Project name: digital reform of sketch plate punch
1. Introduction of programme
Hydraulic punch is widely used in punch of sheet metal. Its main products is nut shim and other shaped pattern. Die decides the pattern and size of products. At present, its production way is that skilled labor finishes manual punch by judging punching positon on the sketch plate.
The problems exist in production mode:
1) low security. Interaction exists between die and panel. When panel is under stress, hands may be brought into punching area, causing accidents. The operators should be highly centralized and prevent occupational accidents all the time. Therefore, the security is low and it is easy for accidents to happen.
2) low use ratio of panel. As punching position is judged manually, the level of skilled labor decides use ratio of panel. Perfect distance of bores is 1.0~1.5mm. as a result, the manal judgement has much randomness.
3) high defective index. As the bore distance is small, manual punching will cause edge of two adjacent bores to coincide, producing waste products. In the competive market, the defective index is key to enterprise’s success.
4) low working efficiency. Though in panel of continuous punching, speed of manual punching is not slow. However, it is often to meet leftover material position which is hard to deal with, the operator should judge position exactly, which increases judging time, slows down speed and reduce combined efficiency.
5) poor working conditions. In an environment of much noise, operators are required to be highly centralized in mind, which makes them bear huge working strength and tired. Therefore, digital reform of punch is essential.
The project uses much key skills. The operators only has to put sheet metal into fixture and the system will finish shooting, trepanning, pay-off, punching and returning and so on. What’s more, its working efficiency is higher than manual punching, solving key technical issues such as digital control, and imaging, automatic jacking and servo control of integrity of jacking software and visual.
Figure 1 is panel materials to be processed.
Figure 2 is the scrap materials.
Figure 3 is reformed hydraulic digital punch
Figure 1 Leftover materials to be processed
Figure 2 Waste
Figure 3 Digital reform
2. Achievement of using “replacing workers by robots” (including application units’ production mode, labor’s skills proficiency requirements and technology advantage of the equipment before replacing, as well as saved labor and cost and increased efficacy and economic efficiency after replacing )
Before reform: the enterprise fihishes manual punching by skilled labors. The workers have to take the panel and jucge punching position according to diameter of die, which relies on manpower too much. The enterprise has a difficulty in using labors. Especially in the recent two years, market price is too competitive, which causes economic efficiency plummet down. Most enterprises gain profit by selling waste products and are difficult to maintain. If accidents emerge, enterprises and individuals will experience snow plus frost.
After reform: key technology of reform is divided into 3 parts. One is computer imaging technology. The workers only have to clamp the panels, then the digital device will shoot automatically and seize edge image of panels as shown in figure 4. Second is automatic jacking. The computer finished bore jacking by set punching size, to promote panal utilization ratio. It is shown in figure 5. The third is digital CNC control, finishing pay-off, punching and return of material and so on as shown in figure 6.
Figure 4 Imaging technology
Figure 5 Automatic jacking
Figure 6 Details of digital reform
After reform, workers have to put panels into and do not need to judge its position. The follow-up work is finished by digital control, which reduces the requirement for workers’ proficiency. Even the green hands can adapt to work after training, bring convinience to the enterprice. Besdes as digital control device is used commonly, the reform fee is low. The reform fees from enterprise can earned in a year. The manifestation: general workers replace skilled worder; reduce or eliminate occupational accidents; reduce working time; improve utilization of panel and reduce defectiveness ratio. The above advantages can reduce cost, promote economic benefit and realize replacing of workers by robots.
Key data before and after reform is shown below:
Program
Before reform
After reform
Production mode
Munual
Digital control
Security
Very low
High
Panel utilization ratio
80%
99%
Defectiveness index
5~10%
<1%
Processing efficiency(taking punch with the same tpe an example)
2.5 bore per second
3 bores per second
Promote efficiency of 20%
Requirement for worker’ skills
Skilled worker (needing cultivation)
No
Workerd employed by enterprises
Employment difficulty
Green hands can master directly
Raw materials and stamping workpieces suitable for feeder
The factory workshop occupies an area of 3,000 square meters, with more than 10 sets of professional machining equipment, produce 150 sets of equipment per month and equipped with test flow equipment to ensure delivery on time for customers.
Large Scale and complete production line Strict quality Control and Delivery at any time
