel conveying machine, vertical necking machine, high-speed new vertical barrel making equipment, internal spray automatic stacking unit, painting stepping bucket machine, automatic collecting process cover machine, A series of new barrel making equipment such as open barrel glue strip production line, open barrel lock hoop machine, painting accumulator, oven quick stop device, etc. It has won many national patents. We have adopted a large number of new technologies, new materials, The new technology, the improvement of automation, the new equipment manufactured, energy saving, environmental protection, reducing labor intensity, improving automation, reducing operators, greatly improving the efficiency and quality, praised by customers.
The following is a brief introduction of the configuration and use of the equipment we produce at the production site. We will focus on the latest high-efficiency, environmentally-friendly and fully automatic steel drum production equipment developed and shared with you.
1. KJ-1810 new type CNC unwinding and leveling dislocation stamping production line
Ordinary CNC unwinding and leveling misalignment stamping production line, barrel steel sheet width (width) 916 ~ 920, leveling slitting width 916 ~ 920, length 1797 ~ 1800. The barrel cover steel coil width (width) is 1250.
KJ-1810 new CNC unwinding and leveling dislocation stamping production line, barrel body steel coil width (width) 1810, leveling and slitting width 1797 ~ 1800, length 916 ~ 920. The barrel cover steel coil width (width) is 1250.
Benefit analysis: barrel body steel coil width (width) 1810 is more than barrel body plate steel width (width) 916 ~ 920, the market price of raw materials per ton is 200 yuan cheaper, taking 1.2 thick barrel body as an example, each barrel cover weight 15.65kg according to The annual output of 500,000 steel barrels is calculated:
Steel required: 15.65kg × 500000 = 7825 tons
Can save steel funds: 200 yuan / ton × 7825 tons = 15.65 million yuan.
The economic benefits are significant through the above analysis. This is why we are developing the KJ-1810 new CNC unwinding and leveling offset press line. This production line has a broad prospect. Now a well-known domestic enterprise is using this production line with reliable quality and obvious economic benefits. Many domestic and foreign companies are interested in purchasing this production line, and we are now negotiating with it.
Second, automatic double lock production line
Nowadays, the traditional locking and manual operation, the barrel mouth piece is manually placed in the lock port, and is manually pushed to the press machine to start the lock installation, the labor intensity is high, the production efficiency is low, and the operator has safety risks, achieving continuous high speed. There are also difficulties in automatic production.
The automatic double-lock production line is the barrel filling inlet and the exhaust port (large and small mouth) which are processed through the double-punching composite mold, and the locking operation of the barrel mouth piece (large and small) and the barrel cover is completed by the press machine. The process is fully automated.
This production line has been exported to the UAE.
The production line is mainly composed of the barrel cover stepping conveyor unit, the barrel mouthpiece (large and small) step conveying unit and the locking system.
Third, the wrong displacement material manipulator
After the barrel cover is blanked, the scrap is cut by the scrap shearing machine, falls onto the receiving table, and is removed from the wrong displacement device by the wrong displacement device. After being collected, it is packaged and shipped out.
The device uses the robot to automatically complete the accumulation of scraps after the canopy is blanked, and the stacking is neat, and the effect is better than manual. The device has simple structure, low use cost, no wearing parts and convenient maintenance. With plc control and contactless signaling, the action is stable and reliable, stable and noise-free, there is no safety hazard, and the stacking speed can be adjusted as needed. It consists of a receiving platform, a wrong displacement device and a waste trolley.
Fourth, the typical case analysis - high-speed full barrel equipment production line
Take the complete line of barrel equipment designed by our company for Shanghai customers as an example to explain the production line of high-speed full-scale barrel equipment. The production line produces 8 beats per minute, which is suitable for processing open and closed steel drums, steel drums inside and outside, high-clean steel drums, and the machine operation control mode is applicable to automatic or manual, online or single machine.
Mainly composed of the following parts:
1. Frequency conversion automatic seam welding unit
It consists of frequency conversion automatic seam welding machine, automatic upper plate manipulator and out barrel conveying.
(1) Frequency conversion automatic seam welding machine
The principle of AC variable frequency resistance welding is not only three-phase inverter welding control technology, but also high degree of automation, stable performance and reliable welding quality. The welder fully considers the characteristics of the steel drum plate, the use conditions of the power grid and other factors, and has strong adaptability to the plate size, high welding power factor, energy saving.
Since the welding machine adopts a three-phase inverter power supply mode, the power consumption of the power grid is balanced. High power factor. Without rectifiers, equipment reliability is greatly improved. The labor intensity is reduced, the operating cost is reduced, the welding parameters are not frequently adjusted, the applicability is strong, the operation is simple, the energy saving is saved, and the economic benefit is improved.
The machine has been tested by the US authority ROMAN: it has the following advantages
â—†Three-phase AC power input, power balance.
◆ High power factor, COS¢ reaches 0.9.
â—† Power consumption is reduced by approximately 60%.
â—† For the same welding workpiece, the welding time is shortened, saving time and electricity; the welding stability zone is enlarged.
â—†High quality welding quality, high welding frequency, small heating area and high permeability.
â—†The electrode life is greatly improved (up to 10 times higher than the ordinary power frequency).
â—†The welding control adjustment is simplified.
â—† Can be connected to a standard AC transformer.
â—† Especially suitable for the welding of three-layer board, the welding of very thin materials and the requirements of precision welding.
â—† Less splashing.
â—† Fast response control to current improves the quality of solder joints.
â—† Energy saving.
According to the principle of different power supply methods, from the power angle analysis, through theoretical calculation, the frequency conversion AC welder (three inverter control technology) has the most power.
The measured data from the production site in Shanghai can prove the correctness of the above analysis.
US Calando welder: incoming line current 170 ~ 180A;
Welding machine power: 170A × 380V = 64.6KW
Yingkou AC frequency conversion welding machine: three-phase incoming current <90A
Welding machine power: 90A × 1.732 × 380V = 59KW
AC frequency conversion welding machine has medium frequency welding performance, without secondary rectifier, the reliability of the welding machine is improved
(2) Automatic board manipulator
The automatic feeding system is an automatic equipment designed to quickly transport a single sheet of steel by adopting advanced technology at home and abroad and adopting more advanced control theory. The main purpose of the machine is to fully automate the transportation, separation, grabbing and transportation of the åž› steel plate. The machine has high transportation efficiency, accurate positioning and convenient adjustment. Advanced technology, reasonable structure, PLC control and contactless signaling, stable and reliable operation; Germany imported steel single and double sheet detection patent device for monitoring, so that the equipment can run safely; smooth and no noise, easy operation, easy maintenance .
(3) Out barrel delivery
The AC speed is used to control the speed of the barrel, and the steel barrel after welding is connected as required.
If there is no welding seam rolling unit of our company after the automatic welding machine, we can use the welding machine to weld the flat wheel to flatten the weld, so that the surface of the weld is smooth and beautiful. The barrel is conveyed with a cutter and the ends of the tongue are cut off.
2, weld rolling unit
â—Overview:
The automatic weld rolling unit is a set of special equipment for fully automatic control and mechatronics. The main function is to further improve and improve the quality of the weld by rolling the longitudinal weld seam of the seam welder. The weld rolling unit features high degree of automation and stable performance. By rolling, the thickness of the plate at the weld site is matched to the thickness of the original steel plate. The surface quality of the steel drum is obviously improved.
â—Device configuration
The composition of the unit is mainly composed of sewing machine, barrel center positioning machine, weld rolling machine, edge trimming machine at both ends, multi-station magnetic conveying chain and other equipment.
â—Flat layout
The weld rolling unit can be individually threaded and can have an independent conveyor system as shown.
In addition, it can also form a mid-section equipment production line together with the trimming, the ribs, the corrugated front three machines and other online equipment (such as the leak detector). Either way, you can meet the requirements of the device.
â—Features after rolling
The welded seam after rolling has a significant difference compared with the welded seam which is not rolled. The indentation line after welding is gone, the surface of the weld is convex, and after the rolling and crimping process, the convex It disappeared. In addition, the seam at the lap joint has no feeling of blocking the hand, and the seam is not as obvious as before the rolling, and the thickness of the double-layered lap joint is thinned and tends to be reasonable. The bulging edge of the weld bead at both ends of the barrel sleeve is sheared off after being sheared by the trimming machine.
This line has a production rate of 600 pieces per hour.
Thickness after rolling: 1.25 to 1.5 times the thickness of the steel plate. After rolling, the surface of the weld is brighter, the weld metal is more dense, and almost no weld is found after painting.
3, barrel and steel barrel molding production line
The main components include: high-speed hydraulic edge machine, high-speed hydraulic expansion machine, high-speed hydraulic W corrugator, high-speed crimping machine, multi-station conveyor chain, automatic cover unit, leak detector, blow barrel machine, sewing machine , barrel cleaning machine and other auxiliary equipment.
The four mainframes, such as the edge-triggering machine, the ribbing machine, the corrugated “W†rib machine, and the crimping machine, are not introduced. The main purpose is to improve the efficiency and reduce the labor intensity, and reduce the auxiliary equipment and supporting equipment that the operator configures:
(1) Edge changer quick change device
When producing the production of open and closed steel drums, it is not necessary to suspend the production line for a long time. Instead, the operation buttons are used to realize the quick change of the mold, which almost achieves seamless conversion and improves the efficiency.
(2) Sewing machine
Automatically find the location of the weld seam, and cooperate with the splicing assembly to achieve the fixed position of the steel barrel weld and the injection hole, and improve the competitiveness of the steel drum market.
(3) Blowing machine
Also called a dust sweeper. It purifies the dust in the barrel before the steel drum is crimped to make the steel drum cleaner.
(4) Automatic capping machine
The automatic bottom cover device before crimping can ensure the position of the barrel mouth and the weld seam as needed, and the device for arranging the bucket cover is simple to operate. It can realize unmanned automatic cover and greatly reduce labor intensity.
(5) Automatic barrel cleaning machine
Instead of manual rubbing, it saves costs and reduces labor intensity.
4. Degreasing and phosphating drying production line
The steel drum or barrel sleeve from the middle section is transported into the degreasing and phosphating drying line via a buffer.
The production line features a degreasing phosphating line for the bottom cover and the barrel. The steel drum is cleaned and transported in a single row; the bucket frame is cleaned in a single row and shares a conveyor chain with the steel drum; the bottom cover is on the side of the steel drum, and the double row vertical cleaning advances and rotates at the same time.
Separate control of cleaning line bath temperature, cleaning transfer line speed, pre-degreasing pump, degreasing pump, one water washing pump, two water washing pump, phosphating pump, three water washing pump, four water washing pump, and pure water washing pump.
Cleaning and drying transmission line: the barrel frame and the bottom cover each have a set of special conveying chain, the barrel frame drying transmission mode: vertical drying; the bottom cover drying transmission mode: vertical drying forward while rotating;
Quick furnace shutdown device: We use a quick shutdown device that is easy to maintain and save energy (can be cooled quickly at the end, shut down the fan), reducing fan running time, saving energy and time.
5, surface coating production line
The main components are the exterior painting booth, the spray booth in the barrel and bottom cover, the drying tunnel inside and outside, and the air-cooling device inside and outside.
Here we will focus on the external paint spray stepping machine and the internal spray automatic stacking unit.
(1) Painting stepper bucket machine
The paint stepping bucket machine is an advanced conveying equipment for spraying and recoating the surface of the steel drum by means of fast stepping and conveying steel drums. It is the main equipment for steel drum spraying equipment. The main features are:
â—†Using advanced technology design at home and abroad, the steel drums can be quickly and smoothly transported to various painting stations in a stepwise manner.
â—† When the steel drum is delivered to the painting station, the steel drum is always in the rotating state. After the position is reached, the spraying operation can be carried out.
â—† In order to solve the problem that the paint film of the barrel bottom is incomplete during the painting and conveying process, we added one paint finishing station at the last station of the painting. This saves time and saves space and improves work efficiency.
â—†The whole machine adopts PLC automatic control system to make the equipment run safely and smoothly. The touch screen control adjustment mode is adopted to make the adjustment simpler, the operation is safer and the method is more convenient.
(2) Internal spray automatic stacking unit
The internal spray automatic stacking unit is designed to facilitate the large-scale realization of the bottom cover of the barrel after the internal spraying, and realize the automatic stacking of the bottom cover of the barrel. It can realize continuous automatic production of inner spray cover to baking.
main feature:
â—† The bottom cover is layered and stacked, up to 10 at a time.
â—†Multiple turnover baskets for continuous production.
â—† PLC automatic control, reliable operation.
We can also tailor the equipment to different requirements according to customer requirements. Interested friends can also communicate afterwards.
Active development, courage to explore, and innovation are our development strategies. Attention to detail, continuous improvement, and the pursuit of perfection are our quality policy. The mountains are clearer, the water is greener, the energy consumption is lower, and the high efficiency is our hope. Today, we are very honored to be here with you to discuss the development and future of the industry. Here, once again, we thank everyone for giving us this opportunity today, and thank all the leaders, CEOs and colleagues for their long-term support and care for the North barrel. At the same time, I hope that you can continue to support Yingkou North Co., Ltd. We are willing to provide our customers with the most advanced and sophisticated equipment.
thank you all!
Multi-function Pens, Best Multi Function Pen
JNY International Trade Co., Ltd , https://www.jny-stationery.com