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The automatic metal processing production line is similar to the previous manual assembly line, except that the equipment is upgraded to automation and the workers are eliminated. Robots, truss manipulators, etc. are used to realize automatic loading and unloading of equipment, conveyor lines, AGVs, etc. are used to realize the connection of various processes and material transfer, and automatic stereoscopic warehouses are used to realize material storage. The goal is to achieve full automation of all processes from raw material input to finished product output.
With the advancement of Industry 4.0 and the development of the Internet of Things, the functions of automated production lines are also expanding. In addition to basic automation functions, information content has also been added, such as the common SCADA, i.e., data acquisition and monitoring control system. Automatically collect the process data and equipment parameters of the production line, and provide a large-screen display interface to show the operation status of the production line in real time.
According to the differences in manufacturing industries and processes, there are many types of automated production lines, such as automated mechanical processing production lines, automated assembly production lines, automated spraying production lines, automated welding production lines, automated electroplating production lines, etc. The most typical ones are two: one is an automated mechanical processing production line, which is used in the mechanical parts processing industry. The other is an automated assembly production line, which is used for the later assembly production of various products.
Common machining methods include turning, milling, planing, grinding, drilling, boring, punching, sawing, inserting, etc.
Contents related to machining include processes, machine tools, cutting tools, fixtures, chip breaking, tool setting, in-machine measurement, tool compensation, cleaning, etc.
The composition of an automatic metal processing production line is a system composed of multiple automated units, which together complete various aspects of metal processing. Each unit is composed of automated equipment and systems, which can work together efficiently, reduce manual intervention, and improve production efficiency and product quality.
The following is the detailed composition of the automated metal processing production line and an introduction to each link:
Automatic feeding system: used to automatically deliver metal raw materials (such as metal plates, bars, pipes, etc.) to the processing equipment of the production line.
Vibrating plate/vibrating screen: used to deliver irregularly shaped metal parts in a certain direction and position.
Automatic feeder: such as hydraulic feeder, robotic arm, conveyor belt, etc., can move bulk metal raw materials to the designated location.
Warehousing and inventory management: The system monitors the inventory of raw materials and automatically updates the inventory information to ensure the supply of metal materials required for production. Through technologies such as barcodes and RFID tags, the quantity and status of materials can be grasped in real time.
Automatic rack/storage unit: Some production lines are equipped with automatic racks to store and retrieve materials on demand to ensure the continuity of the production line.
Metal processing is the core part of the production line. The automated metal processing production line realizes automated operation through high-precision CNC equipment.
CNC milling machines: used for milling of metal parts, capable of completing complex curve or plane processing.
CNC lathe: mainly used for rotation processing of metal parts, suitable for processing shaft and sleeve parts.
CNC grinder: used for surface grinding of precision metal parts to achieve high-precision size and surface quality requirements.
CNC drilling machine, tapping machine: used for drilling, tapping and other hole processing.
Laser cutting machine is often used for precision cutting of thin sheet metal, especially for cutting tasks that require high precision and complex contours. The laser beam has high energy density and can achieve precise cutting in a very short time. It is suitable for cutting metal sheets with irregular shapes or complex patterns.
Automated stamping production line is used for batch production of metal parts, especially for rapid processing of thin sheet metal. The stamping machine uses the die to stamp, draw, bend and other operations on metal materials.
Automated die exchange system: reduce the time of manual die change and improve the utilization rate of equipment.
Laser welding: used for precision metal welding, especially for welding of high-strength and thin metal plates.
Robot welding system: The combination of automated welding robots and laser welding and other technologies can complete high-quality and efficient welding tasks.
MIG welding, TIG welding: different types of welding methods, choose the appropriate welding technology according to the type of metal and welding requirements.
Such as automatic cutting machines, polishing machines, bending machines, etc., these equipment are precisely controlled by CNC systems to achieve efficient and precise metal processing.
Robots play an important role in automated metal processing production lines, mainly used for automatic handling, welding, assembly and other tasks.
Automatic handling systems can realize automatic transmission and handling of metal workpieces through equipment such as robotic arms and AGVs (automatic guided vehicles). The accuracy and repeatability of robots are very high, which can reduce the errors and labor intensity of manual handling.
Welding robots are widely used in industries such as automobile manufacturing and aerospace for automated welding of high-precision metal structural parts. Robots can be combined with technologies such as laser welding, MIG welding, and TIG welding to achieve high-quality welding.
Vision systems (such as industrial cameras and laser scanners) that work with robots are used to identify the shape, position and direction of workpieces, enabling robots to accurately complete tasks such as assembly and handling.
In the automated production process, product quality control is very important, and a variety of automated inspection methods are usually used for real-time monitoring.
Laser measuring instrument: used to detect the dimensional accuracy of processed parts.
Infrared sensor: used for detection of surface temperature, welding quality, etc.
Visual inspection system: detects the appearance quality of parts, such as surface cracks, scratches, dimensional deviations, etc. through high-resolution cameras and image processing algorithms.
Inspection data is fed back to the production control system in real time, automatically adjusting the processing parameters to ensure the consistency of product quality.
The control system of the automated production line needs to collect a large amount of production data and optimize the production process by analyzing this data.
Through sensors and IoT technology, production equipment, robots, measurement systems, etc. are connected to the cloud or local data platform to achieve real-time monitoring, data analysis and remote management of equipment and production processes.
The role of the MES system in the production line is to monitor the production process, optimize production scheduling, and aggregate workshop-level production data to a higher-level ERP system for production planning, material management, etc.
Use big data analysis technology, combined with artificial intelligence algorithms, to optimize the operating efficiency of the production line, reduce the occurrence of failures, and predict equipment maintenance needs in advance.
Automated packaging and logistics systems are used for the finishing of finished products, reducing manual intervention and improving overall production efficiency.
Automatic boxing, sealing, labeling, sorting, etc. are completed by robotic arms and automated equipment.
AGV (Automated Guided Vehicle): used to transport workpieces within the factory.
Automated warehouse: Store finished products or raw materials in automated warehouses and access them through automated equipment.
This system is the "brain" of the automated metal processing production line, coordinating various links in production to ensure the efficient operation of the production line.
PLC (Programmable Logic Controller): Controls various automated equipment to ensure that the equipment operates according to the predetermined program.
SCADA (Supervisory Control and Data Acquisition System): Realizes real-time monitoring of the production line, data collection, alarm, production scheduling, etc.
The automated metal processing production line is a highly integrated system that covers multiple links such as raw material preparation, metal processing, robot application, quality inspection, and data analysis. Each link is equipped with advanced automated equipment and intelligent systems, which can maximize production efficiency, reduce costs, and ensure product quality. Through continuous technological innovation, automated metal processing production lines are moving towards a more intelligent, flexible, and green direction.
The advantages and characteristics of automated metal processing production lines are mainly reflected in the following aspects:
Automated metal processing production lines achieve rapid switching and efficient operation of various process links by reducing human intervention. For example, the combination of CNC machine tools, automatic feeding, automatic measurement and testing equipment can significantly shorten the production cycle and increase the production speed of products.
The high-precision control of the automation system can ensure the processing accuracy and consistency of each part and reduce the errors caused by human factors. Through precise CNC systems and automated testing methods, the production line can ensure that the product meets quality standards in each process step, thereby improving the overall quality of the final product.
Automated production lines reduce dependence on labor, especially in repetitive and labor-intensive work links such as feeding, handling, inspection, etc., which can effectively reduce labor costs and free up manpower to engage in more valuable work.
Since the automation system can reduce workers' direct contact with high-temperature, high-pressure and high-speed mechanical parts, it can effectively improve the safety of the production process. Automation technology can also monitor production equipment in real time, detect abnormal conditions in time and automatically shut down, thereby avoiding accidents.
Automated metal processing production lines can meet the needs of multi-variety and small-batch production through programming and system scheduling, and can also be flexibly adjusted according to production needs. With the continuous advancement of technology, the scalability of production lines is becoming stronger and stronger, and the production scale and type can be adjusted according to market demand.
Automated metal processing production lines usually integrate advanced energy management and environmental protection technologies, such as energy-saving motors, pneumatic systems, and automated waste recycling systems, which help reduce energy consumption and reduce pollution to the environment. For example, the automatic collection and processing system of waste can effectively reduce material waste and improve resource utilization.
Modern automated production lines usually integrate the Internet of Things (IoT) and big data analysis technologies, which can monitor the operating status, production progress, quality data and other information of equipment in real time. The collection and analysis of these data provide valuable decision-making basis for production management, optimize production scheduling, and improve overall production efficiency.
Automated production lines are usually equipped with automatic detection and diagnosis functions, which can warn of equipment failures in advance, reduce the time for manual maintenance, and reduce the frequency of unplanned downtime. This is crucial to improving overall equipment utilization and reducing maintenance costs.
With the development of technologies such as artificial intelligence, machine learning and deep learning, automated metal processing production lines will become more and more intelligent. Through intelligent algorithms, production lines can achieve adaptive adjustments, automatically optimize process parameters, and further improve production efficiency and product quality.
The integrated management system of the automated production line can track and record the entire production process and provide complete traceability for the product. This is of great significance to meet the increasingly stringent requirements of modern industry for quality management, legal and regulatory requirements, and customer needs.
Automated metal processing production lines not only have obvious advantages in improving production efficiency, product quality, reducing costs and improving safety, but also can further optimize the production process through intelligent and data-based management, and enhance the competitiveness and market responsiveness of enterprises. With the development of technology, automated metal processing production lines will play an increasingly important role in the future manufacturing industry.
In the automated machining production line, according to the difference in the production line structure, it can be divided into two types:
- Automated machining production line without internal parts storage buffer area
- Automated machining production line with internal parts storage buffer area
There is a big difference in the beat principle of the above two types of automated machining production lines. This article mainly introduces the structural composition and beat principle of the automated machining production line without internal parts storage buffer area.
The automated mechanical processing production line is mainly composed of six parts in terms of mechanical structure:
- Automatic parts conveying system
- Single machine tool processing workstation
- Robot execution system
- Quality inspection workstation
- Production auxiliary system
- Upper control system
The various machine tool processing workstations are connected together through the conveying system. The original parts (unprocessed parts) enter from one end of the production line. After arriving, they are loaded and unloaded by robots. After completing the processing at a workstation, they are transported to the next adjacent workstation by the conveying system. Each workstation completes different processing procedures, and the parts that complete all processing procedures after passing through the last workstation.
There may be some inspection workstations on the production line to automatically inspect the processing quality of the workpiece during processing. In addition, there may be some manually operated workstations to replace the automated processing procedures that are technically difficult to realize automated processing and cost-uneconomical.
Since the mechanical processing of parts usually requires high processing accuracy, the positioning accuracy of the parts is naturally required to be high, so the automatic transportation of parts uses a special fixture, namely the "travel fixture" to transport. The travel fixture can not only accurately position the parts to be processed, but also move, position and clamp them on the processing workstation. Since the parts can be accurately positioned on the travel fixture, and can also be moved, positioned and accurately positioned on the processing workstation, the accurate positioning of the parts relative to the processing tool can be ensured. Since the travel fixture needs to be used cyclically, this kind of automated processing production line is usually closed at the beginning and end.
The automatic conveying system is mainly used to complete the circulation and conveying of parts. The main types are: 1. Belt conveyor line 2. Roller conveyor line 3. Double-speed chain conveyor line 4. Plate chain conveyor line 5. Others (the actual application is based on the specific scenario, and the appropriate conveyor line is selected for parts conveying. For example: for light-loaded non-metallic parts, belt conveyor line is selected; for light-loaded metal parts, double-speed chain conveyor line is selected, etc.).
The robot execution system mainly completes the loading and unloading of parts according to the established path. The main types are: 1. Standard industrial robot 2. Non-standard truss robot 3. Others (the actual application depends on the specific scenario and the appropriate robot is selected).
The quality inspection workstation is mainly used to complete the appearance defect and size inspection of the product. The main types are: 1. Contact three-coordinate measurement 2. Non-contact optical measurement-2D/3D camera 3. Others (actual application depends on the specific scene, and the appropriate method is selected for measurement).
The advantage of three-coordinate measurement is high measurement accuracy, which is generally aimed at products with high inspection requirements. However, three-coordinate measuring instruments also have problems such as high inspection environment requirements, slow inspection speed and high price, and need to be selected according to specific circumstances.
The production auxiliary system is mainly used for the centralized treatment of metal waste and cutting fluid after machine chip processing. The main types are: 1. Centralized liquid supply system 2. Waste chip treatment system 3. Others (the actual application is based on the specific scenario, and the appropriate treatment system is selected).
Build a centralized liquid supply system in the workshop. After each processing is completed, it will enter the system for processing immediately. After removing various debris and correcting the indicators, it will restore the optimal performance of the newly prepared liquid to supply liquid, realizing the cycle without replacement, greatly extending the service life of the tool and processing fluid; oxygenate, sterilize, and cycle the cutting fluid on holidays to increase the dissolved oxygen saturation of water to prevent the growth of anaerobic bacteria; bactericides can be quantitatively added according to the performance parameters of the processing fluid without manual participation.
Automatically process the waste chips of all machine tool equipment products, and directly cold-press the turning chip raw materials into 2-10 kg block waste chips through high pressure. The whole process does not require heating, additives or other processes, so as to facilitate storage and transportation and reduce losses during recycling and reuse.
The upper control system mainly completes the motion control of all equipment in the entire machining line according to the established logic program. The entire production line adopts network bus communication control to achieve the requirement that units can be combined/split at will. Each unit has multiple communication protocols. HMI uses RS232 communication, ROBOT and AOI use TCP/IP communication, inverter uses RS485 and other communication methods, and other sensors are connected to ElCO Spider67 I/O Module and then enter the PLC system through TCP/IP. In this way, the unit can be quickly switched and the scalability of the later equipment can be guaranteed.
Automatic metal processing production lines are widely used in multiple industries, mainly including:
It is used for processing automobile parts, such as engine parts, chassis, body, etc., to ensure high precision and efficient production.
In the production of high-precision parts such as aircraft engines and aircraft structural parts, automated production lines provide the required precision and consistency.
Automated processing is used for mass production of metal parts such as home appliance shells and internal accessories, which improves production efficiency and product quality.
Including the processing of mechanical parts, such as gears and bearings, automated production lines greatly improve the precision and consistency of the production process.
It is used for the manufacture of components such as metal shells and connectors. Automated production helps meet the needs of precision processing and high production.
In the fields of oil, natural gas and nuclear energy, automated production lines are used to process high-strength metal parts to ensure the durability and safety of equipment.
It is used for large-scale production of steel structure components, such as steel beams and steel columns, to meet the requirements of high strength and rapid production.
In the processing of hull and engine parts, automated production lines can ensure efficient production and meet strict quality standards.
Mainly used in the production of precision metal parts, such as surgical instruments, implants, etc., automation technology ensures high precision and hygiene standards.
Automatic metal processing production lines are an important production method in modern manufacturing. With its high efficiency, precision, low cost and high safety, they are widely used in many industries such as automobiles, aviation, home appliances, energy, electronics, etc. With the advancement of technology, automated metal processing production lines will show their potential in more fields and promote the intelligence and modernization of the manufacturing industry.