快速换模技术在大中型客车行业冲压加工中的应用

以1030T压力机为例,对其在精益生产的推进过程中进行分析,应用了快速换模技术,通过使内换模和外换模分离、缩短内换模时间等步骤,使换模时间由原来的34min减少为13min,设备利用率由45.9%提高到75%.     

基于价值流分析的铰链生产改善研究

以某生产铰链的公司为例,经过调研该公司的铰链生产线是单人、单线、单机操作,存在工序繁琐、换模时间长的问题,导致生产周期长,产能突破不大。通过价值流图分析,引入连续模以及实现快速换模的方法对铰链生产进行优化。投入使用能把冲压落料、整平面度、侧切角度、沉孔4个工序连续完成的冲床,制定时间推移图,运用并行作业实现快速换模,使得冲压落料、沉孔、整平和侧切这4道工序合并为1道工序。实践表明,每月4个工序所需时间减少5.45天,每月换模时间减少1.6天。     

基于快速换模技术的冲压设备利用率改善

为了提高制造企业的整体设备效率(Overall Equipment Effectiveness, OEE)以及保障多品种、小批量的均衡化生产,不同产品的切换必须实施快速换模(Single Minute Exchange Of Die,SMED)。在快速换模理论的指导下,对A公司不同种类钢片的生产冲压车间开展快速换模研究,首先对其中的换模流程进行分析,然后通过区分内外部作业、尽量转化内部作业为外部作业,缩短内外部作业时间等步骤进行改善,通过实施快速换模,有效缩短了换模时间,从原来的33.2分钟降到23.2分钟,整体设备效率提升了13%。     

蒙皮拉形机快速换模系统力学安全性分析

拉伸成形是飞机钣金的基本成形方法。由于飞机蒙皮种类繁琐、生产批量小,在拉形的过程中需要频繁的更换模具,而现有国内蒙皮拉形机换模仍为传统换模方式,换模时间长,换模过程繁琐。针对这一情况,研发出了一套蒙皮拉形机快速换模系统,能从根本上提高蒙皮拉形机的换模效率,进而提高蒙皮拉形机的生产效率。采用有限元方法,对所提出的蒙皮拉形机快速换模系统进行力学安全性分析,研究了该系统内部重要零部件在极限工况下的应力分布,对整个换模系统的完善与再优化具有重要的意义。分析结果显示:该蒙皮拉形机快速换系统是结构安全的。     

冲压设备快速换模技术研究

针对冲压设备换模工艺时间长的问题,建立了换模时间与冲压工序在制品数量的关系模型,并在该模型的基础上,提出了一种综合应用流程图、排列图和鱼骨图寻找和优化影响换模时间因素的快速换模改进方法,减少了冲压设备的换模时间和冲压工序的在制品数量,并用实例验证了模型和方法的可行性。     

压铸生产中快速换模装置的设计

针对Y公司压铸生产中模具更换时间长,劳动强度大,存在安全隐患等缺点,结合企业设备的特点和运行的实际情况,介绍一种新型换模装置的设计。该装置主要包括连接部分设计,气缸推板、固定板和导杆设计,辅助支撑板与限位块设计。整个结构简单实用,操作方便迅速,安全可靠,可有效缩短换模时间,提升压铸生产效率。对比人工换模与换模装置换模过程,后者相对前者工作时间减少率为60%,有效提高了生产效率和设备利用率,适用于企业精益生产的推行。     

基于快速换模技术的生产线换线过程改善研究

针对以多品种小批量为特征的生产型企业,为提高其整体设备效率(Overall Equipment Effectiveness,OEE),以精益生产中的快速换模(Single Minute Exchange of Die,SMED)技术为理论指导,以案例为依托,对法国某植物药妆企业的生产包装车间开展快速换模研究。通过分析换模时间存在的浪费,进行了一系列优化改进措施,包括区分缩短内外部作业,优化换模作业流程,建立调试参数尺寸计算模型等,取得了良好的效果。研究结果显示,生产线平均切换时间由原来的110 min降至55 min,切换时间缩短了50%,整体设备效率从64%提高到76%。     

四工位真空吸附成型机换模机构的改造

文中针对1980年代白色家电行业从国外进口的真空吸附成型机换模难、耗时长的缺点,通过改变模具固定方式、装模位置,并增加一定数量的执行机构和磁控开关,对现有设备换模机构进行适度自动化的低成本改造,以提高换模效率,实现快速组织生产并响应市场的能力.     

锻造液压机的快速换模装置

主要介绍了锻造液压机的换模装置,通过比较分析,体现了新型换模装置的快速性、高效性,更适应现代液压机的快速锻造。     

全自动模具更换系统在大型冲压线上的应用

介绍了全自动模具更换系统在大型自动化冲压线上的应用,包括自动换模准备条件,自动换模动作分解与步骤,模具管理与识别系统,自动换模ADC监控与诊断等.大型冲压线采用自动化更换模具系统大大地减少了换模时间,使压力机具有更高的可靠性和生产效率.     

Developing a PDM/MRP integration framework to evaluate the influence of engineering change on inventory scrap cost

Quick response to market change has become a critical strategy for businesses in the global competitive environment. Since product design usually occupies a major time period of the product development process, shortening the time spent in the re-design stage has become an important issue for businesses. In this research, an environment integrating a PDM and an MRP application was proposed. By applying the concepts of Activity Based Costing (ABC), this environment can be used to support designers in a part re-design project to analyze inventory scrap costs. Using ARIS software, an eEPC model describing the re-design process in PDM, as well as the scrap cost analysis process, was developed. The major function of this integrated environment is to support the designer in making quick and proper decisions to reduce the inventory scrap cost of existing parts during the product re-design project.     

冲压模具的维修与保养

模具的预防性维修和保养,在很大程度上能减少品质事故,降低维修成本.通过对冲压模具的维修与保养及结构改进过程的介绍,说明模具维修的重要性,保证了冲压正常生产,提高了模具的质量.实践证明,在有条理预防的同时,结合计划性的保养,对模具施行合理的改进措施,可极大的提高生产效率和产品品质.     

A concurrent manufacturing strategy for One-of-a-Kind Products with complicated sculptured surfaces

In this paper, we propose a computer-aided system for concurrently designing and manufacturing a customised or One-of-Kind Production (OKP) mould or die which has complicated sculptured surfaces. Considering the OKP production characteristics of high customisation and concurrent product development and production, we believe that the concurrent consideration of both the design and the manufacturability of a mould or a die would be necessary. This concurrence can be realised by providing timely manufacturability information feedback after a design is completed or a feature is modified or added in the design. The other problem is that the sculptured surface geometry model of a mould or a die does not contain any machining information. Hence we developed an intermediate data model for capturing manufacturing features when we are modelling the geometric form of a mould or a die. The system is based on CADDS5 which is a commercial CAD/CAM system. Two modules for data extraction, coverting and modelling as well as for manufacturability analysis have been developed and added to CADDS5. Using this computer-aided system; a designer can interrogate geometry and machining constraint information through a user friendly interface to avoid defects and inefficiency resulting from an earlier design, and can finalise the design by making quick incremental adjustments. The system has been implemented in a mould and die manufacturing company in China. This implementation leads to less rework and shorter lead time.     

浅谈加工中心在新产品开发中的作用

模具是批量生产的基础 ,模具的制造周期和质量直接影响到产品的批量生产能力和产品质量。传统的模具制造是手工制造方式 ,其质量低、速度慢 ,无法满足新产品开发的要求 ,制约了企业的发展。而加工中心以其柔性强、精度高、速度快、性能稳定等优点 ,加上 CAD/CAM,使复杂曲面、型腔的加工易如反掌。文章介绍了南宁机械厂加工中心在新产品开发中的作用。     

Method for improvement of die-casting die: combination use of CAE and biomimetic laser process

Die service life improvement is an important problem in high-pressure die-casting industry. Die service life, which is defined as the maximum product number produced before it fails, and die performance directly determine the production cost and quality of die-casting product. To reduce the repair and maintenance costs, an approach to prevent die from thermal damage and prolong the die lifetime is required. Biomimetic laser-remelting process (BLRP) provides a promising method to improve the service life of die-casting mold. However, the laser processing regions can only be determined by experiences. In order to determine the exact laser processing regions for a set of new die before BLRP, a combination system of CAE and BLRP is proposed in this paper. Through analyzing the mold filling process and the temperature distribution, potential thermal cracks are worked out by numerical simulation system, which are the laser processing regions. The method proposed in this paper advances the efficiency of the BLRP. And practical production validates the veracity and the reliability of the method.     

面向并行工程的车间生产准备

并行化的生产准备是进一步缩短产品开发周期的重要途径之一，这里针对某一模具车间提出了生产准备的并行化方案。并分析了影响并行化生产准备实施的４个关键因素，即集成环境、模具设计及工艺编制的规范化、有效的库存管理、人的因素。并行化的生产准备将会大大的缩短生产准备时间，降低成本，提高企业的竞争实力。     

管夹产品连续模探讨与设计

根据以前的单工序模具,结合产品的外观结构和特点,提出合理的设计方案,分析其工艺路线,设计出一副经济实用的连续模,从而提高生产效率,降低生产成本,并对模具关键部件的设计进行说明和结构优劣的比较。     

一模多用注射模具设计研究

分析降低塑料制件成本的方法,提出为了降低成本,将满足一定条件的几种规格形式的塑料制件用一副模具成型出来,就是一模多用模具;同时研究了一模多用注射模具四种形式的分类及条件,结合生产实例分析模具设计要点,模具巧妙结构特点等。经生产实践证明,在一定的条件下,使用一模多用注射模具可以减少模具数量,降低成本,大大提高企业的市场竞争力。     

Applications of 3D scanning and reverse engineering techniques for quality control of quick response products

Quick error comparisons of fabricated parts and an original CAD design is often a difficult yet important issue in product quality control. In this paper we present an integrated technique of 3D scanning with reverse engineering and rapid prototyping technologies. This will be applied to the entire quality control phase of quick response products during the manufacturing process. By using 3D scanning and reverse engineering technology in conjunction with rapid prototyping technology, the geometric data of components can be easily and rapidly measured and analyzed. The detailed report can be printed out directly to fulfill the requirement of total quality control for quick response products. The proposed technique is especially suitable for fragile or soft material made products, like thin shell or rubber parts. With its accuracy and ease of operation, this integrated method is able to help manufacturers improve their global competitiveness in the 21st century.     

BOD微生物传感器快速测定法的适用性探究

运用BOD微生物传感器快速测定仪，对微生物传感器快速测定法的检出限、精密度、准确度等一系列实验室质量控制要求进行了测定。并在此基础上，对大量不同行业和环境水体的实际样品进行了BOD快速测定法与国标五日生化需氧量法（BODs）对比实验，通过所得到的比对数据以BODs为基准对BOD快速法的适用性进行了探究。