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How does Dekuma use TRIZ theory to improve pipe cutting machine?

Abstract: With the continuous improvement of productivity of extrusion production line main unit, the capacity of its downstream equipment shall also be continuously improved to fulfill the requirements. This section introduces the method that Dekuma solves the problems of difficult adjustment of the cutting machine feed mechanism and difficult control of the feed speed with TRIZ innovative theory.

Keywords: TRIZ extrusion line Cutting Machine

 

01  The main problems of commonly-used feed mechanism in the industry

The feed mechanism of the cutting machine commonly used in the industry meets the processing requirements of the feeding and retracting with a group of hydraulic pump, supply hydraulic oil to hydraulic cylinder to control the swing movement of tool arm.

To cut pipes with different diameters and different wall thicknesses, firstly, it needs to adjust the initial feeding position, and meanwhile, it also needs to effectively control the feed amount of the tool arm; on the other hand, the feeding length is generally controlled by the cylinder stroke, and the initial position of the feed is controlled by adjusting screw of hydraulic cylinder support assembly.

In addition, for different cutting methods, the feeding speed shall also be controlled. The feeding speed is realized by adding the flow control valve in hydraulic circuit. If the speed is too fast, it will easily damage the cutting blade or saw blade.

1. Tool Arm Assembly   2. Cylinder Assembly   3. Cylinder Support Assembly

（1）Difficult to adjust the initial position of tool arm

The initial position of tool arm shall be adjusted by adjusting screw of hydraulic cylinder support assembly. It needs to loosen or tighten the lock nut and rotate the adjusting screw. Due to lack of suitable marking scale, it can only perform the action of feeding and retreating after preliminary adjustment, observe whether the cutting thickness can be completed, and finally lock the adjusting screw. However, when adjusting with this method, the working space is limited, and adjustment is very inconvenient.

（2）Difficult to control the tool arm feeding speed

The feed of tool arm is adjusted by the flow control valve, and it is difficult to obtain a suitable feed speed. The speed is easy to become too fast or too slow. The operators shall adjust the appropriate feeding speed for many times, which requires high technical level of the operators.

（3）Slow feeding speed

The feeding speed has only one speed when passing through the flow control valve, especially under working conditions with relatively slow feeding speed, the tool arm takes more time in approaching stroke. Taking the 40mm feeding stroke as an example, 20mm is approaching stroke, which requires 30s; the remaining 20mm working stroke also takes 30s, and it takes total 1min to complete the cylinder stroke.

 

 

02  Solve problems with TRIZ theory

The TRIZ theory was first proposed and summarized by the Soviet scientist Genrich S. Altshuler. TRIZ theory contains many systematic, scientific and operational creative thinking methods and analytical methods for finding problems. After years of development, TRIZ theory has become a mature classical theoretical system for solving practical problems in product development.

The general method of TRIZ theory to solve problems is that, first, abstract the special problem to be solved into a standard problem; then obtain a general solution based on the methods and tools provided by TRIZ theory; finally, obtain the final solution based on the user’s experience.

Heavy Duty Chipless Cutting Machine DKM-PO450

 

（1）Find and analyze problems – abstract into standard problems

Based on the analysis of the actions of feed mechanism, Dekuma’s engineering team conclude that in the approaching stroke, the feeding speed is expected to be faster, to reduce the feeding time and improve efficiency; while in the working stroke, the feeding speed is expected to slow down. On the one hand, it is aiming to reduce the load resistance of hydraulic cylinder; On the other hand, it is to reduce the rigidity requirement of the whole mechanism, and to improve the service life of the blade. From this analysis, the feeding speed shall be combined fast and slow, forming a pair of physical contradictions.

 

（2）Conduct resource analysis to find out contradictions

Four separation principles are summarized with TRIZ theory according to space, time, condition and system level, which are space separation, time separation, condition separation, and whole-part separation.

Among them, the principle of time separation is to separate the conflicting parties in different time periods, aiming to solve the problem or reduce the difficulty of problem. Based on analysis, Dekuma’s engineering team solve the problem of different speeds required by feeding speed at different times with this principle.

Comparing the corresponding 12 innovative principles in the principle of time separation, the “fast principle” that completes harmful operations at the fastest speed serves as the most effective one of the 12 innovative principles. For the feed mechanism, slow approaching travel can be considered as a harmful operation, which is very harmful to the improvement of efficiency.

 

（3）Problem solving

To quickly complete the harmful operation, the “fast principle” is adopted to solve the problem of approaching stroke. Dekuma introduces a deceleration cylinder, which quickly feeds and oil return to complete the action during approaching stroke. When it comes to the working stroke, the oil return of cylinder reduces the speed of working stroke by decelerating to meet the process requirements.

 

 

03  Main advantages of the new segment-controlled feed mechanism

To solve the problems encountered by commonly used feed mechanism in the industry, achieve the convenient operation of the extrusion production line, and reduce the cycle time required to replace different pipe specifications, Dekuma’s engineering team has developed a new segment-controlled feed mechanism, with the main advantages and principles as follows:

（1）Fast adjustment of tool arm initial position

The position of tool arm can be adjusted quickly by way of clamp-type tool arm assembly. The operation method goes as follows. Loosen the fixing screws of the clamping block, and swing the tool arm quickly to the marking scale line of the required specification according to the scale displayed on the sign, and then tighten the fixing screws of the clamping block. The initial operation of tool arm position adjustment is thus completed.

（2）Control the oil via deceleration cylinder

Therefore, two stages of fast and slow feed speeds can be achieved. Fast feed is adopted during the approaching stroke, and slow feed is adopted during the working stroke, which can effectively reduce the feeding cycle of tool arm. Taking the 40mm feed stroke as an example, 20mm is the approaching stroke, the time required for fast feed in the approaching stroke is 1s, and the time required for slow feed in the working stroke is 30s, and it takes total 31s to complete the whole stroke, which can save approx. half time of the original mechanism.

（3）Springs configured by deceleration cylinder and feed cylinder

The hydraulic cylinder can be reset actively, allowing the action of tool retracting to be completed faster, which further reduces the time of the whole process and improves the stability of actions.

1.Deceleration cylinder   2.Cylinder  3.Telescopic tool holder

04  Various processes of tool feed and retracting – description of actions of feeding cylinder and deceleration cylinder

（1）Fast feeding speed

The oil flow to no rod cavity of feeding cylinder, and the rod cavity cylinder returns oil into the deceleration cylinder. Before the piston of the deceleration cylinder reaches the limit position, the piston can move quickly, and the return oil of piston enters the hydraulic tank via valve body.

（2）Slow feeding speed

After the piston of deceleration cylinder moves forward and gets contact with the limit point, the piston will stop, and the oil can only return to the hydraulic tank via throttle valve. Thus the forward speed of the cylinder is reduced significantly, and it enters the slow-speed stage until the feed reaches in position.

（3）Fast retract speed

Both the deceleration cylinder piston and the hydraulic cylinder are set with return springs. The oil passes through the deceleration cylinder piston and quickly pushes the deceleration cylinder piston back to its original position driven by the spring’s reset thrust. Also acted by the spring force, the oil cylinder realizes fast return action.

（4）Retract in place

After the piston of the deceleration cylinder returns in place, the oil passes through the check valve. The piston installs with a check valve, allowing the oil to quickly pass through the piston, enter to rod cavity, and push the tool arm to return to the origin position quickly.

 

05  Conclusion

By applying the invention principle of TRIZ theory, Dekuma has proposed the idea of solving the problem of feed segmented control, which improves the action performance of feed mechanism cylinder and the time of each process.

The new segmented-control feed mechanism developed by Dekuma doubled the feeding speed, and ensured the stability and reliability of the retracting action. The cutting machine, as part of the extrusion production line, can better match the productivity of the entire production line!

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The Application of Dekuma intelligent management system

Abstract: Given the current situation of rubber and plastic product manufacturers, this paper proposes a new technology of “Dekuma Intelligent Management System” to help clients solve data analysis difficulties of rubber and plastic equipment.
Keywords: Digitalization; Equipment Operation; Production Progress.
Driven by the Made in China 2025 Policy and Industry 4.0 proposed by Europe, new technologies, represented by cloud computing, big data, mobile Internet, IOT and AI, have gained rapid development in recent years, which poses a great challenge to traditional development mode.
1、Current shortcomings of rubber and plastic equipment manufacturers
The traditional mode is like everyone is paying with software, but you go out with cash and inconvenience of transactions comes to you at any time. 
As long as people live in the digital age, changes have to make. Reflecting on most of the existing enterprises with rubber and plastic equipment for production, general pain points include:
（1） Data logging methods are lagging behind
Manual copying of data (product quantity, defective quantity, SPC) results in large errors and data loss.
（2） Equipment monitoring is not in place
Fail to fully grasp the operation status of rubber equipment, with no early warnings; it cannot support uniform management, and it cannot be monitored at any time.
（3） Low Usage
Fail to make correct and timely equipment operation plans.
（4） Old-fashioned Management Mode
The independent operation of equipment and low efficiency; fail to be integrated with ERP and MES; restrict the development of enterprises.
（5） Low Level of Information Integration
It fails to grasp the production progress of orders and estimated completion date, and it fails to have a global control over the order.
2、Importance of data
All rubber and plastic manufacturing enterprises hope to reduce costs, lift efficiency, mitigate uncertainties, and improve competitiveness. How to achieve goals one by one or move one step closer?
We start from the pain points and analyze the goals layer by layer. It is not difficult to find the root problem: all it needs is accurate data support, and changes need to be based on evidence; the most important factor to solve problems and move closer to the goal is data – accurate underlying data.
3、Source of Dekuma Intelligent Management System
As a professional rubber and plastics equipment manufacturer with complete solutions, Dekuma has experience, technology, process, and understanding of end-customer needs.
On the condition of making full use of our own advantages and capabilities, we have developed a set of data acquisition system: Dekuma Intelligent Management System (hereinafter collectively referred to as “Dekuma Intelligent”).
The system can help clients solve practical problems during operation, reduce costs to varying degrees, and significantly improve work efficiency.
4、Dekuma intelligent modules help customers solve problems
Through in-depth communication with clients, combining with the process and needs of on-site work, we have designed and optimized various intelligent modules.
Continuous optimization and upgrading in practical applications can truly help clients solve problems, reduce costs and improve efficiency.
Certificates and Awards
5、Introduction toDekuma Intelligent Module
1、The data acquisition function module includes:
（1）Visual Interface Management
It displays the name, status, real-time data, production progress, equipment utilization and other important parameters of all machines, allowing the information to be seen at a glance in front of the computer, eliminating passive waiting for information.
（2）Process Deviation Management
It provides management of the deviation between the set value of the process parameter and the actual value, which is presented in the system in the form of prompts.
（3）Alarm Management
It provides production abnormal alarm display, statistics and grouping.
（4）Trend Management
It generates trend graphs based on real-time production data, identifies production abnormalities at the first time, accumulates process parameters, and compares them with normal values.
（5）Report Management
It supports export of report in EXCEL, including standardized delivery of production parameter reports, alarm reports, and quality inspection reports.
（6）Actual Kanban
Status Kanban, Production Kanban, Comprehensive Kanban, and SPC Kanban are available.
（7）System Management
There are client login management, permission settings, system settings, and information input.
Machine Infographic
2、Production management module includes:
（1）Report Customization
It customizes reports according to client needs (the presentation modes in the report is diversified).
（2）Energy Management
It provides use of water, electricity and gas, program design and report presentation.
（3）Production Analysis
Each machine can provide detailed parameters, e.g. working status, mold number, product name, target quantity, completion rate, estimated completion date, and equipment utilization, allowing to make correct production plan adjustments at any time.
（4）Data Interaction
Docking with mes or erp systems: Allow machines in production plant to become a true member of big data.
（5）One-code Tracing
Digital quality tracing function: realize the quality traceability of the whole cycle from raw materials, production, quality inspection, and ex-warehouse products.
（6）Process Information
Collect production line work station alarm information: The production management personnel can obtain the work station information in real time via Kanban board, and arrange the management personnel to handle in time.
（7）Production Scheduling Management
It supports work order import, work order analysis, production management, and production tracing.
（8）Data Push
The client can customize the alarm trigger conditions and formulate an alarm push mechanism; notify the corresponding personnel via platform, on-site alarm lights, message push, etc.
（9）Machine Remote Debugging
Log in to device management platform in a remote manner, to call the acquisition unit in the platform and debug any PLC and HMI.
Summary Panel
6、Scope of Application of Dekuma Intelligent
Dekuma Intelligent has a wide range of applications. Basically, any device with an open interface can be connected; for devices without open ports, we can also perform relative processing.
Our team and technology master various communication protocols – both Http protocol self-researched, and the prevailing protocols in the market, including OPCUA, Mudbus-Tcp, S7 and etc. The acquisition of most PLCs on the market can provide suitable technical solutions.
7、Security and Architecture of Dekuma Intelligent
The construction of Dekuma Intelligent can provide local area network solutions, and can also support cloud servers. Due to the strong closeness properties of local area network, which requires clients to have their own computer room and IT department, we tend to recommend cloud servers.
Use only one network cable to connect the machine to the cloud platform, which significantly saves the cost of building basic network facilities in the early stage as well as the maintenance cost in the later stage. Compared with the local area network, the cloud end is featured at the following advantages:
（1）Security
Cloud service can prevent ARP attack and MAC spoofing, backup is made on a regular basis, and data will never be lost;
（2）Reliability
High performance, extremely low fault rate, flexible expansion or reduction of resources according to application requirements;
（3）Stability
In case of any faults, the data will be automatically migrated to other cloud servers, which ensures normal use of system;
（4）Low Maintenance Cost
Basically, the cloud server provider is responsible for maintenance, and we only need to pay service fee for spaces.
Hardware Architecture Diagram
8、Conclusion
Data has become the most important production factor in the information age. Obtaining accurate data may allow you to take the lead in the future development of rubber and plastics manufacturing industry.
Dekuma Intelligent serves as a powerful tool to transform basic data into information, thereby driving productivity.

No matter whether you are willing to develop in the digitization trending, or whether you can accept the digital transformation, the torrent of the time will still drive you forward.

The future will be dominated by big data. Your choice made now will decide to become a stumbling block or an accelerator for development of rubber and plastic manufacturing enterprise……

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Cosmos Press Solution for Backing Plate of Brake Pad Production

Abstract: This paper introduces an environmentally-friendly and efficient servo hydraulic press for production of backing plate of brake pads launched by Cosmos Presswhich widely used in the brake pad industry in past few years.

Keywords: automobile brake pad, production of steel backing, automatic production.

 

In whole automobile components industry, braking system is a key part of automobile. Without it, the driving safety of the automobile cannot be guaranteed.
The brake pad is one of the important components in the braking system. In addition to the quality of friction block, the quality of the brake pad is greatly affected by the flatness and the sheared edge quality of backing plate. Its flatness, sheared edge zone and size are directly related to the service effect of the backing plate.
The larger the burr and the more uneven the sheared edge and flatness, the higher the braking noise and the worse the braking effect. Therefore, the production process and the special equipment for backing plates are very important.

1. Difficulties in production process and special equipment for backing plate

Our investigations in Guangdong, Jiangsu, Zhejiang, Hebei and Shandong district reveal that the production of backing plate has the following features: the steel plate is relatively thick, generally 4-6mm, while the backing plate is generally designed with rivets and holes for installation on the caliper, therefore, the production processes are various and accuracy requirement is high.

At present, in the industry, the conventional punching process is the main production method. The main production equipment are mechanical presses. Some factories will use traditional hydraulic presses in some processes.

The control of quality is difficult in the production process with mechanical press and traditional hydraulic press. The production with mechanical press has a great impact on the service life of die. There is no domestic machine manufacturer to produce precision pressing equipment for backing plate. Some customers with high quality requirements will use imported fine blanking press which improves the quality of backing plate. However, the fine blanking press with price of several millions greatly increases the production costs. In addition, it is not conducive to flexible production with different specifications and in small batches, and affect the competitive advantage of enterprise.

Furthermore, the mechanical press generates great noise during punching process, so it is not environmentally friendly. Workers must wear ear protector for protection, the worse working environment cause difficulties in recruitment. With the improvement of urbanization, a factory which generates noise and is not environmental friendly is often complained, so the working time is greatly limited!

 

 

2.  Introduction to functional characteristics of Cosmos servo driven hydraulic press

Automobile brake pads are vulnerable parts with large production volume. With the rapid growth of the automobile market and the increase of automobile owner, all automobile brake pad manufacturers are expanding their plants to increase productivity, and new manufacturers are also running into the market.

To meet the needs of customers, Cosmos Press, under the support of the group’s strong R&D strength, has launched a special environmentally-friendly, low noise level and efficient servo driven hydraulic press for production of backing plates. The machine matched with the molds can fully cover the typical production processes of backing plates including 1.chamfer forming; 2.stamping; 3.pin forming and 4.fine stamping;

At the beginning of the design, the characteristics of “large quantity and low price” of backing plate production were known. On the premise of meeting the function, the costs of the equipment should be minimized, and the redundant design should be well controlled, to ensure that each kilogram of steel of the equipment is useful, and each component is appropriate at this position.

 

 

3. Advantages of Cosmos servo driven hydraulic press

3.1 Compact structure, easy operation, and automation

This machine is different from the traditional small table hydraulic press. Its hydraulic electrical system is reasonably designed and arranged on top. It is compact, has no obstacles around the machine, and is convenient for operation and installation of the mold. It does not affect the placement and handling of products. It is deeply favored by the workers on site. There is no obstacle around. Therefore, neither single machine automation nor multi-machine automation is affected. The production mode of multi-machine automation device reduces the manpower.

 

 

3.2 Rigid and lightweight machine body structure

The machine body structure avoids the “short, flat and fast” method of the small table machine, that is, three platens are made of heavy steel plates to achieve the purpose of rapid design and production. The three platens composed of top platen, moving bolster and fixed bolster are made of high-quality nodular cast iron. The reinforcement structure adjusted by finite element analyses is more reasonable, enhance good strength and small stress deformation, and has more optimized weight and safety factor ratio. Therefore, it avoids the phenomenon of “the wool coming from the sheep”, i.e. customers spending more money on machine weight.

 

 

3.3 Low noise level, environmentally-friendly, high-speed and stable hydraulic system

3.3.1 Low noise level and environmentally-friendly

The optimized servo motor hydraulic pump system only generates approximately 70dB to 80dB noise level during operation, and almost doesn’t generate noise in idle time, which greatly reduces the noise problems in the working environment. The operator enjoys moving from mechanical press workshop to servo driven hydraulic press workshop. To a certain extent, it also reduces the pressure of labor recruitment.

3.3.2 Pressure and position accuracy

The moving position and the pressing pressure are controlled and detected by precision linear transducer and pressure sensor. The pressure sensor matched with servo driver control can realize stepless regulation of working pressure. The working pressure for production of large and small backing plates can be set according to demand, which improves the quality and stability of products, and improves the “uncontrollable pressure and vulnerable mold” during punching operation; the pressing pressure can provide data support for new product development according to the size and accuracy requirement of product.

3.3.3 High-speed response

The highlight of the hydraulic system is used of imported Rexroth directional valve matched with the domestic mature two-way large-flow cartridge valve technology which not only realizes high-speed response to meet the production efficiency, but also reduces the manufacturing costs of the high-speed hydraulic system. The specially designed cartridge valve system reduces the resistance of the hydraulic oil flowing at a high speed, reduces the calorific value and the energy consumption, ensures the long-term high-speed response without stuck phenomenon, and ensures 24 hours stable and automatic production of press hydraulic system installed with oil cooler.

3.3.4 Control system

The “PLC+ touch screen + servo driver” control can realize the intuitive and efficient setting of the process flow and parameters. The flexible pressing process is adopted. Based on current backing plate production process and years of experience, Cosmos Press’ machine contains most of the pressing technologies of production process in the market. It can do the pressing process that cannot be completed by the mechanical press, realize the flexible and multi-purpose use of one machine, reduce the expenses and floor areas of production line, and lower the production costs.

 

Instant and effective action prompts

 

3.3.5 Unique finishing process structure

Based on the requirements of production process of backing plate, the machine is designed with a special cushion cylinder structure for finishing process. The sheared edge zone and dimensions of backing plate produced by the customer’s mold with the cushion cylinder structure, can reach the precision requirement from main engine factory. A special proportional pressure valve is equipped on the two-way cartridge valve to realize the floating blank holding force during finishing. By adjusting the floating blank holding force, the sheared edge zone of finished backing plate can meet the requirements. Besides, under the support of the floating force, the geometric dimensions of the previous processes of the backing plate will not be affected. A certain leveling effect will also be achieved.

Equipped with a special mold frame, it can be used in the reverse finishing process, that is, the ram cylinder is used for pressing and leveling, and the cushion cylinder is used for finishing. This process action is applicable to products requiring high leveling force.

The finishing process meets the quality requirements of backing plates. Three or four machines are combined to form an automatic line for production of backing plates. Customers do not have to spend millions on purchasing imported machines. It reduces the production costs of products, realizes the flexible production with different specifications and in small batch, and improves the product competitiveness.

4. Other advantages

4.1 Energy saving

The servo motor as the power source of machine. In working, it outputs the torque according to the real-time loads. Its power loss is small, 50% less than the traditional induction motor fixed with displacement pump, and at least 30% less than the traditional induction motor with variable pump.

4.2 High productivity

Its productivity is equal to that of mechanical press. It can complete punching action within 1.3s-1.6s and complete finishing action within 1.7s-2.3s.

 

 

5. Conclusions

Its successful development has solved three problems in traditional brake pad production process with mechanical press, i.e. “difficult recruitment & low per-capita productivity, noisy and high energy consumption”, relieves the pressure of environmental protection of an enterprise in production, greatly improves the product competitiveness, creates profits for users, and makes contributions to the development of automobile industry in China.

 

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