Application of Automation Technology in Forging Process
The forging process uses advanced automation technology, primarily replacing traditional manual operations with industrial robotic systems. This shift particularly enhances tasks such as pushing forgings in heating furnaces, loading and unloading operations, shaping, and trimming. The effective implementation of automation technology can simplify workflows and lighten the personnel workload while significantly enhancing the surface quality of forgings. Furthermore, it helps minimize cutting allowances during processing and optimizes production efficiency to the greatest extent possible.
Feasibility of Applying Automation Technology in the Forging Process
Technical Foundation Guarantee
In the evolution of the forging industry in my country, a transition has occurred from traditional manual operations to a modern mechanical production mode. During this shift, the level of mechanical automation has notably advanced. A wealth of new technologies and models enables more avenues for the application of automation technology in the forging process. With the continual advancement of computer control technology, various types of forging automation software products have emerged, notably servo-driven stepping beam manipulators that are adept at controlling multi-joint robots. These advancements enable batch automated production, curtail processing costs, enhance product reliability, and provide a robust foundation for hardware and software integration. Additionally, the growing demands for product quality from consumers and high-end clientele necessitate the adoption of automation technology to mitigate quality issues typically associated with manual operations. By leveraging these technologies, processing speeds can be accelerated, human resource dependencies reduced, and mechanized models developed. While there is a distinct difference between the development of forging automation technology in my country and that of Western nations, opportunities exist to adopt best practices from abroad to enhance the use of automation in our industry.
Great Potential for Future Development
Despite the late adoption of automation technology in forging processing, profound potential for development remains. Currently, the forging process has evolved from the automation of single mechanical units to a more complex rigid and flexible automation model for production lines. Moving forward, we can anticipate a pivot towards intelligent systems that create sophisticated forging production and processing mechanisms. While the automation of individual units addresses the complexities of traditional manual operation, it still has certain dependencies on human interaction. Conversely, the rigid automation of production lines connects mechanical systems with I/O hardware, thereby eliminating the need for human input. Flexible automation, on the other hand, incorporates advanced technologies that enhance the overall forging processing and production systems. Through flexible automation, field buses establish robust control architectures, allowing for the dynamic monitoring of production interactions, accurate data collection, and rapid fault diagnosis. Therefore, the application of flexible automated production relies on optimized network architectures and expert control systems to raise the level of automation within forging operations.
Advantages of Automation Technology Application
In many sectors of the forging production landscape, outdated mechanical equipment and poor working conditions prevail, oftentimes necessitating manual labor. This scenario not only hinders production efficiency but also compromises product quality. The burden on operators in these environments is considerable, leading to heightened risks and safety concerns. Particularly, handling materials at temperatures exceeding 1200°C raises the potential for severe burns, while heat radiation poses additional threats. The exhaust from heating operations may contain toxic substances, and elevated noise levels can endanger the auditory and visual well-being of operators. Utilizing automation control technology can mitigate these risks by deploying robots and automated systems to supplant manual operations. This shift not only streamlines loading and unloading but also allows for precise, timely, and quantified operations—reducing staff workloads and enhancing safety as well as product quality. This illustrates the multifaceted benefits inherent in embracing advanced automation technology within the forging process. Companies should thus prioritize automation technology to refine their forging processes and overall operational quality.
Suggestions for Applying Automation Technology in the Forging Process
Strengthen Automation Transformations
To effectively implement automation technology in forging, it is crucial to intensify the transformation of existing equipment. Each transformation should align with the specifications of diverse equipment to meet enterprise-level production demands. For example, many forging companies in my country operate outdated equipment that cannot be readily upgraded to modern bus control automation standards. In such cases, organizations should pursue single-machine automation to minimize workloads and reduce operation intensity while controlling production costs—thus averting quality issues stemming from manual errors. Moreover, securing process stability and reliability is critical, as is the continuous technical enhancement of processing and production systems. Certain key processes, such as pre-forging and final forging, may retain some manual operations to maintain production flow, while die forging hammer processes can fully embrace automation. Focusing on small to medium-sized hot die forging can yield significant automation upgrades through advanced stepping beam manipulators, while large die forging applications can witness the coordinated operation of multiple robotic units to facilitate automated production.Lastly, enhancing the qualifications of technicians and maintenance personnel ensures effective utilization and upkeep of automation systems.
Enhance Automated Production Lines
Custom Forging enterprises should actively pursue the advancement and optimization of automated production lines, leveraging automation technology fully to ensure the overall automation level of their systems and machinery. Drawing on successful practices from other industries can spark the development of automated hot die forging lines that leverage bus systems for comprehensive control. Implementing a dual-layer bus electrical control architecture, where remote devices manage upper processes and on-site systems handle lower tasks, fosters integrated operations for heating, pressing, trimming, and unloading equipment. The automated production line systems may also incorporate semi-automated, fully automated, and manual operation modules tailored to various processing scenarios. Critical to this development is enhancing process flow design, creating automated feeding and logistics support systems, and employing lubrication cooling devices to ensure optimal surface quality. Regularly removing oxide scale and impurities bolsters the dimension accuracy and extends mold life, directly impacting production performance.
Refine Automation Control System Architecture
Design the Hardware Components
During the design phase of automation control system architecture for forging, the hardware aspect holds critical importance. Companies should address the signal switching requirements and logical complexity inherent in descaling, trimming, and cooling systems. Designing the key control CPU and touch interfaces facilitates improved human-computer interaction. Additionally, establishing dedicated signal input and output modules enhances data communication and system integration with Ethernet platforms.
Design the Software Components
On the software front, constructing the PLC system and MHI architecture is paramount. Modular programming should be employed to create a structured primary loop program that can effectively manage various input and output requirements. Each cycle can leverage robot signal interfaces, descaling equipment signals, and cooling line signals in response to production needs. Special focus on function modules, such as safety locking and fault diagnosis, bolsters system functionality. The human-computer interface should cater to the varied conditions encountered in forging, incorporating robust monitoring of robot signals and equipment statuses along with prompt alerts for any anomalies. Ensuring high-quality programming, particularly for the specific requirements of forged products, plays a pivotal role in sustaining innovative automation applications.
Conclusion
To sum up, as the process of forging production evolves, traditional technologies will no longer suffice to meet the demands of high-quality processing. The strategic integration of advanced automation technologies is essential for upgrading processes, enhancing forging quality, and elevating production standards. In light of this, forging enterprises must prioritize automation technology adoption, enhance their systems, and diligently refine both their software and hardware designs.