Stamping Automated Production Technology In the traditional stamping production line, sheet metal handling between front and rear equipment depends on manual fetching and placing. With the continuous improvement of production rhythm, manual feeding not only can not meet the needs of high rhythm, but also brings potential safety hazards. Because the personnel concentrate on improving the speed of taking and discharging materials, neglecting the harm of equipment movement, there are often accidents of equipment pressing into the hands and causing disabilities. Therefore, the automatic production line of manipulator instead of manual operation emerges at the historic moment.
Automated production, that is, the use of equipment instead of manual realization of the plate transportation between the front and rear part of press power machines. It not only avoids the risk of injury, but also improves the production efficiency by about 35%. After 2005, the automatic production technology of stamping parts in domestic automobile manufacturing enterprises sprang up like bamboo shoots after a spring rain, which opened the curtain of stamping automatic production.
Introduction of Main Production Process Parameters of the Press Power Machine
At present, the mainstream press power machine is mechanical closed press power machine, which can be used for blanking, forming, bending, calibration, shallow drawing and other cold stamping processes of sheet parts. The technological parameters of press are very important, which not only affect the forming quality of products, but also have a great impact on efficiency, cost and even safety. Following is a brief description of some important parameters and accuracy of the press:
Conclusion
Press power machine is the main equipment in stamping production process. With the rapid development of automotive industry, the demand for various high-quality equipment in automotive industry is also increasing. In the development of stamping process, there are three processes: manual line production, automatic intermittent production and automatic high-speed continuous production. Production equipment plays an important role in each update of modes.
The power press machine is driven by a motor through a transmission mechanism to exert technological force on the workpiece. The transmission mechanism is the deceleration mechanism of belt transmission and gear transmission, and the working mechanism is divided into screw mechanism, crank connecting rod mechanism and hydraulic cylinder.
Power press machines are divided into three categories: screw press, crank press and hydraulic press. Crank press is also called mechanical power press machine.
The screw power press machine has no fixed lower dead point. For larger die forgings, it can be formed by multiple strikes. It can be single, continuous beating and inch moving. The impact force is related to the deformation of the workpiece. When the deformation is large, the impact force is small, and when the deformation is small, such as cold shock, the impact force is large. In these respects, it is similar to forging hammer. But its impact force is closed through the frame, so it works smoothly, and its vibration is much smaller than that of the forging hammer, so it does not need a large foundation.
The lower part of the power press machine is equipped with a forging ejection device. The screw press has the functions of die forging hammer, mechanical press and other forging and pressing functions. It has strong versatility and can be used in die forging, blanking, drawing and other processes. In addition, the screw power press machine is widely used because of its simple structure and easy manufacture.
Power press machine is a general term. And it includes punch, hydraulic press, with characteristics of versatility and high production efficiency. it makes metal have plastic deformation and fracture to process parts through exerting strong pressure to the metal blank. So I will take you to have a detailed understanding of the press.
Pneumatic power press machine
Pneumatic power press machine is composed of Pneumatic-hydraulic booster cylinder, worktable and control logic valve. It uses pneumatic and hydraulic power to press! Gas source of 3KG – 7KG can reach 1 ton to 100 tons of high pressure output!
Screw power press machine
Screw and nut are used as transmission mechanism in screw power press machine, and the forward and reverse rotary motion of flywheel is transformed into a forging and pressing machine with up and down reciprocating motion of slider by screw transmission. While working, the motor makes the flywheel rotate faster to save energy, and at the same time, the slider moves downward through the screw and nut. When the slider contacts the workpiece, the flywheel is forced to decelerate to a complete stop, and the stored rotational kinetic energy is transformed into impact energy, which strikes the workpiece through the slider and deforms it. After the blow, the motor reverses the flywheel and drives the slider up to its original position. The specification of screw press is showed by nominal working force.
Crank power press machine
Crank power press machine is one of the most commonly used cold stamping equipment, which is used as the working platform of cold stamping die. The utility model has the advantages of simple structure and convenient use. According to the structure of the bed, crank press can be divided into open crank press or closed crank press; according to the number of driving connecting rods, it can be divided into single point press or multi-point press; according to the number of sliders, it can be divided into single-action press or double-action press.
Multi-station power press machine
Multi-station power press machine is an advanced press equipment, which is the integration of multiple presses. It is generally composed of wire head unit, feeding mechanism, press and wire tail. The fastest rhythm can reach more than 40 times per minute, which can meet the needs of high-speed automatic production. Wire head unit can be divided into stacking unit, magnetic belt and cleaning, oiling equipment, etc. Feeding mechanism is generally composed of feeding arms; Press is generally divided into multiple sliders and single slider and choose according to different needs. The tail part is generally composed of conveying belt.
1. Operators should be familiar with the structure and performance of the equipment and master the operation methods.
2. Before work, the equipment should be inspected. The equipment should be switched on and operated without any abnormalities. Then the equipment should be started to run empty for 3 minutes. Only when the motor runs at full speed without any abnormality can the clutch be combined to make the power press machine work.
3. According to the lubrication system diagram of the equipment, lubricating oil should be added regularly according to different parts.
4. Attention should be paid to the following points when installing the die of the power press machine: (1) The slider must be opened to the lower dead point and the closing height must be correct when installing the die. Avoid eccentric load as much as possible. When installing and debugging the die, measures such as cushion plate should be taken to prevent the upper die parts from falling and injuring hands. (2) Preliminary positioning of the die is tightened, and then the punch is moved close to the die. Then, while observing, the punch nut is twisted to align the die to ensure that the gap around the die is equal. (3) Tighten the die. After pointing and observing the alignment of the die, test the parts, and check whether the parts have flash phenomenon. If there is, make local adjustment. (4) The die must be reliable so as not to damage the die and punch.
5. when operating the power press machine, you should be focused and can not chat while working.
6. Every time you step on the foot switch, your foot should leave. You should not always put your foot on the foot switch to avoid accidental touching of the switch and causing accidents.
7. When feeding or receiving materials, it is strictly forbidden to extend hands or other parts of the body into dangerous areas. Auxiliary tools should be selected for processing small parts. When the die is stuck in the blank, only tools are allowed to be release and remove it.
8. It is absolutely forbidden to blank two sheets at the same time regardless of the size of the workpiece.
9. When the operator leaves his post, he must turn off the power supply in time and not make the equipment run when no one is there.
10. In the process of operation, attention should be paid to safety at all times. When the machine tool breaks down, it should stop immediately and ask the maintenance personnel to check and repair it.
11. After the work is finished, the die should be dropped and the power supply should be cut off. Clean up the debris and hygiene around the surface of the equipment in time to ensure a good working environment and personal safety.
Abstract: servo turret power press machine is an indispensable NC machine tool in sheet metal processing, and the equipment will inevitably fail. In this paper, by observing the shape and size of burr after plate processing, material stripping and overshoot of hole distance during processing, and other common faults, the fault points and causes of equipment are preliminarily judged. And combined with common alarm information, the troubleshooting methods are summarized.
Turret power press machine is one of the necessary means of sheet metal processing. In recent years, servo turret power press machine has basically replaced mechanical press and hydraulic press. Servo turret power press machine has many practical advantages, such as energy saving, high efficiency, environmental protection and machinability to form complex shapes. Understanding the common fault causes of servo turret power press machines is helpful to the maintenance of the equipment, and it can solve the problem quickly and avoid downtime for long.
1. The burr is too big after plate processing
Under this situation, whether the clearance between the upper die and the lower die is suitable should first be checked. Usually the clearance between the two sides of the upper die and the lower die is 20%-25% of the thickness of the plate. Sometimes this happens when the plate is not replaced in time for the corresponding clearance of the lower die. Another possibility is that the die is blunt, and the edges of the upper die and the lower die can be observed. If there are obvious rounded corners, it is necessary to grind the die or replace a new set of moulds. Generally, if the grinding depth of the lower die exceeds 0.5 mm, gaskets will be needed. The depth of grinding generally does not exceed 1 mm.
If there are burrs on the half side of the sheet metal, it is suggested that there are deviation of the alignment of the upper and lower dies. At this time, it is generally necessary to contact the manufacturer after sales service to adjust the alignment with the special mandrel.
2. The knife which is cut through rotary die has burrs.
At present, the rotating die structure of turret power press machine on the market can be mainly divided into two kinds: one structure is typical characterized that the worm wheel and worm deceleration direct drive die base, which is installed in the follower of the docking fork, moves with the turntable; the typical feature of the other structure is that worm wheel and worm reducer is installed in the active side of the docking fork. Structurally speaking, the first kind of rotating die has higher precision.
The reason that there’s burr in the cutting edge is that the angle of the cutting tool in the rotary die punching is not perpendicular to the feed. There are many possibilities for this phenomenon. According to the different structure of the rotary die, the inspection is different. The first type of rotating die structure needs to check whether the driving belt of the rotating die is too loose, whether the expansion sleeve of the pulley is loose, and whether the coupling connecting screw is loose. Besides the possible problem of the first type, the second type needs to check the concentricity of the connecting fork and the clearance between the sleeve and the fork.
3. pulling material
There are three main possibilities for pulling material. The direct consequence of pulling material may be scrap of sheet metal or even damage of equipment.
(1) When the punch does not return to the upper dead point, the sheet metal moves. At this time, it is necessary to check whether the upper dead-point switch of the power head is normal and whether the system program has been changed.
(2)stripping: Punch can not pull the sheet material out of the sheet metal, and the sheet metal moves. The stripping is due to insufficient unloading force. When the die goes up, the punch can not withdraw from the sheet metal, and the sheet metal goes up together. This kind of situation generally has the omen. When you discover that the sheet blanking has abnormal noise, it has the phenomenon of stripping, so you need to take the following measures promptly: ①use the bigger punch with additional inverted cone. ②Increase the upper die clearance. ③Check the strain degree of unloading spring and replace it when necessary. ④use die with sharp edge. ⑤Use heavy-duty die. ⑥Lubricate plate. ⑦adopy large workstations.
(3) Scrap rebound: The scrap is stuck between the sheet metal and the die, and the sheet metal moves. Waste rebound can be prevented and solved by the following measures: 1. Push rubber column should be installed on the end face of punch, and it should be replaced in time without missing. 2. Clean up the oil on the board. 3. Complete demagnetization of the die. 4. Reduce stamping frequency properly.5. Increase the modulus. 6. Use anti-rebound die. 7. Increase the gap between upper and lower dies.
4. Over-tolerance of hole spacing
First, observe which direction is out of tolerance, and check whether the expansion sleeve of the coupling and pulley of the lead screw is loose in the direction of out-of-tolerance; if the equipment is used for a long time, check the accuracy of the lead screw and the clearance between the die and the turntable; at the same time, check the set parameters, such as speed gain, speed loop integral gain, speed loop proportional gain, load inertia ratio and servo. Whether the gain of position loop meets the actual requirements or not, if not, the corresponding parameters need to be adjusted according to the waveform.
5. Solutions to Several Common Alarm Problems
(1) The switch signal is not in place, which may be the reason that the switch is loosening so that it is displaced; or the switch wiring has problems. Please check the line.
(2) The piercing accuracy is not stable, and the servo axis of the machine tool is sometimes fast and sometimes slow in the course of operation. The reason for this phenomenon is that the parameters are not set correctly. It is necessary to check the settings of acceleration and deceleration and whether each gain meets the actual needs according to the waveform.
(3) No alarm, no response to return to the origin. In general, the cause of this situation is that it is not in the position of the rotating die. Because when the machine tool returns to the reference point for the first time, it needs to move the rotating die shaft. If the rotating die shaft can not move, it will wait all the time.
6. conclusion
The above description is the fault and cause analysis which is common and generally exists. There are many small faults that need specific analysis.
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