Transform equipments to expand capacity

The 1-4 whole row of equipment in the first stage of moulding workshop has been idle for a long time, and the utilization rate is very low. In 2018, the company promoted the equipment transformation project of the whole line, which was carried out in two batches and two stages, and completed the transformation in April 2019.

Number of modifications: SBA-YJ-1-4-1-SBA-YJ-1-4-16, a total of 8 groups of 16 equipment

Reasons for renovation: outdated equipment, outdated electrical control system, unable to meet the existing product production process, uneven temperature control, cumbersome maintenance, oil system is too complex, spare parts are not easy to purchase, energy consumption is high. At present, it is out of service, resulting in waste of resources.

The purpose of the transformation is to improve the utilization rate, realize intelligent control, reduce equipment energy consumption, simplify maintenance and meet the production process of the product. By rebuilding the temperature control system, the temperature of the hot plate can be uniform and the qualified rate of the product can be improved.

Contents of the transformation:

Item 1: electrical control system

Advantages: PLC + man-machine interface control makes control more precise, process can be diversified, parameter input more convenient, operation more convenient, layout more reasonable and neat, display more intuitive, maintenance more convenient and faster, and parts interchangeability stronger.

Item 2: Oil System

Advantages: Using double proportion, double pump and single motor to control the oil circuit, realizing the pressure of the equipment, adjusting the speed arbitrarily, meeting different production processes, reducing the energy consumption of the equipment, making maintenance more convenient and simple. The layout is concise, beautiful and practical.

Item 3: Temperature Control System

Advantages: The original equipment is a single point heater plate, heating is not uniform, easy to short circuit. The retrofit adopts multi-point temperature acquisition and multi-channel control. The heating tube type hot plate is heated uniformly, with high temperature control accuracy, energy saving and high efficiency, convenient temperature setting, easy replacement of heating tube, low maintenance cost, high smoothness of equipment and good insulation effect.

Item 4: Operating Box

Advantages: Reasonable layout, concise and clear, single-step control, easy operation, clear marking.

Item 5: Heat Insulation Plate

Advantages: The original graphite heat insulation board has poor heat insulation effect, large heat energy loss, and obvious heat insulation effect of synthetic fiber heat insulation board. It saves electricity more than the old heat insulation board. Every day, it saves electricity=(5.01-4.68)*2*24=15.84KW/day.

For the first time, a set of 1-4-9 and 1-4-10 equipment was rebuilt on site in our company. After the modification, it has been assessed and qualified, and has begun to use normally.

The second batch has also been transformed:

In Transformation:

After transformation:

At present, the reconstructed equipment has completed acceptance confirmation, and has entered the production and use stage one after another. Through the transformation of 100T large mould to 200T equipment, the newly developed mould can directly utilize the 1-4 equipment which has been transformed. The utilization rate of the equipment can be increased by more than 30% compared with before. It can relieve the pressure of the increasingly tense equipment, release the production capacity and provide strong support for the company's expansion and development.

At the same time, the old equipment should be transformed into valuable waste, and the new equipment can be achieved at a cost of about 1/3, which not only saves the cost, but also enlarges the production capacity.