汽车板簧冲压成型生产线中英文对照V0

美国DELTA 控制器用于板簧冲孔成型设备改造

北京市思路盛自动化系统集成有限公司 孙涛 slsheng@

Joining workcells together and streamlining output from one stage to the next, if done correctly, is a surefire way to boost metalforming productivity. One company proving this out, Dayton Parts, Harrisburg, PA, manufactures for the vehicle aftermarket. Part of a manufacturing operation that dates to the 1920s, the company’s leaf-spring production process was upgraded this past year to automate and connect the leaf punching and forming processes into a smooth flow (Fig. 1).

将不同加工单元重新组合形成一条连续生产的设备一定会大大提高生产效率。美国Dayton Parts ，Harrisburg ，PA 一家做车辆配件设备的公司对此进行了成功的实践。这台设备1920年就投入使用了。最近这家公司将生产板簧的冲压和成型工序组合在一起形成了协调地连续作业。

Dayton Parts’ leaf springs,

made from 1⁄2- to 1-5⁄8-in.-

thick 6150-grade high-carbon bar stock, must be

heated to 1800 F in both

punching and forming

production steps. Before

the streamlining upgrade,

this meant heating the

springs twice. Now, with

the new closely coupled

arrangement, the leaf

springs need only one

heating prior to punching

and forming, saving energy

and time, and as much as

doubling process

throughput. Dayton 配件生产的板簧规格从1/2英寸（26.2 mm ）到1-5/8英寸厚（41.275mm ） 6150级高碳棒料材料，有冲孔和成型工序。在冲孔和成型工序前分别需要将零件加热到982摄氏温度。在改造前加工板簧需要两次加热。改造后重新组合加工工序，只要加热一次就可以完成冲孔和成型，既节能省时还能成倍提高产量。

The integrated Dayton Parts workcell has proven the advantage of close coupling and networking of processing stages. The updated line has reduced reheat and changeover downtime to a minimum, while achieving cycle times as short as 17 sec. per part. Fig. 1—This CAD rendering shows the forming station (right) and the punch press (left), with the furnace in the middle. Leaf-spring material moves right-to-left from the furnace to the punch press, and then left-to-right to the forming station. 这个CAD 图形中右边边是成型设备左边是冲孔设备加热炉在中间。板簧片由加热炉出来后移至左边完成冲孔再移至右边成型。

“We’re seeing 95 percent combined uptime for the machines,” says Joseph Garcia,

project manager for Dayton Parts, “and the material handling and energy savings for the company were sufficiently large to pay for this project in one year.”

组合在一起的加工工序充分展示了工序衔接距离短，每个工序衔接及时的好处。经过改造后的生产线避免了重复加热，衔接时间短到17秒。Dayton 配件的项目经理Joseph Garica 总结说：“改造后设备提升了95%的生产效率。材料消耗和能源的节省是如此大，我们一年就可以收回这个项目的投资。

Motion Controllers Ke y to Combined Processes

运动控制器是实现组合工序的关键 Achieving rapid cycle times for

the combined machine requires

precise control and close

communication between the motion operations performed in

the process stages. Supervisory

control is performed by a

programmable logic controller

(PLC), but to control the

individual motion axes, PLCs

with special capabilities for

multiaxis coordination are

required. At the

recommendation of local

distributor Penn-Air & Hydraulics of York, PA, Dayton Parts’

engineers chose the RMC150

and RMC75 motion controllers from Delta Computer Systems, Inc., Battle Ground, WA. 实现组合工序的高速生产要求在生产的每个环节都有精密控制和快速通讯交换数据。整个设备的整体控制可以通过PLC 来完成，但是各个定位轴的控制需要有多轴控制能力的PLC 来完成。 在当地分销商 Penn-Air & Hydraulics 的推荐下Dayton 配件的工程师选择了美国DELTA 计算机系统有限公司的RMC150和RMC75运动控制器。

The hot punch for the leaf-spring process is powered by six motion axes (Fig. 2) under control of the RMC150—no problem, as a single RMC150 can control and coordinate the motion of as many as eight axes simultaneously. A pusher axis advances the part against an end gauge, which is positioned by another motion actuator to oppose the pusher in order to set the length between the end of the plate and the center hole to be punched. Two centering jaws along the width of the plate activate to center the hole accurately along that width. The pusher and end-gauge axes travel via position control, Fig. 2—A detailed rendering of the hot punch shows the six motion-control axes used in its operation.

详细结构图展示冲孔设备六个轴的作用