1 . Project history
The 12-meter press brake mainly manufactures automotive components such as longitudinal beams, auxiliary beams, connecting plate thickened cross beams, as well as new, trial and special-shaped products, and super long and ultra thick connectors.
There are 8 thickness options, ranging from 3mm to 10mm.
The machine has 263 specifications and 554 varieties, with an average monthly production of 272 varieties.
As demand for heavy-duty vehicles continues to increase, there has been an increase in small and multi-batch production. However, the large-scale press brake production cycle cannot keep up with these demands, leading to a prolonged supply cycle due to frequent adjustments.
two . The main shortcomings
2.1 Low adjustment accuracy
The fixed dead positioning block is used in the adjustment and positioning mechanism of the system.
If the positioning block becomes damaged, distorted or worn over time, the four individual machine positioning points will become misaligned.
To accommodate repeated adjustments and test moldings, it is necessary to add a gasket and insert a plate.
2.2 Poor reliability
The impact force generated by large bending components in the positioning block is substantial, causing the positioning block fixing screws to loosen, the insertion plate to shift, and the positioning deviation to exceed 2 mm, resulting in a deviation in the dimensions formed.
To ensure accurate bending dimensions, it is necessary to adjust and fix the positioning point twice.
two . 3 Extended production cycle
The frequent adjustments required for the gasket and insert plate are cumbersome and prolong the batch production cycle, making it difficult to meet delivery schedules.
To resolve these issues, we propose a transformation plan for the positioning system of large-scale press brake machine.
3. Modification scheme
The insertion plate position adjustment mechanism has been changed to a screw-type design.
Three holes are drilled on the original positioning block plate, and two of them are equipped with adjustable screws, which makes debugging and installation more convenient.
3.1 System working principle
This device is a precision feed adjusting device, known as a thread adjusting device.
As shown in the illustration below, the accuracy of the system is adjusted by adjusting the upper and lower screws.
Instructions for adjusting the positioning block: (for one-person operation)
- Use a hex wrench to loosen the positioning block fixing screw.
- Hold the positioning block with one hand to prevent it from rotating sideways.
- Use a wrench to turn the upper or lower adjustment screws, moving the positioning block forward or backward.
- After positioning, tighten the positioning block screw using the hex key.
The threaded adjustment device offers this great advantage in the adjustment process.
Simplified system block diagram
3.2 Work plan and technical solutions
| NO. | Scheme | Project | To assume | Implementation of the plan (August) | confirm | ||
|---|---|---|---|---|---|---|---|
| 1st to 10th | 13 to 18 | 20 to 25 | |||||
| 1 |
Design, manufacturing and installation: |
On-site measurement | ____ | 08.02 | OK | ||
| Design graphics | ____ | 08.07 | OK | ||||
| Machining | ____ | 08.09 | OK | ||||
| two | Installation and debugging | ____ | 08.09 | OK | |||
| Effect tracking | ____ | 08/13-08/25 | OK | ||||
During downtimes, we improve the positioning accuracy of the large press brake without affecting production.
To accomplish this task in a short time, we first familiarize ourselves with the positioning structure of the equipment, remove any devices that need to be replaced, install the new positioning block adjustment device, and then perform the necessary debugging.
We employ an early technical readiness strategy utilizing parallel, cross-functional multi-channel operations. Installation and debugging work can be completed within a week, allowing the equipment to be put into operation and shortening the transformation time, ensuring production.
4 . Economic benefit and effect after use
Positioning block adjustment time has been reduced from 64 minutes to 22 minutes per day. This results in an average daily reduction of 42 minutes, calculated over 23 business days per month. This equates to a total decrease of 966 minutes, equivalent to an increase of 2.01 work shifts. The reduction in adaptation time will allow the completion of 26 additional species, ensuring that parts delivery will not be impacted.
5 . Final thoughts
The application of new technologies, materials and techniques to modernize old equipment has promising prospects. Our company faces the challenges of global economic competition and much of our existing equipment needs to be updated. This process can save a company a significant amount of money, improve employee working conditions, increase processing accuracy and efficiency, conserve energy, and reduce equipment failure rates.
