Research and application of high performance barrel stopper capping machine
Research and application of high performance barrel stopper capping machine
Japan Xinri Steel Barrel Co., Ltd.
Translation / Meng Lingmei
First, the purpose
1. Remove defective fittings and diagonally oversized lids (manufacture a suitable device).
2. Stabilize the tightening torque of the lid and manage the parameters (manufacture a final screwing device).
Development Background:
1980s
1990s
2000s
2010s
Accessories
Manual operation
Operated by tools in 1998
An improved version of internal development in 2002
R&D new equipment in 2012
First tightening device
Installed at the Panasonic Institute in 1988
→
→
→
Final tightening equipment
Installed at the Panasonic Institute in 1988
→
→
Development of new equipment in 2010
The developed equipment is being installed at every factory. The final tightening device and equipment accessories were installed at the Sagamihara plant in August 2010 and March 2012, respectively. The final tightening equipment was installed at the Sanyo plant in February 2012.
Of course, the Osaka and Nagoya plants are also scheduled to install these devices.
Second, the barrel top cover equipment
1. Development background
(1) Structure and problems of previous equipment
1 The small mechanism of this piston device is very practical.
2 This device cannot handle inclined flanges.
3 Piston and barrel flange center alignment is not very accurate.
(2) Improvements to the structure of the previous equipment.
1 A more practical small mechanism for piston devices.
2 Due to the use of a spherical turning device, it is possible to handle inclined flanges.
3 Still can't align the exact center of the piston and flange.
2, the three conditions for the correct use
Past experience has suggested that there are three conditions that affect the proper use of equipment:
1 Be sure to follow the condition of the detection flange. The general tilt is caused by the top of the barrel.
2 Eliminate the main problem that the flange and the barrel center cannot be aligned.
3 The pressure of the piston is further optimized.
In this regard, it is necessary to develop a device to solve the above three problems.
3. Comparison of equipment improvement and improvement before improvement
Equipment before improvement
Slightly improved equipment
Improved equipment
Handling flange tilt
Unable to process
Spherical driven automatic centering mechanism
The tilting device of the flange can be corrected in the main drive mechanism
Prevent center misalignment
Can't prevent
Can't prevent
Automatic error correction from the X and Y axes. Can prevent center misalignment
Optimize the pressure of the piston
The cover unit uses a spring and a spring on the spring
The cover unit uses a spring and a spring on the spring
Use cylinder instead of spring to automatically balance piston pressure through constant air pressure
4. Introduction to equipment development
[Flange tilt tracking]
(1) Separating the upper cover device from the lifting device so that the main cover device can be inclined along the top surface of the tub.
(2) The upper cover device can be moved up and down in the vertical direction of the top of the bucket.
(3) Finally, the upper cover device is perpendicular to the inclined flange.
[Preventing Center Dislocation]
The portion of the barrel that rotates includes three layers, including X, Y-direction guides with rollers. Slide the center of the piston to within 3 mm of the center of the flange.
Cover device
Inside the device
[Optimize the pressure of the piston]
The two monitoring mechanisms and three solenoid valves are combined by a rotating shaft equipped with a dedicated lifting cylinder so that the pressure can be automatically adjusted.
5, online installation
6, time chart
7, summary
(1) Top cover defect rate
Reduced from 2% to 0.1%.
(2) It can be confirmed that the correct installation of the hardware conforming to the three conditions has been delivered at the initial stage of development.
Third, the barrel is finally tightened equipment
1. Development background
Previous problems with the structure of the device
(1) Adjust the tightening torque by adjusting the spring on the cylinder.
(2) There is a problem
1 Torque size cannot be set quantitatively.
2 Because of the uncertain changes in torque during user use, problems with the looseness of the barrel plugs often occur.
It is therefore necessary to develop equipment with torque feedback control.
2. Comparison of equipment before and after improvement
Equipment before improvement
Improved equipment
device
Torque is adjusted by adjusting the spring of the cylinder
Electronically controlled servo drive
Tightening torque setting
Cannot be set quantitatively
Quantitative equipment
Torque change
Air pressure has a very high impact on the perceived torque of the device
Control accuracy is higher than repeated torque
Torque data saving
Cannot save and detect because the torque data cannot be obtained
Ability to acquire and store data and manage it in batches
Torque error detection
Since the limit of the torque size is set, the error can be detected.
3. Improved equipment introduction
Features: When the tightening is completed, the torque will feedback the system, the system will give the maximum torque value, and the set value and actual value will be displayed separately. With a variable speed regulator, the speed varies with torque. It can work on a variety of different sizes of steel drum products and different bucket types.
The controller can be connected to a PLC or touch screen for operation.
Tightening accuracy: 1% FS → 50N?m × 1% = ± 0.5N?m
Minimum output device: 0.01N?m
4. Check the precision of the servo tightening equipment (offline test)
(1) rubber seal
(2) Elastic plastic sealing ring
1 The actual data of the tightening torque can be reproduced and each small change can be recorded.
2 The same set of data for torque indicates that, in fact, the rubber seal is less torque than the elastomeric seal.
3 Draw a linear curve of the rubber seal and the elastic plastic seal according to the actual data compared with the set value.
It can be determined that the torque repeatability is high and the device is effective.
[Reference] Instructions for torque measurement using a torque wrench:
1 The type of torque wrench shown in the photo below is used for the measurement.
2 The measured torque values ​​are in the direction in which the barrel is tightened.
3 “Measure torque value with a torque wrench†is the torque value in the tightening direction when the tightening head starts moving the barrel plug at a low speed of 1 rpm.
5, online installation
6, time chart
7, online torque accuracy
Improved to greatly reduce torque changes
(different types of gaskets)
Standard tightening torque
Torque before equipment improvement
Changes after improvement
Elastic plastic washer
Barrel plug: 20±5N?m
11.5N?m
2.0N?m
Small barrel plug: 13±6N?m
11.0N?m
2.5N?m
Rubber gasket
Large barrel plug: 14±5N?m
10.5N?m
2.5N?m
Small barrel plug: 12±6N?m
15.5N?m
3.0N?m
7, summary
Quality improvements:
(1) The tightening device can be controlled and set.
(2) The tightening torque is stable and reliable.
(3) Data management is possible.
Improve quality and incorporate into a strong quality management system:
(1) Torque stability
The tightening torque can be set according to different types of barrel plugs, and speed control and setting can be performed.
The variation of air pressure and mechanical accuracy has no effect on the torque, and the accuracy deviation of the torque value can be repeatedly adjusted.
(2) can store torque data
A large amount of data can be saved so that quantitative values ​​and trends can be managed.
(3) Detection of tightening torque error
The range of maximum and minimum torques can be set, warnings are exceeded and the defective steel drum is indicated.
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