The improvement in production efficiency after the automation transformation of the plate rolling machine production line is 35% -70% for conventional batch regularized plate rolling scenarios, and over 80% for extreme adaptation conditions (such as high load production of a single variety). The core improvement comes from manual intervention in compression and process stability enhancement.
1, Specific sources of core improvement (1) Compression of auxiliary working hours
During manual rolling, the auxiliary time for loading and unloading, centering, and size adjustment accounts for 40% -60% of the total working hours; After the automation transformation, the proportion of this part of time has been reduced to less than 10%.
Manual single changeover debugging takes 20-40 minutes, while automated changeover (automatic adjustment of roller distance, centering reset) takes 2-5 minutes.
2, Differences in improvement under different working conditions
Batch production of a single variety (such as pressure vessel bodies and large air ducts): After renovation, efficiency has increased by 60% -80%, equipment utilization rate has increased from the original 60% to over 90%, and there is no additional loss due to frequent model changes.
Multi variety small batch production (such as sheet metal samples, non-standard cylinders): After the transformation, the efficiency has been improved by 35% -50%, and the proportion of auxiliary time for small batches is still high. Automation only replaces repetitive manual operations.
3, Limitations on the increase in magnitude
Incoming material size accuracy: If the incoming material deviation exceeds ± 0.5mm, the automated centering system requires additional manual intervention for calibration, reducing the improvement by 10% -15%.
Adaptation of the transformation: Only the semi-automatic transformation of the original manual plate rolling machine with CNC system, automatic centering mechanism, and automatic loading and unloading is carried out. The higher the adaptability, the closer the improvement is to the upper limit; The improvement rate of fully automated equipment updates is similar to that of semi-automatic transformation, but the initial investment is higher.
