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milling production line automation

tube mill machine | rolling mill machine | lotos 2020

tube mill machine | rolling mill machine | lotos 2020

Tube Mill Machine | Rolling mill machine | LOTOS 2O19 is a new welding technology, which coats thin stainless steel on the surface of carbon steel pipe with high strength, the product has the features of both artistic appearance, therefore, corrosion resistance of stainless steel and high strength of carbon steel. It is the best substitute for stainless steel pipe as its lower price compared with that of welded steel pipe.

Choose us, you do not only get the tube Mill Line from us, but you also get technology from us. We select the best welding method for customers from high-frequency welding, TIG welding, plasma welding, and laser welding depending on the usage, welding requirements, and production efficiency.

The tube mill is widely used in household commodities, shoe racks, public facilities, and guardrails such as all kinds of clothes racks, retractable poles, article racks, all-purpose combination racks, table, and chair legs, indoor handrails, ship and bus racks, and outdoor guardrails.

Firstly, the stainless steel strips are made to go through various quality checks and are trimmed at the edges. The strips pass through the number of rollers as per the required size. In the tube mill, the strip is gradually converted into a tubular shape. The fitted welding machine is then used to weld trim edges of the strip welding process. In this way, rolled pipes and tubes are formed.

The rolled stainless steel pipes thus manufactured are cut to the required lengths depending upon the industrial demand. These stainless pipes and tubes are then subjected to cleaning to remove the dirt. Further, a heat treatment is given to these rolled pipes and tubes to remove the stresses that may occur due to welding and formation processes. Heat treatment is given on the continuously rolling hearth furnace. The furnace is fitted with temperature recorders and controllers. After the heat treatment process, the stainless steel tubes and pipes are straightened and subjected to pickling for removing scales from the surface.

In some cases, the required size may not be obtained from the mill directly. Then, the cold operation process can be used to obtain the desired size. In the cold drawing process, the tubes or pipes are coated with oxalic and soap solution. This solution acts as a lubricant to reduce friction while cold drawing operation.

The drawn-out tube or stainless steel pipe is then subjected to cleaning, heat treatment, pickling, and straightening. The computerized inkjet marking machine is used to do the marking on the finished pipes or tubes.

Raw material (steel coil) uncoiling shearing and butt-welding material accumulating non-power leveling mill-forming high-frequency welding removing burrs outside of weld seam Zinc spraying cooling sizing roughly straightening fixed-length cutting run-out table

Sizing device: Mainly fine shaping pipe after welding and controlling size accuracy. Every 6 sets of the horizontal roll stand, vertical roll stand and drive gearbox, 12 sets of a universal shaft.(structure same as forming device)

automation of milling machines

automation of milling machines

The HALTER LoadAssistant can be used by a CNC miller for loading of rectangle workpieces. Both small and medium series can efficiently be loaded by the robot arm into any existing or new CNC milling machine.

With which CNC machine brands?Akira Seiki, Bridgeport Hardinge, Deckel Maho, DMG Mori, Doosan, Eumach, Haas, Hardinge Bridgeport, Hermle, Hurco, Hyundai, Hwacheon, Kitamura, MAS, Mazak, Mikron, Mori Seiki, Nakamura Tome, Okuma, Quaser, Samsung, Spinner, Takisawa, Victor.

automated production lines - e plant maintenance

automated production lines - e plant maintenance

An automatedproduction lineconsists of a series of workstations connected by a transfer system to move parts between the stations. This is an example of fixed automation, since these lines are typically set up for long production runs, perhaps making millions of product units and running for several years between changeovers.

Each station is designed to perform a specific processing operation, so that the part or product is constructed stepwise as it progresses along the line. A rawworkpart enters at one end of the line, proceeds through each workstation, and emerges at the other end as a completed product.

In the normal operation of the line, there is a work part being processed at each station, so that many parts are being processed simultaneously and a finished part is produced with each cycle of the line.

Modern automated lines are controlled by programmable logic controllers, which are special computers that facilitate connections with industrial equipment (such as automated production lines) and can perform the kinds of timing and sequencing functions required to operate such equipment.

Machining is a manufacturing process in which metal is removed by a cutting or shaping tool, so that the remaining work part is the desired shape. Machinery and motor components are usually made by this process.

In many cases, multiple operations are required to completely shape the part. If the part is mass-produced, an automated transfer line is often the most economical method of production. The many separate operations are divided among the workstations. Transfer lines date back to about 1924.

Pressworkingoperations involve the cutting and forming of parts from sheet metal. Examples of such parts include automobile body panels, outer shells of major appliances (e.g., laundry machines and ranges), and metal furniture (e.g., desks and file cabinets). Morethan one processing step is often required to complete a complicated part.

As discussed above, numerical control is a form of programmable automation in which amachineis controlled by numbers (and other symbols) that have been coded on punched paper tape or analternativestoragemedium.

The initial application of numerical control was in themachine toolindustry, to control the position of a cuttingtoolrelative to theworkpart being machined. The NC part program represents the set of machining instructions for the particular part.

By sequencing these positions in the program, the machine tool is directed to accomplish the machining of the part. Aposition feedback control system is used in most NC machines to verify that the coded instructions have been correctly performed.

However, initial entry of the program into computer memory is often still accomplished using punched tape. Since this form of numerical control isimplementedby computer, it is calledcomputer numerical control, or CNC.

Another variation in the implementation of numerical control involves sending part programs over telecommunications lines from a central computer to individual machine tools in the factory, thus eliminating the use of the punched tape altogether. This form of numerical control is calleddirect numerical control, or DNC.

Other machines using numerical control includecomponent-insertion machines used inelectronicsassembly,draftingmachines that prepareengineeringdrawings, coordinate measuring machines that perform accurate inspections of parts, and flame cutting machines and similar devices.

In these applications, the term numerical control is not always used explicitly, but the operating principle is the same: coded numerical data are employed to control the position of a tool orworkheadrelative to some object.

To illustrate these alternative applications of numerical control, the component-insertion machine will be considered here. Such a machine is used to position electronic components (e.g., semiconductor chip modules) onto aprinted circuitboard (PCB).

A typical printed circuit board has dozens of individual components that must be placed on its surface; in many cases, the lead wires of the components must be inserted into small holes in the board, requiring great precision by the insertion machine.

The program that controls the machine indicates which components are to be placed on the board and their locations. This information is contained in the product-design database and is typically communicated directly from the computer to the insertion machine.

Assembly operations have traditionally been performed manually, either at single assembly workstations or on assembly lines with multiple stations. Owing to the high labour content and high cost of manual labour, greater attention has been given in recent years to the use of automation for assembly work.

Assembly operations can be automated usingproduction lineprinciples if the quantities are large, the product is small, and the design is simple (e.g., mechanical pencils, pens, and cigarette lighters). For products that do not satisfy these conditions, manual assembly is generally required.

Automated assembly machines have been developed that operate in a manner similar to machining transfer lines, with the difference being that assembly operations, instead of machining, are performed at the workstations.

A typical assembly machine consists of several stations, each equipped with a supply of components and a mechanism for delivering the components into position for assembly. Aworkheadat each station performs the actual attachment of the component. Typicalworkheadsinclude automatic screwdrivers, staking or riveting machines, welding heads, and other joining devices.

A new component is added to the partially completed product at each workstation, thus building up the product gradually as it proceeds through the line. Assembly machines of this type are considered to be examples of fixed automation, because they are generally configured for a particular product made in high volume. Programmable assembly machines are represented by the component-insertion machines employed in the electronics industry, as described above.

Material-handlingapplications include material transfer andmachineloading and unloading. Material-transfer applications require therobotto move materials orworkparts from one location to another.

Many of these tasks are relatively simple, requiring robots to pick up parts from one conveyor and place them on another. Other transfer operations are more complex, such as placing parts onto pallets in an arrangement that must be calculated by the robot.

Machine loading and unloading operations utilize a robot to load and unload parts at a production machine. This requires the robot to be equipped with a gripper that can grasp parts. Usually the gripper must be designed specifically for the particular part geometry.

Spot welding of automobile bodies is one of the most common applications of industrial robots in the United States. The robot positions a spot welder against the automobile panels and frames to complete the assembly of the basic car body.

Spraypaintinginvolves the manipulation of a spray-painting gun over the surface of the object to be coated. Other operations in this category include grinding, polishing, and routing, in which a rotating spindle serves as the robots tool.

Analternativestrategy is to produce a mixture of different product styles in the same assembly cell, requiring each robot in the cell to identify the product style as it arrives and then execute the appropriate task for that unit.

Designs in which the components are to be added from the same direction using snap fits and other one-step fastening procedures enable the work to be accomplished much more easily by automated and robotic assembly methods.

There are certain characteristics of industrial jobs performed by humans that identify the work as a potential application for robots: (1) the operation is repetitive, involving the same basic work motions every cycle; (2) the operation is hazardous or uncomfortable for the human worker (e.g.,spray painting, spot welding, arc welding, and certain machine loading and unloading tasks); (3) the task requires a work part or tool that is heavy and awkward to handle; and (4) the operation allows the robot to be used on two or three shifts.

A flexible manufacturing system (FMS) is a form of flexible automation in which several machine tools are linked together by a material-handling system, and all aspects of the system are controlled by a central computer.

An FMS is distinguished from an automatedproduction lineby its ability to process more than one product style simultaneously. At any moment, each machine in the system may be processing a different part type.

The components of an FMS are (1) processing machines, which are usually CNC machine tools that perform machining operations, although other types of automated workstations such as inspection stations are also possible,

In addition, a fourth component of an FMS is humanlabour. Although the flexible manufacturing system represents a high level of production automation, people are still needed to manage the system, load and unload parts, change tools, and maintain and repair the equipment.

Although other automated systems are typically controlled by computer, the term computer process control is generally associated with continuous orsemicontinuousproduction operations involving materials such as chemicals, petroleum, foods, and certain basic metals.

In addition, these products are usually mass-produced. Because of the ease of handling the product and the large volumes involved, a high level of automation has been accomplished in these industries.

(4) generation of reports to management indicating equipment status, production performance, and product quality. Today computer process control is applied to many industrial operations, two of which are described below.

The typical modern processplantis computer-controlled. In onepetrochemicalplant that produces more than 20 products, the facility is divided into three areas, each with severalchemical-processingunits.

Each process computer monitors up to 2,000parametersthat are required to control the process, such as temperature, flow rate, pressure, liquid level, and chemical concentration. These measurements are taken on a sampling basis; the time between samples varies between 2 and 120 seconds, depending on the relative need for the data.

If process parameters exceed the specified normal or safe ranges, the control computer actuates a signal light and alarm horn and prints a message indicating the nature of the problem for the technician. The central computer receives data from the process computers and performs calculations to optimize the performance of each chemical-processing unit.

Advanced controlalgorithmscan be applied by the computer to optimize the process. In addition, the computer is capable of sensing process conditions that indicate unsafe or abnormal operation much more quickly than humans can.

Like the chemical industries, the metals industries deal in large volumes of products, and so there is a substantial economic incentive to invest in automation. However, metals are typically produced in batches rather than continuously, and it is generally more difficult to handle metals in bulk form than chemicals that flow.

The rolling process involves the forming of a large, hot metal billet by passing it through a rolling mill consisting of one or more sets of large cylindrical rolls that squeeze the metal and reduce itscross section.

Several passes are required to reduce the ingot gradually to the desired thickness. Sensors and automatic instruments measure the dimensions and temperature of the ingot after each pass through the rolls, and the control computer calculates and regulates the roll settings for the next pass.

Control programs have been developed to schedule the sequence and rate at which the hot metal ingots are fed through the rolling mills. The production control task of scheduling and keeping track of the different orders requires rapid, massive data gathering and analysis.

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