China Yituo Technology Material Research Institute: to create a "different" forging production line
2022-11-04
Forging is an important basic process in the production of equipment manufacturing products, which often gives people such an impression: high temperature, sultry, dust all over the sky. Its bad working condition has always been a short board of industrial intelligent promotion. The intelligent precision forging production line, which recently won the 2018 China Agricultural Machinery Science and Technology Award, has made a significant improvement.
Recently, located in China Yituo process materials research Institute opposite the workshop, the reporter saw the production line is running. The feeding equipment will transport pieces of billet to the weighing device, and the qualified billet will enter the heating link after the preliminary screening and weighing, and then the handling - forging - automatic inkjet - online detection. The generated products will be shipped out of the production area after automatic cutting and palletizing by the robot. All the processes are completed in one go, truly realizing the "machine replacement".
Xia Zhanxue, a first-level expert from China Yituo Technology Materials Research Institute, said that for the equipment manufacturing industry, its intelligent transformation usually needs to go through the "three steps" of digitalization, automation and intelligence, and the data collection and processing in the first step is often a difficult problem. Because of the severe working conditions, its processing temperature is often thousands of degrees Celsius, delicate and fragile instruments are difficult to continue to operate. Therefore, the introduction of warm forging technology to make forging "not so hot" has become a highlight of the construction of the production line.
Compared with the traditional hot forging, warm forging is a technology that adopts lower temperature for forging forming. While changing the traditional "one pot end" extensive processing method of heat treatment, the warm forging of the material with simple structure and small deformation is also helpful to improve the product quality and increase the service life of the product. In addition, the environment for data acquisition in forging process can be improved by warm forging.
The method of data collection is also one of the features of the production line. By using non-contact blue light measurement technology, the intelligent precision forging production line can realize the online measurement of the key dimensions of high temperature forgings, which can monitor the quality of the forging in the whole production process and help to trace the key quality. According to the measurement results, the system can also generate the corresponding change curve, so as to indirectly reflect the change trend of the related die. Through the above technology, the intelligent forging production line has realized the online detection of the forging parts and the monitoring and early warning of the size change trend for the first time in the forging industry.
Once the data collection problem is solved, the next step to deal with is the data application problem. Xia Zhanxxue said that in the current intelligent transformation, enterprises implement the direction of "what you see is what you get", also known as "digital twin", that is, through accurate modeling and data transmission, the remote digital control and real mechanical operation form a one-to-one correspondence, and through data analysis and application and follow-up to achieve production improvement.
With the analysis of a number of sensing equipment construction and related system construction, intelligent precision forging production lines using the digital design, virtual reality technology, provide a scientific basis for precision forging process parameters optimization, greatly reduces the product production cost, and in the production line layout planning stage can complete 3 d visualization technology research and development and application, promote the application of digital technology in the field of forging technology.
At present, the production line has entered the mass production stage, so far has produced 400,000 pieces of related parts.
A set of figures obtained through real-time analysis can illustrate the overall technological improvement of the intelligent precision forging production line. According to statistics, compared with the traditional production line, the project can shorten the product development and trial production cycle by 30%, reduce the downtime of the production line by 40%, reduce the labor cost by 65%, and increase the production efficiency by 20%. Its overall level has reached the domestic leading, among which the forging hot state online detection technology, process parameter optimization and control compensation system has reached the international advanced level.
In addition, as an independent scientific research result of China Yituo Technology Material Research Institute, the intelligent forging production line transformation scheme has been applied to many units in the industry. This has also become one of the typical cases of China YITuo's continuous efforts in recent years to transform from an equipment manufacturer to a service provider.
Recently, located in China Yituo process materials research Institute opposite the workshop, the reporter saw the production line is running. The feeding equipment will transport pieces of billet to the weighing device, and the qualified billet will enter the heating link after the preliminary screening and weighing, and then the handling - forging - automatic inkjet - online detection. The generated products will be shipped out of the production area after automatic cutting and palletizing by the robot. All the processes are completed in one go, truly realizing the "machine replacement".
Xia Zhanxue, a first-level expert from China Yituo Technology Materials Research Institute, said that for the equipment manufacturing industry, its intelligent transformation usually needs to go through the "three steps" of digitalization, automation and intelligence, and the data collection and processing in the first step is often a difficult problem. Because of the severe working conditions, its processing temperature is often thousands of degrees Celsius, delicate and fragile instruments are difficult to continue to operate. Therefore, the introduction of warm forging technology to make forging "not so hot" has become a highlight of the construction of the production line.
Compared with the traditional hot forging, warm forging is a technology that adopts lower temperature for forging forming. While changing the traditional "one pot end" extensive processing method of heat treatment, the warm forging of the material with simple structure and small deformation is also helpful to improve the product quality and increase the service life of the product. In addition, the environment for data acquisition in forging process can be improved by warm forging.
The method of data collection is also one of the features of the production line. By using non-contact blue light measurement technology, the intelligent precision forging production line can realize the online measurement of the key dimensions of high temperature forgings, which can monitor the quality of the forging in the whole production process and help to trace the key quality. According to the measurement results, the system can also generate the corresponding change curve, so as to indirectly reflect the change trend of the related die. Through the above technology, the intelligent forging production line has realized the online detection of the forging parts and the monitoring and early warning of the size change trend for the first time in the forging industry.
Once the data collection problem is solved, the next step to deal with is the data application problem. Xia Zhanxxue said that in the current intelligent transformation, enterprises implement the direction of "what you see is what you get", also known as "digital twin", that is, through accurate modeling and data transmission, the remote digital control and real mechanical operation form a one-to-one correspondence, and through data analysis and application and follow-up to achieve production improvement.
With the analysis of a number of sensing equipment construction and related system construction, intelligent precision forging production lines using the digital design, virtual reality technology, provide a scientific basis for precision forging process parameters optimization, greatly reduces the product production cost, and in the production line layout planning stage can complete 3 d visualization technology research and development and application, promote the application of digital technology in the field of forging technology.
At present, the production line has entered the mass production stage, so far has produced 400,000 pieces of related parts.
A set of figures obtained through real-time analysis can illustrate the overall technological improvement of the intelligent precision forging production line. According to statistics, compared with the traditional production line, the project can shorten the product development and trial production cycle by 30%, reduce the downtime of the production line by 40%, reduce the labor cost by 65%, and increase the production efficiency by 20%. Its overall level has reached the domestic leading, among which the forging hot state online detection technology, process parameter optimization and control compensation system has reached the international advanced level.
In addition, as an independent scientific research result of China Yituo Technology Material Research Institute, the intelligent forging production line transformation scheme has been applied to many units in the industry. This has also become one of the typical cases of China YITuo's continuous efforts in recent years to transform from an equipment manufacturer to a service provider.
this is imported forging machine of tongxin precision forging company:
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