基于精益生产方式下的履带板冲压自动化生产线技术研究与应用

发布时间：2018-03-18 05:33

  本文选题：履带板　切入点：冲压　出处：《山东大学》2017年硕士论文　论文类型：学位论文

【摘要】：履带板作为工程机械底盘件不可或缺的零部件之一,由于其属于易损件,市场需求量极大,无论是单独的配件供应还是配套主机都具有广阔的市场前景。国内现阶段规模较大的履带板生产企业均采用冲压的方式来实现履带板的加工成型,但采用的生产线都是自动化程度比较低的人工冲压线。相比自动化冲压生产线,人工冲压线普遍存在的缺点是安全系数低、冲压效率低、生产成本高、劳动强度大等,本文采用精益生产的方式方法,利用价值流程图对生产过程进行分析并寻找改善点,通过冲压线自动装置的设计和自动线效率的提升,实现了履带板冲压加工的连续自动化生产,为企业生产效率提升和产品单件成本降低提供了保障。同时由于并未对现有设备工装进行大规模的改动,资金投入较小,可复制性强,可以为各种规模的履带板生产企业提供借鉴。通过对履带板冲压生产线各工序现状的分析,以降低履带板生产成本、提升履带板冲压生产自动化程度为目的,利用精益生产的方式方法,以价值流程图为工具,通过数据采集和归纳完成了 8190-MV(N)履带板价值流程图现状图和未来图的绘制,识别了冲压自动化研究过程中的改善点和改善方向:以冲压连续流实施为方向实现冲压线的自动化,并通过快速换模、冲孔工序产能提升等对生产线进行效率提升及优化,消除中间工序在制品,提高冲压效率、减少劳动者。结合履带板冲压生产过程和履带板产品结构特点分析履带板冲压连续流实现的条件,得出了自动化设计的关键模块:自动送料、自动定位和自动控制系统的设计。经过理论分析和数据计算,自动送料装置采用了辊式自动送料机构并利用液压油缸完成履带板的上料和翻转;自动定位装置采用气动可调式结构并安装于液压机工作台上,实现自动定位的同时还可以实现不同长度履带板的快速切换;自动控制系统采用欧姆龙CJ1M系列PLC进行控制,通过对自动控制程序的设计,实现了冲压过程的全自动化,同时应用同步技术减少滑块运行和送料、定位动作时间的间隔,提高了生产效率。采用快速换模的理论和方法,通过对换模过程的测定,分解换模过程的动作和节拍,区分并转化内外部换模时间,对内部换模动作进行优化改善并进行了标准化,最终达成各工序换模时间全部小于40min的目标。对冲孔工序自动化生产的停机时间进行了分析,找出了影响冲孔自动化生产效率的主要原因,即位置尺寸定位装置结构及调整方式的不合理,通过对该定位装置整体结构的重新设计,在确保产品质量稳定性的同时有效减少了工装调整的频次和时间,降低了设备停机率,提高了班产量,从而实现了履带板冲压自动化生产时各工序生产能力的平衡。
[Abstract]:One of the parts of crawler board as the base of engineering machinery part, due to its vulnerability, the great market demand, either alone or machine parts supply has broad market prospects. At this stage of the domestic large scale crawler board production enterprises by stamping way forming track plate, but the the production line is manual stamping line automation is relatively low. Compared with the automatic stamping production line, universal artificial punch line of the disadvantage is the low safety factor, stamping low efficiency, high production cost, high labor intensity, this paper adopts the method of lean production mode, the value flow chart to analyze and find out the production process to improve, through the design of the punch line of the automatic device and automatic line efficiency, realizes the continuous automatic production of stamping of crawler board, for the enterprise Provide a guarantee to enhance the efficiency of production and reduce the cost of single product. At the same time not on the existing tooling equipment for large-scale changes, capital investment is small, highly reproducible, can provide a reference for the track plate production enterprises of all sizes. Based on the analysis of track plate stamping production line of each process status, in order to reduce the production cost of track plate, lifting track plate stamping production automation for the purpose of using lean production methods, to value flow graph, through data collection and induction completed 8190-MV (N) rendering crawler board present status and future value flow chart diagram, identify the stamping automation research in the process of improving and improving direction: with the continuous implementation of automation for stamping direction of stamping line, and through the quick die punching process, production capacity and other production lines to upgrade and optimize efficiency, eliminating the middle In process, improve the efficiency of stamping, reduce workers. Combined with the track plate stamping process and crawler board product structure characteristics analysis of stamping continuous track plate. The conditions of the key module automation design: automatic feeding, automatic positioning and automatic control system design. Through theoretical analysis and calculation, automatic feeding device the roller type automatic feeding mechanism and the hydraulic cylinder to complete the crawler plate loading and turning; automatic positioning device adopts pneumatic adjustable structure and is installed in the hydraulic machine worktable, realize automatic positioning and fast switching can achieve different length of track plate; automatic control system adopts OMRON CJ1M series PLC control, through the design of the automatic control program, to achieve the full automation of the stamping process, and the application of synchronous technology to reduce the slide operation and feeding, positioning 浣滄椂闂寸殑闂撮殧,鎻愰珮浜嗙敓浜ф晥鐜，

本文编号：1628251