In recent years, with the popularization of computer technology and the wide application of intelligent technology, the production of non-standard equipment for automated production has arisen. Compared with general non-standard equipment, its superior performance and use value can greatly improve production efficiency and reduce production costs, so it has gained the popularity of the market and enterprises and become an important development direction of the production and manufacturing industry, which has a significant impact on the optimization of China's production mechanism.
Definition:
The so-called non-standard automation equipment is a kind of sound, light, electromechanical integration equipment tailored to the special needs of customers. Its main feature is to use computer CNC or programmable controller PLC to control various moving parts such as cylinders, oil pumps, motors, motors to achieve a specific action, so as to process qualified products. The reason why it is called non-standard is that this type of equipment can only complete the requirements specified by the customer, if the customer and the product is changed, it can not be used, so it causes its application range is very narrow, about its design, manufacturing is also full of challenges and potential great risk. So what are the main steps involved in the customization of non-standard automation equipment?
Step 1: Do the program
The solution is the key to solve the customer's problem, and its good or bad directly affects the signing of the business contract and the subsequent design and manufacture. But we often find that a set of equipment after a lot of hard work to design and produce, but found that there are many places can not meet customer needs, so either by adding parts again, or through the site repeatedly modified debugging, reluctantly delivered to customers, and this toss down, most of the profits will be eaten up, or even loss of money. This is a scarred result that no one wants to see. Looking deeper into the reasons, I think it is not deep enough to communicate with the customer in the early stage, meticulous, the customer's products, working conditions and technical requirements are not thorough, to the subsequent design and production of a series of work has laid a large pit.
Step 2: Design selection configuration When the program is determined, you have to start the design, or set the drawings on the basis of the original drawings and modify them. This process, if lucky, may be completed in a few days, but if the amount of change, it is almost necessary to overturn the original drawings, re-type the design. For example, due to cost constraints, the need to adjust the cylinder, motor grade downward, choose other brands, thus requiring changes to the installation and size, or to meet the new customer requirements, the need to add new features, the amount of changes to the drawings will increase, the need to re-select the design calculations, and finally to fully verify whether the altered drawings can meet the needs of the program.
Step 3: Installation and commissioning
When all the drawings are realized, into a visible outsourcing parts, outsourcing parts, homemade parts, we need to move to the installation and commissioning stage. After the workers use wrenches, welding machines and various fasteners, these parts will be installed into a piece of equipment and the same requirements of the drawings, we will have a sense of initial achievement, but can not be happy too early, after the commissioning is a big test of the mechanical, electrical, and procedural. From a local action to an action to open the signal, so that the cylinder, electric motor up, and then to a process a process to complete the local product processing, and finally to the joint adjustment, simulation to achieve a product complete production process, which requires programmers, mechanical and electrical designers present, in cooperation with the commissioning staff to complete each step of production work to ensure that the product processing molding is reasonable, smooth, qualified. If the logic of the production process of a single product is correct, the whole machine system should be further tested to see if it is stable and reliable. This is the time to determine whether the equipment is qualified, successful, and can be delivered to customers with confidence.
If a mechanical structure is unreasonable, it needs to be changed, if the signal sensing is not stable, sensitive or missing, the parameters of a sensor or wiring, installation and position size should be corrected. If the process is not reasonable, then we need to modify the program, adjust the parameters, so that the cylinder action stroke, speed, motor steering, speed and other parameters to get more accurate adjustment.
Our final requirement for the equipment is that it is as simple as possible to just turn on the power to the console, start the operation button, and then complete a workflow without any hindrance, thus bringing considerable economic benefits to the customer.
Step 4: After-sales service
The difficulty of after-sales service is that the customer site conditions are often very simple, poor, to the maintenance of equipment, transformation brings great difficulties. This requires them to have comprehensive skills to overcome all difficulties, to understand both mechanical and electrical, and even understand the modification and operation of the program (of course, this will generally modify the parameters can be). Field equipment failure or defects are often caused by inadequate design or not careful installation and commissioning, but also by improper operation of the customer or changes in working conditions, which requires after-sales service personnel to do their best to solve the problem by all means, and sometimes requires the cooperation of the company's main camp to complete.
In any case, non-standard automation equipment in the context of Industry 4.0 manufacturing, the general trend, has become the mainstream of machine replacement, industrial upgrading.
