Assembly Automation R&D Processes

Customers’ On-Demand for Automation Solution Risk Assessment & ROI

The automation risk assessment covers various aspects such as stability, reliability, safety and efficiency of the equipment. These include equipment failure rate, maintenance capability, environmental friendliness, accuracy, and other indicators.

The purpose of the automation project solution risk assessment is to identify hazards, estimate and evaluate risks so that they can be mitigated. Machinery safety assessment should be started in the design phase so that it is more economical and efficient to modify the machinery during the design phase. If the mechanical design has been completed or the equipment has been manufactured, then only additional protection or risk reduction measures, for the design, this additional protection measures will increase the cost and may limit the ease of use of the machinery.

In order to ensure the effectiveness of reliability testing, the selection of experimental methods should take into account The type of equipment and environment and other elements. In order to make the test results accurate and effective, the following factors should be considered The following factors should be considered in order to make the test results accurate and valid.

Safety of the equipment

The design of non-standard automation equipment needs to take into account the safety of the equipment, including operation safety and operational safety. The designer needs to consider the functional requirements of the equipment and the operation process, and design reasonable safety measures to ensure the safety and legality of the equipment.

Maintainability of the equipment

The design of non-standard automation equipment needs to take into account the maintainability of the equipment, including the structural design of the equipment, the selection of components, and the maintenance of the equipment. The designer needs to choose components and structures that are easy to maintain and repair to ensure the reliability and stability of the equipment.

Intelligence of the equipment

With the continuous development of artificial intelligence technology, the intelligence of non-standard automation equipment is getting more and more attention from customers. Designers need to consider the intelligent needs of the equipment and choose suitable intelligent technologies and solutions to improve the intelligence and automation of the equipment.

Environmental protection of the equipment

The design of non-standard automation equipment needs to take into account the environmental protection of the equipment, including energy consumption, exhaust gas emission and waste water discharge. Designers need to choose environmentally friendly materials and equipment and develop reasonable environmental protection measures to reduce the environmental impact of the equipment.

To sum up, the design of non-standard automation equipment needs to take into account customer needs, technical capability, safety, maintainability, intelligence and environmental protection. The designer needs to have certain technical ability and innovation consciousness to be able to design a suitable equipment solution to meet the customer’s needs and requirements. At the same time, the designer also needs to have good teamwork and project management skills to be able to coordinate the work of various departments and links to ensure the smooth implementation of the project. In addition, the design of non-standard automation equipment also needs to take into account the market demand and competitive situation, and choose a suitable market positioning and marketing strategy to ensure the market competitiveness and sustainable development of the equipment.

First, the contract should be clear to achieve the main functions and performance of the product

Non-standard automation equipment does not have the corresponding standards like standard products, often each product function and performance are different, the contract should be clearly agreed, such as line speed, processed product accuracy, defective rate, working environment requirements, consumables, etc.

Second, for the parts used, material requirements should be clearly agreed

The components used in non-standard automation equipment are not all non-standard, often have certain standards, only a few are designed and processed for the product, but the materials are generally speaking standard materials. Such as stainless steel materials, can be agreed according to the specific circumstances of 306 stainless steel, 314 stainless steel; the manufacturer and brand of the control system used, such as the agreement Siemens, Mitsubishi, ABB, etc.; control system type can be selected PLC or industrial control computer, etc. (conventional Division I use international first-line brand standard parts to protect customers in the local can buy the corresponding automation standard parts)

Third, the price can be calculated in different ways

The amount of non-standard manufacturing automation is sometimes difficult to predict in advance, and even if the forecast often differs significantly from the actual, and in the process of fulfillment there are often changes in design, and sometimes even in the commissioning process to make substantial design changes, especially changes in design will also involve the cost of components and labor costs that have been processed, or even installed, and the offer is more complex.

Therefore, the price budget of non-standard automation services is quite complex, and the contract must be signed carefully, specifically, you can learn from the experience of the construction engineering field, using a fixed lump sum price, or according to the progress of the calculation of the price one by one, such as a change of circumstances, can be adjusted.

Fourth, the payment method

Non-standard automation equipment payment method is usually prepayment + progress payment, that is, the agreement of automation buyers in a certain period after the signing of the contract to pay a certain amount of prepayment, with the progress of work to pay the corresponding amount, successful commissioning and delivery of the remaining part of the amount.

V. Delivery time

Our company produces the steel raw material from wire cutting, mold, fixture, sheet metal, laser cutting, welding and other processes in our own factory to ensure the quality and delivery time control.

VI. Commissioning time and cost

Non-standard automation machinery line each order has its own special characteristics, debugging stage is recommended to provide as much material and consumables to ensure the rapid operation of the equipment rather than placed in the customer’s factory and then debugging to be more responsible for the customer’s return on investment

VII. Agreement on the attached information and other obligations

For non-standard products, its use, maintenance and other matters need to be informed in writing to the user, naturally need to attach the relevant materials, many companies are currently transmitted in the form of electronic data, which is the same as paper, and more convenient.

Some other accessories, such as the equipment-specific accessories, tools, and for the use of personnel training and other circumstances, the contractor should fulfill the obligation. Such as detailed maintenance circuit diagrams and wearing parts drawings to facilitate future maintenance, improvement, and reduce unnecessary downtime waiting.

Eight, after-sales service and quality assurance period

In view of the non-standard automation equipment after-sales service is more complex, the need for friction between the various parts to cooperate with our proposal to provide customers with 3 days 72 hours before acceptance of the equipment material strict acceptance of equipment stability before sending overseas customers to reduce unnecessary after-sales service and to protect the customer’s production capacity.

IX. Unpredictable risk bearing

As a manufacturer of non-standard automation for more than 15 years must go through a risk assessment before doing the program, through experiments to verify whether there are potential risks need to clearly inform the customer in writing on special complex processes we

X. Intellectual property agreement

Non-standard products also have intellectual property rights, need to be protected, often involving intellectual property rights are patents, exclusive rights of trademarks, computer software copyrights and trade secrets, etc.. For such intellectual property rights, we have a confidentiality agreement to be agreed.

The design solutions for non-standard automation equipment need to have the following aspects:

Mechanical design

Mechanical design is an important part of the design of non-standard automation equipment, including mechanical structure design, transmission system design, motion control design and other aspects. Mechanical design needs to take into account the functional requirements of the equipment, structural layout, material selection and other factors in order to achieve efficient, stable and reliable operation of the equipment.

Several mechanical design tips are listed below:

Determine the design goals: Before mechanical design, first need to determine the functional requirements of mechanical equipment, process flow, use of the environment and manufacturing requirements, etc., as a basis for determining the mechanical design goals. Mechanical design goals are the starting point of mechanical design, only clear mechanical design goals, to be able to work in the design of the target, high efficiency.

Select the right material: mechanical design material selection determines the quality, stability and life of mechanical equipment, so you must select the right material. Usually, mechanical design needs to select the appropriate materials according to the requirements of mechanical equipment and the use of the environment, etc. These materials need to have good mechanical properties, thermal stability, corrosion resistance, processability and reasonable cost characteristics.

Consider structural strength: In mechanical design, structural strength is an important consideration. The structural strength of each part needs to be reasonably allocated in the design to ensure the stability and safety of mechanical equipment. Especially for the load-bearing key parts, careful strength calculation is needed to ensure that they meet the strength requirements.

Optimization of structural design: In the process of mechanical design, the optimization of structural design should be taken into account to improve the efficiency, reliability and productivity of mechanical equipment. Structural optimization can be achieved by reducing the number of parts, improving the materials of parts, and optimizing the layout.

Pay attention to assembly and maintenance: mechanical equipment requires frequent maintenance and overhaul, and the design should take into account the maintainability and easy installation of the equipment. Designers need to fully consider the installation and maintenance of components in the mechanical design to facilitate the use and maintenance of machinery and equipment.

Electrical control

Electrical control is one of the key technologies in the design of non-standard automation equipment, including electrical system design, PLC programming, sensor selection, drive selection and other aspects. Electrical control needs to take into account the control logic of the equipment, operational safety, and durability of the equipment.

Several electrical design tips are listed below:

Determine the design objectives: Before the electrical design, the electrical requirements of the non-standard automation equipment need to be determined, including voltage, current, power, and control mode, which are the basis of the electrical design. At the same time, the actual application of the equipment and the use environment need to be considered to ensure the safety and reliability of the electrical design.

Selecting suitable electrical components: The electrical design needs to select suitable electrical components according to the requirements of the equipment and the use environment, including motors, switches, contactors, fuses, transformers, capacitors and so on. These electrical components need to have good quality, reliability, safety and reasonable cost, etc.

Reasonable design of electrical wiring and layout: In the process of electrical design, it is necessary to reasonably design the electrical wiring and layout to ensure the safety and reliability of the equipment. Especially for high-voltage and high-current electrical parts, attention needs to be paid to the isolation and protection of the circuit to ensure the safety of personnel and equipment.

Make good electrical insulation design: In the process of electrical design, electrical insulation design needs to be taken into account to ensure the safety and reliability of the electrical part. In the electrical insulation design, the insulation performance of electrical components, wiring insulation, grounding and lightning protection need to be taken into account.

Optimization of circuit design: In the electrical design process, the optimization of circuit design should be considered to improve the efficiency, reliability and productivity of the equipment. Circuit optimization can be achieved by reducing the power loss of electrical components, reducing circuit noise, and improving the current waveform.

Software Development

Non-standard automation equipment usually needs to be equipped with special control software to achieve efficient, stable and reliable operation of the equipment. Software development needs to take into account the control logic, human-machine interface, data management, etc. of the equipment.

Several software design tips are listed below:

Determine design goals: Before software design, the software requirements and functional needs of the non-standard automation equipment need to be clarified, including the functions to be achieved, performance indicators, data processing methods, etc. According to these requirements, choose the appropriate software development platform and technical solutions to ensure the feasibility and reliability of the software design.

Modular design: The entire software system is divided into several independent modules, each module is responsible for completing a specific function, and the modules communicate with each other through interfaces, which simplifies software design and maintenance, and improves software reliability and scalability.

Well-designed algorithms: In the software design process, the design of algorithms needs to be taken into account to achieve efficient implementation of device functions. Reasonable selection of data structures and algorithms, optimization of algorithm efficiency and complexity, ensure high performance and low resource consumption of software design.

Exception handling: In the software design, the handling of exceptions, such as input data errors, hardware failures, etc., needs to be taken into account, and these exceptions need to be handled effectively to ensure the stability and safety of the software system.

Code specification: In the process of software design, good code specification needs to be observed to keep the readability and maintainability of the code. Reasonable design of software architecture and code structure, use of meaningful variable and function names, and clear comments to ensure the readability and maintainability of the software design.

Project management skills

The design and manufacturing of non-standard automation equipment is a complex process that involves multiple departments and links. The manufacturer needs to have project management skills to coordinate the work of various departments and processes to ensure the smooth running of the project.

Several project management techniques are listed below:

Define the project objectives and scope: Before the project starts, the project objectives and scope need to be defined, including the project requirements, functions, tasks, time, cost, risks, etc., to ensure that all project stakeholders agree on the expectations and goals of the project.

Develop a detailed plan: Before the project starts, a detailed project plan needs to be developed, including project work tasks, schedule, resource requirements, risk management, etc. The project plan needs to be realistic, taking into account project resource constraints and uncertainties to ensure the project is feasible and manageable.

Have a strong team: Project management requires effective team management and leadership skills, including forming, training, motivating, and managing project teams. Team members need to work closely together, communicate and collaborate effectively to ensure efficient project execution and quality.

Monitor and control project progress: During project implementation, the project progress needs to be closely monitored to identify and resolve project schedule delays and ensure that the project proceeds according to plan to avoid wasting time and resources.

Risk management: During the project implementation process, it is necessary to develop an effective risk management plan, assess and analyze various risks that the project may face, and develop response strategies to reduce the impact and loss of risks.

Communication management: In the process of project implementation, it is necessary to strengthen the communication between project stakeholders, provide timely feedback on the project progress, solve various problems and ensure the smooth implementation of the project.

Manufacturing process and technology

The manufacturing process and technology of non-standard automation equipment has a crucial impact on the quality, efficiency and performance of the equipment. The manufacturer needs to have certain manufacturing process and technology capabilities and be able to select the appropriate manufacturing process and technology according to the requirements and demands of the equipment to ensure the quality and performance of the equipment.

Internal Review:
Organize internal experts to comment on and review the overall scheme of preliminary design.
Main points:
1. To find out design defects as much as possible to avoid major losses caused by program errors.
2. Various modifications by internal experts need to be finalized by authoritative experts whether to modify according to them.

Refined design:
Design all details and complete all design documents according to the scheme adopted by the client.
Key points:
1. Identify the long-cycle outsourcing parts type and place purchase order as early as possible at the beginning of the refinement design.
2. Check carefully within each view to ensure that all parts do not interfere.
3. Express all details in the drawing as clearly as possible.
4. Ensure that each part has clear material, surface treatment and heat treatment requirements.
5. Perform dimensional chain analysis on critical dimensions to ensure that nominal dimensions and tolerances meet design requirements.

Non-standard automation equipment in the field of automatic assembly internal review of common mechanical mechanism audit content reference:

In the automated production, mechanical mechanism as an important part of the automation system, its performance and reliability is essential for the operation of the entire production line reference such as the following mechanical mechanism classification and its characteristics.

I. Linkage mechanism

The linkage mechanism is a mechanism that converts rotary motion into reciprocating motion, and is often used to realize the positioning and transfer of workpieces. According to the number of connecting rod, it can be divided into three linkage mechanism, four linkage mechanism, etc. At the same time, the linkage mechanism can be further divided into crank rocker mechanism, single and double slider mechanism, tie rod mechanism, etc. according to the different structural forms. Among them, the four-link mechanism has the advantages of high transmission accuracy and stable motion, and is widely used in non-standard automation production.

Second, the reduction mechanism

Reduction mechanism is to convert high speed motion into low speed and high torque motion to meet production needs. In the non-standard automatic assembly, reduction mechanism is widely used in various transfer mechanisms and robots and other automation equipment. Common reduction mechanisms include cycloid reducer, planetary reducer, circular arc gear reducer, etc. Different reduction mechanisms need to be selected according to the required reduction ratio, torque transmission and other factors when they are used.

Third, the transmission mechanism

Transmission mechanism is a mechanism to transfer rotary motion to another component, used to achieve a variety of manipulators and transmission mechanism power transmission. Common transmission mechanisms are gear transmission, belt transmission, chain transmission, etc.. Among them, gear transmission has the advantages of high transmission efficiency and high transmission accuracy, which is widely used in non-standard automatic assembly.

Fourth, the guide mechanism

The guiding mechanism is mainly used to realize the positioning and guidance of the workpiece in the automatic production line. In the non-standard automatic assembly, the guiding mechanism is widely used in various transfer mechanisms, assembly lines, robots and other equipment. The common guiding mechanism includes slider guiding mechanism, roller guiding mechanism and bearing guiding mechanism. Among them, the roller guide mechanism has the advantages of high precision guidance, good wear resistance, etc., and is widely used in automated production.

V. Clamping mechanism

Clamping mechanism is a mechanism used to clamp the workpiece, commonly used in automated assembly and processing. In the non-standard automated assembly, clamping mechanism is widely used in a variety of robots and transfer mechanisms. Common clamping mechanisms are pneumatic clamping mechanism, hydraulic clamping mechanism, mechanical clamping mechanism, etc.. Among them, the pneumatic clamping mechanism has the advantages of high clamping force, speed, etc., in the non-standard automated assembly is widely used.

Six, the pendulum mechanism

Cycloid mechanism is mainly used to convert the rotary motion into oscillating motion. In the non-standard automatic assembly, the cycloid mechanism is widely used in various robots and transfer mechanisms. The common cycloid mechanism includes cycloid pinwheel mechanism, cycloid mechanism, crank cycloid mechanism and so on. Among them, the cycloid mechanism has the advantages of high oscillation precision and high transmission efficiency, and is widely used in non-standard automatic assembly.

Seven, parallel mechanism

Parallel mechanism is a mechanism that converts parallel motion into parallel motion. In the non-standard automatic assembly, the parallel mechanism is mainly used to realize the translational motion of various robots and transfer mechanisms. The common parallel mechanisms are parallel four-link mechanism, plane rocker mechanism and so on. Among them, the parallel four-link mechanism has the advantages of smooth motion and high transmission efficiency, which is widely used in the non-standard automatic assembly.

Eight, flexible mechanism

Flexible mechanism refers to the mechanism with flexibility in a certain range, which is often used in the field of automated assembly and robotics. Flexible mechanism can realize complex movement through the strain of flexible materials, and has the advantages of deformation ability and self-adaptability. Common flexible mechanisms include flexible arms, flexible feet, flexible hands, etc. Among them, the flexible arm can realize complex bending motion and has a wide range of application prospects.

Nine, drive mechanism

Drive mechanism is an important part of the mechanical mechanism, used to achieve a variety of motion drive. In the non-standard automatic assembly, the drive mechanism is widely used in various robots and transfer mechanisms. Common drive mechanisms are motors, cylinders, hydraulic motors and so on. Among them, the motor has the advantages of simple structure and high control accuracy, which is widely used in the non-standard automatic assembly.

Ten, sensor mechanism

Sensor mechanism is used to sense the environment and real-time monitoring of mechanical motion status, commonly used in the field of automated assembly and robotics. In the non-standard automatic assembly, sensor mechanism is widely used in various robots and transfer mechanisms. Common sensor mechanisms include photoelectric sensors, pressure sensors, displacement sensors, etc. Among them, photoelectric sensor has the advantages of fast response speed and high accuracy, which is widely used in non-standard automatic assembly.

Eleven, control mechanism

Control mechanism is used to control the mechanical movement of the mechanism, commonly used in the field of automated assembly and robotics. In the non-standard automatic assembly, control mechanism is widely used in various robots and transfer mechanisms. Common control mechanisms include PLC controllers, servo controllers, encoders, etc. Among them, PLC controller has the advantages of flexible programming, stability and reliability, which is widely used in non-standard automatic assembly.

XII. Positioning mechanism

Positioning mechanism is used to achieve the positioning and clamping mechanism of parts, commonly used in the field of automated assembly and robotics. In the non-standard automatic assembly, positioning mechanism is widely used in a variety of robots and transfer mechanisms. Common positioning mechanisms include positioning pins, clamps, etc. Among them, clamps have the advantages of simple structure and easy operation, which are widely used in non-standard automated assembly.

Thirteen, commutation mechanism

The commutation mechanism is a mechanism used to realize the change of motion direction, which is often used in the field of automatic assembly and robotics. In the non-standard automatic assembly, the commutation mechanism is widely used in various robots and transfer mechanisms. Common commutation mechanisms include gears and sprockets. Among them, gears have the advantages of high transmission efficiency and high precision, and are widely used in non-standard automatic assembly.

XIV. Safety mechanism

Safety mechanism is used to protect the safety of workers, commonly used in the field of automated assembly and robotics. In the non-standard automatic assembly, safety mechanism is widely used in various robots and transfer mechanisms. Common safety mechanisms include safety light curtains, safety switches, etc. Among them, the safety light curtain has the advantages of large detection range and fast response time, which is widely used in non-standard automatic assembly.

15、Auxiliary mechanism

Attachment mechanism is used to assist the mechanical movement of the mechanism, commonly used in the field of automated assembly and robotics. In the non-standard automatic assembly, the attachment mechanism is widely used in various robots and transfer mechanisms. The common attachment mechanisms are cylinders, solenoid valves, etc. Among them, the cylinder has the advantages of high speed and high force, which is widely used in the non-standard automatic assembly.

Client Review:
Organize key people from the client to comment and review the proposal passed by the internal review.
Key points:
1. Keep detailed records of all questions and ideas raised by the customer.
2. Discuss and communicate the issues that are not understood by the customer to avoid any loss from them.
3. Record the parts agreed by the customer and the parts that the customer clearly proposes to modify and sign the confirmation by both parties.

Document Review:
Organize the program evaluation designers to review the design documents completed by the refinement design.
Key points:
1. Review the material selection and heat treatment method of the parts for suitability and surface treatment for compliance.
2. Check that all contact dimensions and fit characteristics are correct.
3. Check whether the selection of outsourcing parts is appropriate.
4. Check whether the design documents (including assembly drawings, BOM tables, parts drawings, etc.) are complete

Reasonable choice of outsourcing parts

a) As the saying goes, “you get what you pay for”, but not the more expensive, the better.

b) Formulate the selection guide of standard parts in the company, including the common types of standard parts, brand classification, application occasions, etc.

c) Select the most commonly used basic types as far as possible when selecting.

d) Reduce as much as possible the types of outsourced standard parts.

5) Adopt mature principle structure as much as possible to reduce design risk

Short lead time and long lead time procurement according to the international first-class brands and list the material schedule to facilitate internal management and let customers know the customer’s production cycle.

10 notes on the assembly process of automated equipment
1. Separate assembly operations as much as possible
(1) Easy to decompose into components in order to realize the assembly classification including pre-assembly and end assembly.
(2) Decompose into several assembly units to facilitate parallel operations, shorten the assembly cycle, and facilitate maintenance.
Before the improvement, the bore diameter was smaller than the outer diameter of the gear, and the gear had to be assembled in the box; after the improvement, the parts on the shaft can be assembled first and then installed in the box, which not only improves the work efficiency but also facilitates maintenance.
(3) One end of the acceleration stroke shaft of the turret lathe is installed in the box on the machine body, which is inconvenient to assemble; after improvement, the acceleration stroke shaft is connected by coupling, and the box becomes a separate assembly unit.
(4) The transmission gear is preformed into a separate gearbox and then mounted into the box, which is easy to adjust and assemble.
(5) The assembly group can be tested separately and should be so in variant design in the first place.
(6) Strive not to test individual parts but to test the function of the assembled components or products.
2. Reduce assembly operations
(1)Combine parts together by means of an integrated structure or combined structure.
(2) Reduce the number of coupling elements by using bonding or clamping.
(3) Self-acting alignment and positioning as much as possible.
(4) Reduce the number of parts by functional synthesis.
(5) Simultaneous assembly operations.
(6) Reduce the number of joining parts and surfaces.
(7) It is not necessary to disassemble the assembled components or products for functional testing.
(8) Avoid cutting during assembly. Figure a. After the sleeve is installed into the body, drilling and tapping are required, which increases the assembly workload and prolongs the assembly cycle. After the improvement (Figure a’) shaft or sleeve with the pressure plate stuck in the shaft or sleeve annular groove on the body, the pressure plate can be manufactured by stamping method, the threaded hole on the body can be machined in the cutting shop.
(9) As far as possible, the assembly does not require manual repair.
3. Unify and simplify assembly operations
(1) Adopt uniform jointing direction and jointing method for each component as far as possible.
(2) Select the appropriate joining method to reduce the total labor for machining and assembly.
Depending on the actual situation, sometimes a symmetrical alignment configuration is used, which can simplify assembly. The groove inside the bushing in Fig. a’, with symmetrical structure, is easier to align than the groove and hole in Fig. a, simplifying the assembly.
(3) The use of elastic retaining ring instead of cotter pin and washer can improve the assembly efficiency.
(4) Using elastic washers instead of screws and washers.
(5) Flat retaining ring instead of shoulder, curved retaining ring can limit the gear axial position.
(6) When the axial load is small, use elastic retaining ring instead of flange, nut and shaft shoulder to facilitate assembly and improve assembly efficiency.
4. To ensure the quality of assembly
(1) should set a positioning reference, Figure a two flanges with ordinary bolts, two flange shaft hole has coaxiality requirements, no positioning reference when it is difficult to meet the coaxiality requirements.
Hydraulic cylinder requires the hole on the cylinder head and the cylinder body round surface coaxial. If the cylinder cover 2 and cylinder body 1 are directly connected by thread 3 as shown in figure a, the coaxiality between the threads cannot be guaranteed and the piston rod is easily shifted because of the clearance between the threads. After improvement (Figure a’) another assembly base surface 4 is set.
There should be no radial clearance between the two cone wheel brackets 1 and 2 and the frame, and the assembly base should be set.
(2) the correct arrangement of positioning pins: Figure a support seat installation with two pins positioning. According to the left layout, because the left and right two pin holes to the support axis distance is not required and can not be processed absolutely equal, such as the left hole distance is a + △, the right hole distance is a – △, if the support inadvertently turn 180 ° installation, then the left hole distance is a – △, the right hole distance is a + △, and make the support axis than the original correct position to the left offset 2 △. The improved design (Figure a’) can avoid the above error.
(3) the use of structural measures to compensate for errors: Figure a’ a pair of cylindrical gears in the pinion than the large gear slightly wider than when there is an assembly error, but still ensure that the two teeth along the full tooth width mesh, which can ensure the installation requirements under the premise of reducing the requirements of assembly accuracy.
Figure left and right shoulders do not respectively with parts 2 and bearing inner ring end face to take flush, so as to ensure the installation requirements, but also reduce the requirements of machining accuracy and to avoid assembly repair work.
(4) The use of adjusting parts. As shown in the structure, the outer ring of the bearing and bearing cover 2 between the addition of ring-shaped parts 1, its thickness in the assembly according to the measurement results formulated, the axial size of the component can be machined according to the free tolerance, the accumulated axial error available parts 1 compensation, to ensure the fixed requirements of the inner and outer ring of the bearing.
As shown in the figure is a bevel gear mechanism with high assembly accuracy requirements, requiring the knuckle cone of the two wheels to co-top to ensure correct meshing. Therefore, the assembly should enable the two wheels to move along their respective axes in a controlled manner so that the two wheels can be adjusted to the required proper position. The axial position of the pinion gear is adjusted by shim 1, and the axial position of the large bevel gear is adjusted by shim 2 at both ends of the bearing cover.
Repairing the thickness of the two adjusting pads 1 and 2 can ensure the correct meshing of the two bevel gears.
Use adjusting shim 1 to adjust the coaxially between the screw support and the nut.
When assembling the worm drive, it is necessary to ensure that the worm axis 1 coincides with the midline 2 of the worm gear tooth crown and use the change of the adjustment pad thickness a to adjust the worm axial position to ensure the accuracy of the worm wheel and worm gear meshing.
(5) To avoid double fit to obtain clear positioning and to reduce dimensional tolerance.
(6) To avoid two sections of mating surfaces entering at the same time, Figure a, should be changed to Figure a’. Figure b worm shaft into the box, the two bearing outer rings are not simultaneously but one after the other into the bearing hole joint surface.
(7) Figure a structure in the assembly of part 1, its keyway and the key on the shaft to align more difficult. With the improved design (Fig. a’), the key and keyway are easily aligned.
(8) Use of elasticity to reduce the tolerance requirements for the assembly parts.
(9) When the shaft and hub are tight fit, the shaft diameter protruding from the hub must be turned smaller to facilitate loading and unloading.
(10) Divide the large joint surface into several small surfaces.
5. Should be easy to assemble
(1)Enough space should be left for the height of the screw and enough space for the wrench to move.
(2)Figure a is difficult to assemble, Figure a’ is slightly better to open the process hole beside, and Figure b’ uses double-headed studs to facilitate assembly.
(3)When punching in the pin, there should be an air escape outlet to prevent air from staying in the hole and facilitate assembly.
(4) In order to facilitate loading and unloading, ensure the bearing position, the right end of the shaft diameter should be slightly smaller than the diameter of the journal, so as not to install and remove the bearing when the abrasion of the shaft surface.
(5) Mating parts should be chamfered for assembly. If chamfered 15 ° ~ 30 °, there is a guide part assembly easier.
6. Should be easy to disassemble
(1) for easy disassembly of static fit 1 part, should be configured to disassemble the screw or use a tapered pin with a disassembly screw hole.
(2) Figure a bearing inner ring or Figure b bearing outer ring is not easy to disassemble, should make the shoulder height less than the thickness of the inner ring (Figure a’), or hole convex shoulder height less than the thickness of the outer ring (Figure b’).
(3) The end cover should be left with process screw holes to facilitate the removal of the end cover and avoid damaging the parts with abnormal disassembly methods.
(4) The shaft with a stop rotation device should be considered for easy disassembly. The pin provided in Fig. a can prevent the shaft from turning, but the disassembly of the shaft is more difficult. Change to the structure of Fig. a’, it is easy to disassemble.
7. Consider the craftiness of threaded coupling
If the depth of the screw hole is too large, the bolt will not be tightened or the thread of the hole will be damaged. It is necessary to control the length of the thread and the depth of the screw hole on the bolt or countersink the hole at the mouth of the screw hole to ensure that the bolt is tight.
Figure a only stops the nut, but not the bolt, after the improvement (Figure a’), it stops the bolt and the nut at the same time to ensure the reliability of the stop.
Figure A can not be stopped because there is not enough space around the installation position to bend the claw of the stop washer. After the improvement (Fig. a’), the riding seam screw is used to ensure reliable stopping.
High-speed rotating body coupling bolts of the head, nut and other protrusion, both affect the safety and easy to cause a variety of adverse effects, should be made to sink.
Chemical pipelines and other flange bolts are arranged in the positive below susceptible to corrosion from leaking solutions.
The end face of the nut is not necessarily perpendicular to the thread, there is a gap in the thread, and there is also parallelism error on both ends of the fastener being fastened, and if strong fastening is done at the center of the long shaft, it is easy to make the shaft bend.
When using multiple countersunk head screws, it is not possible to keep the tapered surfaces of all screw heads in the good joint, and the displacement between the couplings will cause the screws to loosen.

Installation and commissioning and site start-up are part of the test of automation project construction capability, and rich field experience is a key point to ensure successful equipment commissioning and system performance. From the production and installation of a production line to the tightening of a screw, our engineers are dedicated to getting the job done. Before the equipment is shipped, we will pre-install and debug it in our factory, and complete most of the debugging and improvement work before the equipment is officially operated, in order to minimize the impact of the equipment installation on the production of the customer’s factory site.

Internal Review:
Organize internal experts to comment on and review the overall scheme of preliminary design.
Key points:
1. To discover design defects as much as possible to avoid major losses caused by program errors.
2. Various modifications of internal experts need to be finalized by authoritative experts whether to modify according to them.

I. Technical requirements

(A), structural requirements
(1). Mechanical mechanism design needs to comply with ergonomics, convenient for personnel operation and maintenance;
(2). Mechanical structure design should be calculated to achieve the strength requirements for normal use and within the safety margin;
(3). The design of the mechanical structure should be based on our specific requirements and FEMA analysis and verification of key points;
(4). The overall design of the mechanical structure should consider the principles of economy, environmental protection and safety.

(2) Material requirements
(1). Structural parts and panels require Q235 steel, transmission parts and general parts require 45#, heat treatment parts require 20-40Cr or other specified materials, all kinds of profiles must be national standard profiles, special requirements according to the specific needs of equipment design;
(2). All materials must have the corresponding certificate of conformity or inspection certificate that meets the quality requirements;
(3). For the materials of special parts, the test report should be provided at the same time, the report mainly involves: composition, mechanical properties, physical properties, etc.

(C), the steel surface requirements
(1). The surface of steel structure parts should be treated by sandblasting, rust removal grade Sa2.5; if the surface treatment is carried out manually, it should be between St2 and St3.
(2). After sandblasting, the primer should be sprayed with red-dan antirust paint once, and the top paint with alkyd blending paint twice, with a total dry film thickness of 125μm; the adhesion should reach ISO grade 1 or ASTM grade 4B;
(3). The surface of the structural parts cannot have obvious defects such as deformation, scratches, bruises, grooves, convexity, missing and delamination.

(D), welding requirements
(1). All welding is required to have the corresponding welding specifications and standards, and welding process verification;
(2). (2). On-site welding is required to meet the requirements of the welding specification;
(3). (3). The weld surface should not have cracks, porosity, slag, unfused, underweld, dummy weld, shape defects and other defects other than those mentioned above;
(4). The butt welds of the flange plate and web plate in the tensioned area of the main beam should be non-destructive, and the ultrasonic flaw detection should be no less than Class I in 11345, and a copy of the report should be provided.

(E), transmission requirements
(1). Transmission design needs to consider the transmission efficiency optimization;
(2). (2) The transmission mechanism requires simple and reasonable, with the least link to achieve the function;
(3). (3) The transmission design should consider the site noise control, and do everything possible to reduce the noise generation;
(4). Transmission (SIEMENS or SEW), motor (SIEMENS or SEW inverter motor), bearings (SKF or NSK) and other components required to specify the manufacturer or brand;
(5). The range of variable frequency motors used: fans, the need to adjust the speed of the drive mechanism, the need to work with the drive mechanism of the transmission system.

(F), hydraulic system
(1). Hydraulic system should ensure its safety, the system’s ability to run continuously, maintainability and economy, and to ensure that the system’s service life is extended;
(2). (2). All components of the system should be designed or otherwise protected against pressure exceeding the maximum working pressure of the system or any part of the system and the rated pressure of each specific component;
(3). The system should be designed, manufactured and adjusted so that the shock pressure and surge pressure are reduced to a minimum. Shock pressure and surge pressure should not cause a hazard;
(4). Should be considered due to blockage, pressure drop or leakage and other reasons affecting the consequences of the safe operation of the components;
(5). Whether the expected or unexpected mechanical movement (including acceleration, deceleration or lifting/clamping of objects) should not cause a dangerous condition for personnel;
(6). System design needs to minimize piping, pipe joints;
(7). Hydraulic system needs to achieve dustproof, explosion-proof function; (7);
(8). (8). All actuators, fittings, valves and other components need to be easily accessible and easy to operate;
(9). Hydraulic system control unit and execution unit to choose Rexroth and other brands, and use the same company products;
(10). (10). In principle, the piping is hard-linked, and only soft connections are used when necessary;
(11). Oil pipe must be phosphate pickling treatment, clean up, the internal tank needs to be sand treatment and de-slagging clean up;
(12). (12). The location of the oil pipe joint should be in an easy to disassemble location, the oil inlet pipe and the oil injection hole should be installed with a filter, and the valve should be made of stainless steel and easy to replace.
(13). (13). The hydraulic system needs to consider the problem of leakage handling during maintenance, and ensure that all joints are within the pressure range and no leakage will occur;
(14). Before assembly should be carefully cleaned components, pipeline accessories, hydraulic components, etc., there should be no dirt impurities.
(15). Pipe length and actual location of the piping, the specific determination, the installation of each pipe in the case of easy maintenance without violating the principle of the system, allowing bending and slight changes according to the actual situation;
(16). After the tube is pre-installed, it must be removed for acid cleaning, and then the second installation;
(17). Pumping station after installation and before commissioning should be repeatedly cyclically cleaned to remove all impurities and dirt so that the contamination level reaches NAS7;
(18). The test reaches the design pressure and shall hold the pressure for 10 minutes, and there shall be no leakage at each connection;
(19). After passing the test, all the hydraulic oil should be emptied, and then the pipeline will be plugged and sealed to prevent contamination;

(vii), pneumatic system
(1). (1) The pneumatic system should ensure its safety, the system’s ability to run continuously, maintainability and economy, and can ensure that the system’s service life is extended;
(2). (2). The pneumatic system control unit and execution unit choose SMC or FESTO brand, connectors and other connecting parts such as the above;
(3). (3). The pipeline in principle with hard connections, and only when necessary to use soft connections;
(4). (4). The air pipe must be phosphate pickled and cleaned;
(5). (5). The movable joint is in the form of pulling and inserting, and the valve is made of stainless steel and easy to replace;
(6). (6). All components of the system should be designed or otherwise protected to prevent the pressure from exceeding the maximum working pressure of the system or any part of the system and the rated pressure of each specific component;
(7). The system shall be designed, manufactured and adjusted so that the shock pressure and surge pressure are reduced to a minimum. Shock pressure and surge pressure should not cause a hazard;
(8). Should be considered due to blockage, pressure drop or leakage and other reasons affecting the consequences of the safe operation of the components;
(9). Whether the expected or unexpected mechanical movement (including acceleration, deceleration or lifting/clamping of objects) should not cause a dangerous state for personnel;
(10). When the sound pressure level caused by the exhaust exceeds that permitted by applicable regulations and standards, mufflers shall be used at the exhaust port. The muffler used in the exhaust port itself should not create a hazard. The muffler should not produce harmful sound pressure.

(H), lubrication system
(1). All key rotating and sliding parts of transmission parts should have lubrication points;
(2). (2). For the difficult to approach the lubrication point, need to be led to the accessible position, convenient for personnel lubrication; (3);
(3). If the lubrication point is relatively concentrated, need to design for centralized lubrication form; (4);
(4). For all lubrication points, must provide lubrication standards, including: lubricating oil type, lubrication cycle, lubrication mode;
(5). The overall design of the lubrication system needs to consider the economy, safety and reliability;

(ix), safety and security
(1). (1). All accessible rotating or moving equipment, exposed transmission parts, rotating parts, etc. are required to do a good job of protection and isolation measures;
(2). (2). Dangerous areas and dangerous locations need to have active protection systems (such as infrared, etc.);
(3). (3). The parts to be maintained at height should have ladders and fall protection measures and maintenance platforms;
(4). (4). Hazardous parts and areas need to be distinguished by color; (5);
(5). (5). It is desirable to have active collision prevention measures, safety signs and warning signs between each part of the equipment or workpiece;
(6). For the conveyor line, the staff should be able to achieve emergency stop operation at any position; the emergency button should be reasonably located, and the switch should be locked;
(7). Certain aspects of the design and manufacture of protective devices should be tested by means of tests, inspections, trials or calculations, etc. The tests should be carried out in the working condition of the protective devices as far as possible;
(8). If necessary, the protective device needs to do impact resistance test. Test the strength of the guard against impact should take into account the characteristics of the materials used in the manufacture of the guard, including the strength of the connections used to connect the guard to the machine or other structure, the strength of the fixing points and the strength of the slide, etc;
(9). Safety guards should not affect the operational status of the observation equipment;

(X), other
(1). (1) Environmental requirements: emission requirements such as exhaust gas, water, noise, etc. should be installed in accordance with national standards, the whole machine should not leak oil, and the materials used should be environmentally friendly as far as possible;
(2). Energy requirements: each power facility design safety margin is reasonable (5% – 25%) control reasonable each electricity, water, gas and other equipment switch control reasonable, reduce energy consumption;

Non-standard automation equipment acceptance criteria
I. Mechanical parts

Paint acceptance:

Smoothness: thickness: color difference

Processing part acceptance: welding part

Whether the external surface size is qualified, whether there is edge biting, porosity, cracks, burn through, weld tumor, arc pit phenomenon size part

Conventional inspection, assembly inspection, acceptance

Second, the electrical part

Non-standard automation equipment needs to meet the technical requirements of

1 Operation panel

1) The operating panel is properly positioned for easy operation

2) indicator lights (tower lights) set complete different functions of the indicator lights set different colors, green (power) yellow (status) red (fault)::
3) key switch set complete, able to move the module alone, the need for a corresponding manual switch::
4) Emergency stop button, connected to a normally closed point:

5)Panel all buttons, switches that can be operated to have a clear indication of the sign, and fixed::

6) equipment in motion, regardless of any position to stop the device, requires the ability to manually operate the reset and continue to run automatically::

7) After an emergency stop of the equipment, the reset operation must be carried out before the manual operation (except for testing and debugging work) reset, and then automatically run again::
8) The panel needs to have a fixed storage protection position, and the lead of the panel should be solid and reliable and leave an operating margin::
9) The operating table should be reasonably arranged to facilitate maintenance and replacement::
10) Mobile operating table must be built-in separate grounding::
11) There are other environmental requirements of the operating table need to do a good job of dustproof waterproof and other sealing measures.

2 control cabinet

1) Control cabinet signage, equipment model, electrical capacity and other technical parameters:
2) Control cabinet to have a power main switch, installation of lighting:

3) There are sockets, 220V 10A or more sockets (according to the needs of the equipment):

4) Each module in the cabinet should be labeled and consistent with the name on the drawing::
5) Cabinet set aside 10% of the installation spare position::
6) terminal block the same terminal only allows a maximum of 3 wires::
7) The terminal block needs to be reserved for spare position:
8) Spare wire should be reserved 10%, and marked with the line number::
9) Each module fixed position is reasonable, easy to disassemble::
10) Electrical wiring should be marked (both ends), and consistent with the drawings::
11)The motion device emergency stop, safety device interlock signal, to have hardware (relay) contact interlock, not only software interlock::
12) grounding of the electrical box, the environment requires good sealing measures such as dustproof:
13) Strong and weak power must be configured separately or separated in the middle.

3 peripheral wiring

1) The total electrical box and peripheral connection lines using wire channels or button-type insulated cloth and other connections, shall not directly use the cable::
2) All wire connections must be made through terminal blocks, no point-to-point joints are allowed:
3) Cable, bellows through the box body need to use standard connectors, not directly in and out of the box::
4) Wire threading in the slot using the appropriate standard soft wire, and set aside 10% of the spare line length::
5) wire interface, corner location, terminal head to do appropriate protection::
6) DC and AC lines are wired separately, and the ground line uses a special yellow and green wire:
7) strong and weak power alignment, the line groove should be separated to avoid crossover.

4 drive part

1) servo motor to have the direction of rotation indication, there is a corresponding overcurrent, overload protection, installation location to be reasonable, set aside for disassembly and installation, the motor junction box to be grounded separately::

2) The exposed part of the coupling joint should be protected.

5 External electrical modules

1) Travel switches, proximity switches, solenoid switches need to be reasonably arranged to facilitate debugging:

2) Each module is fixed firmly, and should have its own label, name, number, etc., consistent with the drawings, and each label facing outward for easy observation.

6 Power supply part

1) The equipment should be able to adapt to the three-phase 38OVAC50H memory grid environment (variable voltage needs to compound the local power supply environment):
2) DC control power supply needs to choose a switching power supply, high stability::
3) DC load power and DC control power need to be set separately.

7. Air equipment

1) Air source part must have a cut-off switch:

2) There must be a main control valve on the air line of the equipment. When it stops unexpectedly, the main control valve can release the remaining pressure quickly to avoid secondary injury.

8 Other

1)Power supply line, power line connection wire with copper wire (not less than 2.5mm) control line not less than 1.5mm.
2)Equipment with protective measures according to the requirements need to be retrofitted with suitable protective equipment::
3)All equipment needs to meet the requirements of the relevant local national import safety regulations;
4) Other outstanding matters are to be executed in accordance with the relevant national standards and specifications.

III. Drawing information

Equipment need to provide the following information

1) Equipment use, maintenance, installation and commissioning instructions:

2)Electrical schematic maintenance circuit diagram (PLC), according to the requirements of the agreement to confirm whether to provide:

3)Conventional information: list of devices (manufacturers, models, etc.), list of consumables:

4) Electrical drawings to comply with CE safety regulations standards and industry standards and norms, the requirements are clear and standardized.

Fourth, the whole machine operation acceptance

1 Performance acceptance

1) Open the equipment and verify the basic information and location (signal light, pressure gauge, control panel, working position):

2)Test whether the working of the moving part is normal, the pneumatic part (cylinder, etc.), the electric part (servo motor) is working normally:
3) Check and test the reasonableness of the work position clamping.

2 Repeatability, load test

1) Clamp the workpiece and carry out the simulation work test (10 ~ 1000 pieces)

2) Test the positioning accuracy in repeated work, whether the workpiece finished meets the requirements, and count the passing rate of:

3) Continuous testing. Acceptance of work compressive strength, current load, air pressure strength, oil pressure, motion component break-in, detailed records are archived for easy access and improvement::

(4) Continuous testing process, monitoring equipment wear parts, statistical wear frequency, to facilitate after-sales maintenance.

3 Other acceptance

1) Whether the equipment meets the functions required by the technical agreement:
2)Whether the structure of the equipment is reasonable, including but not limited to whether the motion control interferes with each other, whether the servo motor output is matched, and whether there is a risk of rigidity in the structure:
3)Safety assessment, for example: in case of sudden power failure, can all motion modules of the equipment immediately stop moving to avoid hurting the operator: and when the equipment is working, personnel enter the dangerous area with or without corresponding safety measures.

Need to provide packing list of goods (such as product name, number of pieces, number of boxes, product specifications, net weight, gross weight, brand, model, customs port, consignee and consignor information, etc.). Information: IPPC mark, bill of lading, box list, invoice, contract.

Mechanical equipment import and export process procedures: booking cabin (booking warehouse) – do container – pick up – inspection – customs clearance –Goods on board the ship out of the bill of lading (warehouse) – shipping – destination port.

Machinery and equipment import customs clearance before the need to prepare the information: machinery and equipment packing list, machinery and equipment commercial invoices, machinery and equipment certificate of origin, product specifications, signed trade contracts, bills of lading and other related information.

Reminder: Before import and export of machinery and equipment to confirm the relevant shipping schedule and the information required for customs clearance; gross weight data should be as accurate as possible to avoid inaccurate data resulting in customs detention.

Information required for export customs declaration:

1. Consignee and consignor information, import and export business rights, information related to export equipment (such as product name, number, number of boxes, product specifications, net weight, gross weight, brand, model), international trade contracts, formal invoices

2. Packing slips, sea/air/land bills of lading, product information: name, equipment usage, processing method, new and old degree

Export notes:

1. First confirm the detailed list of exported machines before exporting, and confirm with the customs broker whether the machines can be cleared smoothly after arrival at the port. Whether there is a need for special attention.

2. Before loading the container, please provide clear photos of the container, including photos of the empty container before loading (floor, container wall), and photos of the half container and after loading, after sealing (seal number, closing photos) to avoid some large machinery and equipment in the loading and unloading process, causing damage to the floor or wall of the container, and additional repair costs when returning the container.

3. When loading the cabinet must be the machine on the oil diesel put dry, such as machine oil leakage must be processed also in out, otherwise the destination port also cabinet will have to wash the cabinet fee generated, flammable and explosive goods are strictly prohibited to load the cabinet.

4. The solid wood pallets required for export must be fumigated and stamped with IPPC logo, plywood pallets export is not restricted.

Automation equipment manufacturers are obliged to provide the necessary training to maintenance personnel:

(1). Training of equipment control principles.

(2). The training of equipment structure.

(3). The operation, programming, setting and monitoring of special control systems.

(4). Necessary general knowledge of repair and maintenance.

Final acceptance work content

(1). According to the technical requirements, check each part of the equipment item by item to see if it meets the requirements, and request the manufacturer to rectify the unqualified items.

(2). Check whether the equipment conforms to the safety norms. Protective fences, covers, safety devices and other safety devices are perfect.

(3). Understand the design ideas of equipment control.

(4). Check whether the number and content of the drawing data meet the requirements. Whether the drawings are consistent with the actual.

(5). Confirm whether the safety protection device is effective through on-site trial operation.

(1). Main information: certificate of conformity, instruction manual, installation and operation manuals, maintenance manuals, packing lists, instructions and certificates of conformity for outsourced parts (including electrical control units); in the case of imported parts, relevant information in English and Chinese should be provided;

(2). Binding requirements: binding requirements hard cover folder, A3 horizontal binding, A4 vertical binding;

(3). The basic part: the basic diagram (including the technical requirements of the foundation);

(4). Mechanical system: general assembly diagram dimensions, component assembly diagrams (including the list of purchased parts and models, motors with power), processing diagrams of vulnerable parts;

(5). Hydraulic, pneumatic systems: system working principle diagram, component connection diagram (including the component manufacturers, models and quantities);

(6). Control system: detailed electrical control schematic diagram (main circuit wiring diagram, control circuit wiring diagram, detailed electrical components list, model and quantity), electrical components layout diagram, wiring diagram (including terminal diagram), provide PLC built-in program backup, programming manual, etc.;

How to do a good job of non-standard automation equipment after-sales service

I, Quality is made, not after-sales service

Non-standard automation equipment after-sales service, a large part is due to the quality of the equipment itself, and these quality problems are mainly from the design and manufacturing. Inspection and testing as the final quality inspection process and quality process control before the equipment leaves the factory, to ensure the quality of the equipment determines the workload and work speed and cost of after-sales service.

Second, the use of manuals and maintenance of technical output

Assist customers to train operation and maintenance technicians, one is to ensure that customers are reasonable and safe use of equipment and daily maintenance of equipment, maximum extension of equipment life and reduce equipment failure rate. Second, the equipment failure or the replacement of wearing parts can be solved by the customer to improve the timeliness of the problem and reduce the cost of after-sales service.

Third, the use of modern communication technology to do a good job of remote after-sales service

Determine a good after-sales service docking technical window personnel with customers to facilitate communication, remote after-sales service, in advance, according to the single machine failure, online failure, actuating components (mechanism parts), sensors (electrical parts), controllers (system hardware), procedures and systems, such as common fault classification, can be the first time the fault to the number of diagnosis, shorten the waiting time online, improve service efficiency and quality!

Four, after-sales problems file and register

After-sales issues are categorized into a file and book, to facilitate the tracking of problems. After-sales issues should be handled in a timely manner, informed to other relevant after-sales personnel, informed to design and development personnel, informed to processing and manufacturing personnel, informed to quality inspection personnel, informed to customers, to reduce or avoid the recurrence of problems, to establish an effective feedback channel and tracking mechanism.

V, After-sales personnel quality construction

After-sales service is an extension of sales, so the comprehensive quality of after-sales personnel requirements are also high! After-sales direct dealings with customers to have a certain degree of communication skills, speaking in good faith, understand respect, broad knowledge, to be able to take charge of the side. Management is people-oriented, so do a good job of non-standard automation equipment after-sales service management, or do a good job of after-sales talent team management!