The Research And Application Of Track Shoe Stamping Automation Production Line Based On Lean Production

Track shoe is one of the indispensable parts in construction machinery undercarriage.As it is one of the wearing parts,there is a high market demand.No matter as individual fittings or the mainframe supporting,it has a broad market prospect.For most track shoe manufacturing companies,the most common forming method is stamping,and it is performed by manual.Compared to the automation stamping product line,the manual stamping product line has many disadvantages,such as low safety coefficient,low production efficiency,high cost and high labor intensity.Use the measure of lean production,the article analyzes the manufacturing process and seeks to do some improvements,using value flow diagram.Meanwhile,there is no large scale changes to the existing equipments,so the capital investment is small and it can be copied easily,providing a good reference for a variety of scales track shoe companies.Through the analysis of each process of the track shoe,this research,using lean production methods and value flow chart,aims to achieve stamping automation and reduce the production cost.By data collection and induction,this article has accomplished the current and future state drawings of 8190-MV(N)track shoe value flow chart,and has identified the research direction:with the direction of implementation of stamping line continuous flow,achieve the stamping line automation.We can also eliminate the intermediate process,reduce on-site operators and improve production efficiency,through the production line efficiency improvement and optimization method,such as quick die change,productivity improvement of stamping process and so on.Combined the stamping process and the structural characteristics,the article analyzes the realization condition of the track shoe stamping continuous flow and finds out the key module of the automation:the design of automatic feeding,automatic positioning and automatic control system.After theoretical analysis and data calculation,the automatic feeding device adopts the roller type automatic feeding mechanism and uses the hydraulic cylinder to complete the feeding and turning of the track shoe.The automatic positioning device adopts the pneumatic adjustable structure which is installed on the hydraulic machine working platform.Besides automatic positioning,it can realize the fast switching of track shoes with different lengths.The automatic control system adopts OMRON CJ1M series to make PLC control.Through the design of the automatic control program,it can achieve the full automation of the stamping process.At the same time,it adopts the synchronous technology to reduce the time intervals of the slide operation and feeding,positioning action,promoting the production efficiency.Using the quick die change theory and method,measuring the model of the process,the article divides the process action and time,distinguishes and transforms the internal and external changeover time,optimizes and standardizes the internal die change action,and finally reaches the target that the changeover time is less than 40min.Analyze the downtime of the stamping process automation production,and find out the main reasons affecting stamping production efficiency:the positioning device structure and the adjustment method are unreasonable.Through the redesign of the overall structure of the positioning device,we can ensure the product quality stability.At the same time,the tooling adjustment frequency,time,and the equipment downtime are reduced effectively,and the output is increased,so as to realize the production capability balance of each process of the track shoe automation stamping.