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Srpski језикSama da shekaru ashirin, ƙungiyarmu a Quangong Machinery Co., Ltd. ta lura da haɓakar samar da kankare. A cikin wuraren gine-gine marasa ƙirƙira a duk faɗin duniya, kayan aikin toshe na gargajiya sukan haifar da ƙugiya: yawan amfani da makamashi, rashin daidaituwar toshewa, da raguwar lokaci akai-akai. Masana'antar mu ta fuskanci waɗannan abubuwan takaici kafin mu ƙirƙira mafita. A yau, muna yin tambaya mai mahimmanci: menene ya raba tsarin na'ura mai aiki da karfin ruwa na zamani daga injunan rawar girgiza? Amsar tana cikin sakamako masu iya aunawa.
MuQGM block yin injiyana haɗa fasahar servo-hydraulic, saka idanu na matsa lamba na ainihi, da tsarin ƙirar ƙira. Ba kamar kayan aikin toshe na al'ada waɗanda ke dogaro da maɓuɓɓugan inji ko injunan haɓakawa ba, injin ɗin toshe QGM yana ba da ƙarfi mai maimaitawa tsakanin ± 1% bambancin. Wannan gabatarwar zai rarraba zaɓin aikin injiniya, tanadin aiki, da dogaro na dogon lokaci waɗanda ke sanya injinmu a matsayin maƙasudin masana'antu. Za mu gabatar da kwatancen bayanai, amsa damuwar masu siye akai-akai, kuma mu nuna dalilin da yasa canzawa zuwa tsarin sarrafa kansa daga Quangong Machinery Co., Ltd. yana tasiri kai tsaye ga layin ku. Bari mu bincika fasaha na fasaha na masana'antar toshe mafi girma.
Kayan aikin toshe na al'ada galibi suna amfani da girgizar inji ko matsi na huhu, wanda ke haifar da rashin daidaituwa. A cikin masana'antar mu, mun lura cewa sama da kashi 40% na tubalan da aka ƙi daga injunan zamani sun haifar da rashin daidaituwa. Na'ura mai toshe QGM tana amfani da tsarin hydraulic rufaffiyar madauki tare da bawuloli masu daidaitawa da amsawar servo. Wannan zane yana tabbatar da cewa kowane bugun jini yana aiki daidai da ƙarfin da aka tsara, ba tare da la'akari da bambancin kayan ba. Bari mu karya abubuwan da ke haifar da wannan fa'ida:
A yayin gwaje-gwaje na gefe-da-gefe a cibiyar mu, kayan aikin toshe na gargajiya tare da injin 45kW ya samar da tubalan 850 a cikin awa ɗaya amma tare da raguwar 7%. Injin ɗinmu na toshe QGM, ta amfani da 37kW servo-hydraulic, ya sami 920 tubalan a kowace awa tare da sharar gida 1.2% kawai. Har ila yau, tsarin na'ura mai aiki da karfin ruwa yana ba da damar masana'antar mu ta gudanar da motsi uku ba tare da zafi ba, godiya ga tanki mai lita 200 da kuma mai sanyaya zafi. Na'urorin gargajiya yawanci suna buƙatar hutun sanyi kowane awa 4.
Bugu da ƙari, tazarar kulawa sun bambanta sosai. Kayan aikin toshe na al'ada yana buƙatar maye gurbin hatimi na wata-wata akan magudanar girgiza, yayin da rukunin wutar lantarkin mu na QGM yana aiki na awanni 6,000 kafin kowane babban sabis. Mun tsara katangar da yawa tare da flanges SAE don kawar da wuraren zubar da ruwa - batun gama gari a cikin tsofaffin kayan aiki. Ga masu siye da suka damu game da horar da ma'aikata, HMI ɗin mu na nuna matsi masu lanƙwasa a cikin yare na gaske, ba kawai alamomin hydraulic ba. A takaice, kashin bayan injin mu yana canza aminci daga caca zuwa garanti.
Toshe yawa yana tasiri kai tsaye ƙarfin gini da sha ruwa. Kayan aikin toshe na al'ada suna kokawa don cimma daidaito iri ɗaya saboda mitar girgizarsu ta kasance koyaushe ba tare da la'akari da cikar ƙira ba. A Quangong Machinery Co., Ltd., mun magance wannan ta hanyar girgiza matakai da yawa da riga-kafi. Na'ura mai toshe QGM ta haɗa da madaidaicin firikwensin mitar (VFD) waɗanda ke share daga 45Hz zuwa 65Hz a cikin daƙiƙa 0.3. Wannan mitar share fage na rushe guraben iska a hankali, sabanin fashewar guda ɗaya a cikin injinan gargajiya. Da ke ƙasa akwai kwatancen siga daga gwaje-gwajen masana'antar mu akan daidaitattun tubalan 190x190x390mm:
| Siga | Kayan Aikin Toshe Na Gargajiya | QGM Block Yin Machine |
| Ƙarfin Ƙarfafawa (kN) | 120-150 (kololuwa, rashin daidaituwa) | 180 - 220 (kayyade, sake zagayowar ta sake zagayowar) |
| Rage Mitar Jijjiga (Hz) | Kafaffen 50Hz | 45-65Hz mai canzawa |
| Toshe Maƙarƙashiya (kg/m³) | 1850-2050 | 2350-2450 |
| Ƙarfin Ƙarfi (MPa, kwanaki 7) | 8.5 - 10.2 | 13.6 - 15.1 |
| Shakar Ruwa (%) | 7.8% - 9.2% | 4.1% - 5.0% |
Yi la'akari da haɓakar yawa sama da 30% a cikin injin ɗinmu na toshe QGM. Wannan ya samo asali ne daga siffofi guda uku: na farko, matakin mu na hydraulic pre-latsawa yana ƙaddamar da kayan zuwa 70% na tsayin ƙarshe kafin babban girgiza; na biyu, mold oscillation yana aiki tare tare da danna kan saukowa, yana hana busa kayan abu; na uku, muna amfani da naushi mai kauri tare da flatness 0.02mm, wanda kayan aikin toshe na gargajiya ba safai suke bayarwa. Daga gwanintar masana'antar mu, yawan yawa yana fassara zuwa tanadin kaya (kunna jigilar ramuka kaɗan) da ƙarancin fashe-fashe yayin warkewa. Abokan ciniki waɗanda suka sauya daga kayan aikin toshe na gargajiya zuwa injin ɗinmu na toshe QGM sun ba da rahoton raguwar amfani da siminti da kashi 22% yayin da suke riƙe ƙarfi iri ɗaya, saboda tubalan masu yawa suna buƙatar ƙarancin ɗaure.
Bugu da ƙari, daidaiton yawa yana rage lalacewa akan pallets. Injin gargajiya tare da katanga marasa daidaituwa sun toshe pallets a cikin watanni 3. Ƙirƙirar kayan aikin mu yana ƙara rayuwar pallet zuwa watanni 18. Saboda haka, farkon babban jari a cikin fasahar mu yana biya ta hanyar tanadin kayan abu, ƙananan tarkace, da ƙarancin abubuwan amfani. Ga manajojin aikin da ke buƙatar kiredit na LEED, raguwar sawun siminti ƙarin fa'idar muhalli ne. Muna gayyatar ku don shaida gwaje-gwaje masu yawa a masana'antar mu - bambancin abu ne mai ma'ana.
Amfanin makamashi shine matsayi na biyu mafi girma na aiki bayan kayan aiki. Kayan aikin toshe na al'ada galibi suna tafiyar da injina gabaɗaya, ko da lokacin hawan kaya marasa aiki. A Quangong Machinery Co., Ltd., mun sake fasalin gine-ginen sarrafa wutar lantarki. Na'ura mai toshe QGM tana amfani da ajiyar makamashi biyu: masu tarawa na ruwa suna ɗaukar dawo da makamashin mai yayin lokacin ɗagawa, kuma masu ƙarfin ƙarfi suna sabunta ƙarfin birki daga injin girgiza. Anan ga yadda masana'antar mu ke rage kWh kowace toshe da 34% sabanin kayan aikin gargajiya:
A cikin binciken watanni 12 a wurin abokin ciniki wanda ke samar da tubalan miliyan 6 a kowace shekara, kayan aikin toshe na gargajiya sun cinye 842,000 kWh. Bayan maye gurbin na'urar mu ta toshe QGM, amfani ya faɗi zuwa 556,000 kWh - ceton $34,000 a $0.12/kWh. Bugu da ƙari, raguwar samar da zafi yana nufin masu sha'awar samun iska na masana'antarmu suna yin kasa da 50%, suna haɓaka tanadi. Yawancin masu toshe kayan aikin gargajiya sun yi watsi da cewa zafin mota yana buƙatar kwandishan mai tsada a cikin tsire-tsire da ke kewaye. Yanayin zafin injin mu yana tsayawa ƙasa da 55 ° C, yayin da injin girgizar gargajiya yakan wuce 85 ° C.
Muna kuma samar da software na saka idanu akan makamashi wanda ke bin diddigin amfani kowane rukuni. Masu aiki za su iya gani a ainihin lokacin waɗanne matakan zagayowar ke amfani da ƙarin ƙarfi kuma su daidaita matakan hanzari. Misali, rage saurin kusanci da 10% yana adana kuzari 7% ba tare da ya shafi fitarwa ba. Abokan cinikinmu sau da yawa suna dawo da bambancin farashin tsakanin na'ura mai mahimmanci da injin mu na QGM a cikin watanni 22 kawai daga ajiyar wutar lantarki. Bugu da ƙari, wasu yankuna suna ba da rangwamen haraji don saduwa da kayan aiki da ingancin injin IE4 - injin mu ya cancanci, yayin da yawancin kayan aikin toshe na gargajiya ba sa. Lokacin ƙididdige jimlar farashin mallakar, ingancin makamashi ba zai iya zama abin tunani ba; shi ne core zane ginshiƙi aAbubuwan da aka bayar na Abubuwan da aka bayar na Quangong Machinery Co., Ltd.
Kayan aikin toshe na al'ada sau da yawa yana buƙatar sa'o'i 4 zuwa 6 don canza ƙira, haɗaɗɗen gyaran hannu, jujjuyawar kulle, da hawan gwaji. Don masana'anta namu, wannan lokacin raguwa yana nufin rasa duka motsi. Na'ura mai toshe QGM yana gabatar da tsarin musanya mai sauri tare da ƙugiya na hydraulic da fil masu daidaitawa ta atomatik. Anan ga ɓarnawar tanadin lokaci da ribar sassauci:
Yi la'akari da yadi na yau da kullun wanda ke samar da nau'ikan toshe 10 a kullum. Tare da kayan aikin toshe na gargajiya, 5 mold canje-canje suna cinye sa'o'i 17.5 na raguwa a kowane mako. Mashin ɗinmu na toshe QGM yana rage hakan zuwa awa 1 a kowane mako, yana ƙara cikakken ranar samarwa yadda ya kamata. Ɗaya daga cikin abokan cinikinmu a Texas ya canza daga injin gado kuma ya ƙara yawan fitarwa na mako-mako daga 28,000 tubalan zuwa 43,000 ba tare da ƙara aiki ba. Musanya gyaggyarawa kuma yana rage lalacewa: injinan gargajiya sukan lalata gefuna iri-iri yayin cirewa saboda rashin daidaituwar ɗagawa. Tsarin ɗagawa mai jagora yana ɗaga gyare-gyare a tsaye tare da na'urori masu aiki tare guda huɗu.
Bugu da ƙari, masana'antar mu tana ba da shirin gyaran gyare-gyare. Lokacin da mold ya kai 500,000 zagayowar, muna regrid da lalacewa saman to asali tolerances. Kayan aikin toshe na al'ada yawanci yakan zama guntu bayan irin wannan hawan keke saboda rashin daidaituwar injin mahaifa yana haifar da rashin daidaituwa. Tsarin tsarin jagorar na'ura na QGM yana kiyaye sa tufafi, yana ba da damar gyare-gyare guda biyu a kowane nau'i - rayuwa mai ninka sau uku sosai. Don manyan ayyuka, wannan yana wakiltar tanadin $50,000 na shekara-shekara. Sabili da haka, saurin canzawar ƙira ba kawai adana lokaci ba; yana kare ɗaya daga cikin kayan amfanin ku mafi tsada. Muna ƙarfafa abokan ciniki su ziyarci masana'antar mu don ganin musanyawa mai rai a cikin ƙasa da mintuna 15.
Kuskuren ɗan adam yana lissafin kashi 63% na rashin daidaituwar samarwa a cikin kayan aikin toshe na gargajiya bisa ga binciken cikin gida a Ma'aikata na QGM suna yin kuskuren ɗanɗano kayan, yin watsi da daidaitawar pallet, ko saita lokutan zagayowar kuskure. Injin yin toshe QGM yana haɗa tsarin ƙwararrun tushen PLC wanda ke sarrafa gyare-gyare. Gine-ginen sarrafa mu ya haɗa da:
Ɗaya daga cikin abubuwan da aka fi godiya shine tsarin sarrafa girke-girke. Masu aiki suna zaɓi kawai "tushe toshe 6 inch" akan allon taɓawa; na'ura mai toshe QGM ta atomatik yana saita mitar girgiza, zurfin bugun jini, da matsa lamba. Kayan aikin toshe na al'ada yana buƙatar gyare-gyaren hannu akan potentiometers, yawanci yana haifar da saitunan kuskure. A cikin zaman horon masana'antar mu, mun ga cewa sabbin masu aiki akan injunan gargajiya sun ɗauki makonni 3 don cimma daidaiton kashi 95%. Tare da tsarin mu mai sarrafa kansa, masu aiki iri ɗaya sun kai 98% inganci bayan sauyi 3.
Haka kuma, injin yana yin rajistar kowane zagayowar a cikin littatafan da za a iya tabbatarwa da blockchain (na zaɓi). Don kwangilar gwamnati da ke buƙatar ganowa, wannan yana ba da ingantaccen bayanai masu inganci: daidai wanda, yaushe, da waɗanne sigogi aka yi amfani da su. Kayan aikin toshe na al'ada ba zai iya bayar da wannan matakin takaddun ba. Har ila yau, tsarin sarrafawa yana annabta kiyayewa: ta hanyar nazarin ƙimar haɓakar matsa lamba, yana yin kashedin lokacin da man hydraulic ke buƙatar canzawa ko tacewa yana toshewa. Sakamakon haka, rashin shiri na rashin kulawa daga sakaci ya zama abu na baya. Mun tsara na'ura mai toshe QGM don zama abokin aiki, ba wasa ba. Quangong Machinery Co., Ltd. yana ba da nazari na tushen girgije kyauta na shekara ta farko, yana taimaka muku inganta ingantaccen samarwa don mafi girman yawan amfanin ƙasa.
Zuba jari a cikin injinan toshe yana buƙatar hangen nesa na kuɗi na shekaru 5 zuwa 10. Duk da yake kayan aikin toshe na gargajiya yana da ƙananan farashi na gaba, jimlar kuɗin mallakar (TCO) yana ba da labari daban. Dangane da bayanai daga abokan cinikinmu na yanzu waɗanda suka sauya daga kayan aikin gargajiya, ga taƙaitaccen bayani:
Daga kwarewar masana'antarmu ta siyar da injunan gadon da aka gyara da sabbin raka'a na QGM, abokan cinikin da suka zaɓi na'urar yin toshe QGM suna ba da rahoton lokacin biya a ƙarƙashin watanni 30. Sabanin haka, masu toshe kayan aikin gargajiya galibi suna fuskantar ɓoyayyiyar farashi kamar yawan amfani da siminti (saboda ƙarancin yawa) da kuma kayan aikin kayan masarufi akai-akai. Har ila yau, yankuna da yawa a yanzu suna tilasta amo da ƙa'idodin fitarwa waɗanda kayan aikin gargajiya suka gaza, yayin da injin ɗinmu na toshe QGM ke aiki a ƙarƙashin 82dB kuma ya sadu da ISO 14001. Don kasuwancin kayan gini da ke neman ci gaba mai dorewa, yanke shawara a bayyane yake. Mu aAbubuwan da aka bayar na Abubuwan da aka bayar na Quangong Machinery Co., Ltd.bayar da garanti na shekaru 3 akan manyan abubuwan haɗin hydraulic, wani abu da babu mai yin kayan aikin gargajiya yana bayarwa. Tuntuɓi injiniyoyinmu na tallace-tallace don gudanar da keɓaɓɓen samfurin TCO don rukunin yanar gizon ku.
Tambaya 1: Shin QGM toshe injin yin na'ura zai iya samar da tubalan na musamman kamar pavers ko kerbstones ba tare da ƙarin keɓancewa ba?
Amsa: Lallai. Ba kamar kayan aikin toshe na gargajiya waɗanda ke buƙatar canje-canjen injina don samar da sifofi daban-daban ba, injin ɗinmu na toshe QGM yana amfani da tsarin ƙirar ƙira. Ta hanyar musanya gyare-gyaren kawai (wanda ke ɗaukar ƙasa da mintuna 15), zaku iya samar da shinge masu tsaka-tsaki, bulo-bulo, bulo mai ƙarfi, har ma da hana duwatsu akan injin iri ɗaya. Matsin na'ura mai aiki da karfin ruwa da jerin jijjiga suna daidaita ta atomatik dangane da alamar RFID na mold. Yawancin abokan cinikinmu suna gudanar da layin samfuri daban-daban guda shida ta amfani da injin yin toshe QGM guda ɗaya, yayin da kayan aikin gargajiya zasu buƙaci keɓaɓɓun injuna. Wannan sassauci yana rage yawan kashe kuɗi da sararin ajiya.
Tambaya ta 2: Ta yaya zuba jari na farko a cikin na'ura mai toshe QGM ya kwatanta da sake gina tsohon kayan toshe na gargajiya?
Amsa: Sake gina tsofaffin kayan aikin toshe na al'ada sau da yawa farashin 60-70% na sabuwar na'ura amma har yanzu yana barin ku da tsohuwar fasaha: babu dawo da makamashi, sarrafawar hannu, da ginshiƙan jagora na sawa. Sabanin haka, saka hannun jari a cikin sabon na'ura mai toshe QGM yana ba ku servo-hydraulics na zamani, aiki da kai, da cikakken garanti. Masana'antar mu ta ga abokan ciniki da yawa sun kashe dala 45,000 don sake gina injin gargajiya kawai don fuskantar wata matsala a cikin watanni 18. Tare da injin mu, ROI daga tanadin makamashi kaɗai yawanci yana daidaita bambancin farashin a cikin watanni 22. Muna kuma bayar da zaɓuɓɓukan haya musamman don sauyawa daga kayan aikin gargajiya.
Tambaya 3: Shin QGM block yin inji yana buƙatar shigarwa na lantarki na musamman idan aka kwatanta da kayan aikin toshe na gargajiya?
Amsa: A'a, an tsara shi don daidaitaccen ƙarfin masana'antu (380V/50Hz ko 460V/60Hz). Koyaya, saboda injin ɗinmu ya fi ƙarfin kuzari, a zahiri yana buƙatar ƙarami mai canzawa fiye da na'urorin toshe na gargajiya na irin ƙarfin fitarwa. Misali, na'ura na gargajiya da aka shigar da wutar lantarki 110kW na iya buƙatar taswirar 150kVA, yayin da injin ɗinmu na QGM yana ba da kayan aiki iri ɗaya yana amfani da wutar lantarki 75kW kawai, yana buƙatar taswirar 100kVA. Wannan yana adana farashin shigarwa. Bugu da ƙari, masana'antar mu ta haɗa da matattara mai laushi da mai jituwa, hana faɗuwar wutar lantarki wanda galibi ya addabi farawar kayan aikin gargajiya.
Tambaya 4: Shin kayan gyara kayan toshe na QGM suna samuwa a duk duniya, ba kamar wasu samfuran kayan aikin toshe na gargajiya ba?
Amsa: E. Quangong Machinery Co., Ltd. yana kula da cibiyoyin rarrabawa a Arewacin Amurka, Turai, kudu maso gabashin Asiya, da Afirka. Sama da kashi 92% na kayan gyara (hatimai, masu tacewa, firikwensin firikwensin) daidaitattun abubuwan masana'antu ne da ake samu a cikin gida. Don ɓangarorin mallakar mallaka kamar hukumar kulawa, masana'antar mu tana jigilar kayayyaki cikin sa'o'i 48. Kayan aikin toshe na al'ada galibi suna amfani da sassan awo na al'ada tare da lokutan jagora na tsawon watanni. Hakanan muna samar da kasidar sassan dijital inda zaku iya gano kowane abu ta hanyar bincika lambar QR akan injin. Wannan yana rage raguwa sosai idan aka kwatanta da farautar sassan da ba a gama ba don kayan aikin gargajiya.
Tambaya 5: Ta yaya fasalin sake amfani da sharar gida akan na'ura mai toshe QGM ya kwatanta da kayan aikin gargajiya?
Amsa: Kayan aikin toshe na gargajiya ba su da haɗaɗɗen sake yin amfani da sharar gida; tubalan da aka zubar ko kuma aka ƙi su tafi wurin shara. Injin ɗinmu na toshe QGM ya haɗa da tsarin sake kwato jika wanda ke wanke jimillar tubalan da aka ƙi da sake amfani da ruwa a haɗawa. Bugu da ƙari, allon jijjiga ƙarƙashin mai ɗaukar hoto yana tattara sabobin siminti da ya zube ya mayar da shi zuwa akwatin ciyarwa. Wannan yana rage sharar albarkatun kasa da kashi 18%. Fiye da shekara guda, matsakaiciyar shuka na iya adana ton 200 na siminti da ton 400 na aggregates. Bayan tanadin farashi, wannan yana taimakawa bin ƙa'idodin muhalli waɗanda galibi ke azabtar da masu sarrafa kayan aikin gargajiya don zubar da shara.