Yingkou North Steel Bar High Speed ​​Automatic Production Line won the Science and Technology Award
Text / Ding Jiawei
[Editor's note] At the 2016 China Packaging Federation Science and Technology Awards Review Meeting, the project of "M8 Series 200-208L Steel Barrel High-speed Automatic Production Line" declared by Yingkou North Baking Equipment Technology Co., Ltd. won the third prize. After winning the third prize, the company's "steel automatic seam welding machine" project won the Science and Technology Award of China Baolian.
Due to the late start of China's steel drum packaging industry, there is still a big gap between the high-speed barrel making equipment and the foreign advanced level. At first, domestic barrel production lines were mainly manual and semi-automatic equipment. Due to its low efficiency and low product qualification rate, the service life of steel drums was seriously affected. In recent years, China has begun to pay attention to the technical development of high-speed barrel automatic production lines, and steel drum manufacturers have begun to install high-speed automated production lines. The share of steel drum high-speed automatic production lines in barrel making equipment is also increasing.
While developing high-speed barreling equipment, the state has also introduced a series of policies to encourage the supporting petrochemical industry. Driven by the rapid development of the petrochemical industry, domestic steel drum packaging production lines and high-speed production equipment have also gradually developed. At present, the domestic high-speed barrel automatic production line is still in its infancy. Although many high-speed automatic production lines are put into production, most of them need to be imported from abroad, which has the disadvantages of poor cost adaptability and high maintenance cost. It still needs to be vigorously developed to fill the gap.
To this end, Yingkou North Barrel Equipment Technology Co., Ltd. independently developed the "M8 series 200-208L steel drum high-speed automatic production line", production system integration technology, production line intelligent control technology, automatic online detection technology, surface coating technology, energy-saving drying Based on key technologies such as technology, we provide customers with a series of high-speed steel drum automated production lines.
The technical index and technical level of the M8 series 200-208L steel drum high-speed automatic production line represent the advanced level of the current high-speed barrel equipment. It belongs to the international advanced technology and is the first in China, filling the domestic technology gap. It has adopted a variety of innovative technical solutions to ensure the smooth operation of the production line. “M8 series 200～208L steel drum high-speed automatic production line†belongs to professional high-end automation, intelligent and information system integration products, and is the key equipment for realizing high-speed steel drum automatic production line.
First, the key technologies involved in the production line
The production line has eight utility model patents and invention patents, and its main innovation key technologies are as follows:
1. Frequency conversion automatic seam welding technology
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 welder 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 about 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.
2, weld rolling technology
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. 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 molding technology
The barrel body is formed by high-speed hydraulic edge-trimming machine, high-speed hydraulic ribbing machine, high-speed hydraulic W corrugator, high-speed crimping machine, multi-station conveyor chain, automatic capping unit, leak detector, barrel blowing machine, sewing machine, It consists of a barrel cleaning machine and other auxiliary equipment. The application of this technology improves efficiency and reduces labor intensity and reduces operator.
4, degreasing phosphating drying technology
The application of this technology allows the bottom cover and the barrel to share a degreasing phosphating line. 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. It can separately control the cleaning line tank liquid temperature, cleaning transmission line speed, pre-degreat 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. Each of the barrel frame and the bottom cover has a set of special conveying chain, and the barrel frame is dried and transported: vertical drying; the bottom cover is dried and conveyed: the vertical drying advances and rotates at the same time.
5, surface coating technology
Adopting advanced technology design at home and abroad, the steel drums can be quickly and smoothly transported to various painting stations in a stepwise manner. When the steel drum is delivered to the painting station, the steel drum is always in a rotating state, and the spraying operation can be carried out after the position is reached. 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 painting station at the final station of the painting. This saves time and saves space and improves work efficiency.
The whole machine adopts PLC automatic control system, which enables the equipment to operate 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.
Second, the main technical performance and technical parameters of the production line
The main performance parameters of "M8 series 200-208L steel drum high speed automatic production line" are as follows:
â—The whole line is suitable for processing open and closed steel drums, steel drums inside and outside, and high-clean steel drums;
â—The whole line running beat: ≥10/min;
â—The whole line is adapted to the thickness of the steel plate: 0.7~1.2mm;
â—The scope of the whole steel drum specifications: 200 ~ 208L (volume);
◠Welding overlap: 2.5 ± 0.5mm;
â— barrel diameter after molding: 560/571.5mm;
â— barrel height after molding: 870 ~ 930mm;
â—Thickness after rolling: 1.25~1.5 times the thickness of the steel plate. After rolling, the surface of the weld is brighter, the weld metal is more compact, and almost no weld seam can be found after painting;
â— Coating adhesion: not lower than the second level specified in GB/T325, the coating is uniform and does not sag;
â— Machine operation control mode: applicable to automatic or manual, online or stand-alone.
Third, the performance index of the production line is compared with similar products at home and abroad
project Carando
(Carando, United States)
Soudronic
(Sudronic, Switzerland)
Federal
(UK Commonwealth)
Beifangzitong
(Yingkou North Barrel)
Seam welded upper plate
Automatic seam welding upper plate
Automatic seam welding upper plate
Automatic seam welding upper plate
Automatic seam welding upper plate
Seam welder
Automatic seam welder
Automatic seam welder
Automatic seam welder
Automatic seam welder
Board edge machine
no
Outsourcing integration
Mechanical edge machine
High speed edge machine
Stiffening machine
no
Outsourcing integration
Mechanical expansion machine
High speed rib machine
Crimping machine
no
Outsourcing integration
Mechanical crimping machine
High speed crimping machine
Find welds and position the bucket
no
no
Automatic online, fiber optic sensing technology
Optical fiber transmission technology automatic seam finding device
Automatic capping machine
Mechanical hand cover
Pneumatic mechanism cover
Mechanical hand cover
Mechanical hand cover
Leak detector
semiautomatic
semiautomatic
semiautomatic
automatic
High speed painting conveyor
no
High-speed stepping paint machine
High-speed stepping paint machine
High-speed stepping paint machine
Degreasing and phosphating
no
no
Outsourcing integration
automatic
Internal spray automatic push cover
no
Automatic online robot
Artificial
automatic
Body and bottom cover
Artificial
Artificial
Artificial
automatic
Inner and outer coating tunnel
Traditional gas drying
Traditional gas drying
Traditional gas drying
Energy-saving gas drying
Inner and outer coating air cooling device
Fan cooling
Fan cooling
Fan cooling
Fan cooling
Feeding before drying
Transfer loading
Transfer loading
Transfer loading
Automatic transmission line
Cutting after drying
Transfer blanking
Transfer blanking
Transfer blanking
Automatic transmission line
Barrel cleaning inspection
Artificial
Artificial
Artificial
Artificial
Work beat
8 / min
9 / min
8 / min
10 / minute
The successful development of the M8 series 200-208L steel drum high-speed automatic production line is of great significance to the development of China's steel barrel industry.
1. Through the practicality of the production line, the production cost of the steel barrel production equipment is further reduced, thereby reducing the cost of the steel barrel product of the barrel making enterprise.
2. Optimized the industrial structure and upgraded traditional industries. Through the development and promotion of the verification and evaluation conditions implemented by the production line, the growth of many barrel companies around the market has been promoted.
3. Improve the production efficiency of barrels and improve the competitiveness of enterprises.
4. Promote talent training, create employment opportunities, and play a positive role in maintaining social stability and creating a harmonious society.
5. Have a positive effect on promoting industry and local development.
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