DKM new rubber track production machine exported to South Korea

Recently, DEKUMA’s upgraded and optimized new RC480 automated rubber track production machine has been commissioned, and successfully exported to South Korea and arrived at the customer’s factory.

 

 

This customer is one of the largest auto parts manufacturers in South Korea, with production bases in many countries and regions, such as China, Europe, Southeast Asia and South Korea headquarters where DEKUMA’s rubber track machines are widely used.

DEKUMA has been cooperating with this customer for more than 10 years, and continuously improves equipment during the cooperation, and creating greater value to the customer.

Today, let’s see how DEKUMA’s rubber track production machines meet customer needs and keep improving.

 

 

Excellent performance of DEKUMA’s rubber track production machine

 

#01 

High degree of automation, reducing labor intensity and manpower requirements

In the past, the traditional production of rubber track required manual feeding, demolding and product retrieval. Generally, the production of a rubber track of several hundred kilograms required 3~4 people to work together.

 

 

After fully understanding the process of track production, DEKUMA has developed the automated rubber track machine, which can realize automated rubber sheet loading, automated demolding and automated reclaiming, and can realize the track tensioning process that cannot be done manually in the production process, so as to improve the quality of finished products.
With DEKUMA’s automated rubber track production machine, only one skilled worker can easily operate 4 machines at the same time, greatly reducing labor intensity and manpower requirements.

#02 

Overcome steel wires week links, and improve the service life of track

The traditional track production equipment lacks steel belt tensioning device, and the production of track has to adopt misplaced connection of steel wires, which left week links on the track.
DEKUMA’s automated rubber track production machine is equipped with automated tensioning device, and the tensioning force is constant throughout the process, which has changed the production standard of rubber track, so that the stress-bearing steel wire belts in track products can be made into a winding structure. It overcomes the weak links in the past and greatly improves the service life of the finished products.
#03 

Advanced non-dynamic clamping and vulcanization structure reduces energy consumption in production process

We have adopted the synchronous clamping technology by multiple sets of clamping oil cylinders, so as to achieve precise synchronization of multiple sets of oil cylinders as well as rapid clamping and pressurization.
After the clamping action is completed, the four cylinders clamp at the same time, so that the mold is evenly stressed and the molded rubber track has no thickness deviation.
During the vulcanization process, the hydraulic pump stops working, but the clamping pressure will not drop significantly, which can effectively reduce energy consumption and lower the production cost of track.

#04 

Highly intelligent operating system realizes simple operation

The highly customized B&R control system for the production of rubber track can be operated simply and easily, with accurate temperature control and faster response, and can save multiple formulas without the risk of loss.
Equipped with DEKUMA iSee4.0 intelligent management cloud platform, it can detect and control the main operating parameters of the equipment in the production process in real time, including energy consumption, temperature, pressure, clamping pressure, time and other key parameters, so as to realize the remote monitoring and maintenance of the operating status of the equipment.
The RC480 rubber track production machine delivered this time is mainly used to produce large rubber tracks. In order to further improve the production efficiency of our customers, we have provided the new equipment with a newly designed mold change carrier. 
The new mold change carrier is equipped with double-layer runners which can rotate on both the upper and lower layers. It can not only bear the track of heavier weight, but also allow the operator to adjust the position of track easily and improve the production efficiency.
Since 2013, DEKUMA has supplied a total of more than 200 sets of automated rubber track machines to more than 10 leading enterprises in rubber track production in China, also exported to South America, North America, Southeast Asia, South Korea, India and other countries and regions.
The cooperation with them is not a simple supply and demand relationship, but an in-depth cooperation. Dekuma will optimize the equipment synchronously based on the improvement of their track production process. Our technical team will visit their production sites every year to understand their first needs, so that our automated rubber track machine will continue to improve and maintain a leading position in the industry.
Even now that it is affected by the COVID-19 pandemic, we have dispatched after-sales service engineers to South Korea to assist customers in completing equipment installation and production commissioning.
If the after-sales are unable to go abroad, relying on the mature technology of Dekuma equipment, standardized packaging and convenient installation, customers can also successfully complete the installation and commissioning of rubber track production by themselves through complete and comprehensive manuals and our remote assistance.
Fast and responsible services, high-end and reliable equipment, all these are the key points to long-term cooperation between DEKUMA and its customers.
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PTFE Moulding Hydraulic Press Key Technology and Application

Abstract: This paper analyzes the production process of PTFE compression molding, and summarizes the causes why conventional pressing pressure and pressing process are easy to cause product defects and scraps.

To solve the problems of surface patterns, cracks, discoloration, hidden cracks, etc., the hydraulic press team of Dekuma has developed a precision servo hydraulic press for blank pressing of PTFE powder product, and solves the problem for customers from the root.

 

01 Introduction to PTFE Properties

PTFE, known as the “king of plastics”, features many excellent properties including colorless, non-toxic, wide temperature resistance, chemical inertness and low coefficient of friction.

It serves as one of the important materials that are indispensable to all industrial sectors, e.g. automobile, national defense, machinery, chemical industry, electronics and other industries. It can also be made into PTFE pipes, rods, belts, plates, etc.

 

 

02 Commonly Used Methods of PTFE

The most common method is compression molding when processing products with PTEE.

The process of compression molding goes roughly as follows: raw material inspection → mashing and sieving → measuring → molding → semi-finished product inspection → sintering → cooling → finished product inspection → packaging.

After investigation on the common problems encountered during production of PTFE compression molding, it can be found that the improper operation of pressing pressure and pressing process may easily cause product defects and scraps, and the unstable pressure output serves as the main reason for cracks.

 

 

On the basis of understanding the customer’s process, the hydraulic press team of Dekuma has developed a precision servo hydraulic press for blank pressing of PTFE powder product, and solves the problem for customers from the root.

 

 

03 Advantages of PTFE Powder Blank Precision Molding Machine

(1) Slow Pressure Rising and Controllable Time

For powder compression, the time will significantly affect the effect of product molding. In case that the speed is too fast, exhaust will be insufficient, which may easily cause problems such as surface patterns, cracks, and large differences in density between both ends and the middle.

For the time control of pressurization, the hydraulic press adopts servo motor oil pump hydraulic system to solve the problem. Under the cooperation of hydraulic pressure and electricity, it has developed a controllable function of slow pressurization based on the set pressurization time, and the pressurization time is controllable from several seconds to dozens of minutes.

 

 

(2)Almost no pressure impact and fluctuation in pressurization stage

At the critical point of signaling pressure, most common hydraulic presses will experience the process of overshoot – fallback – stabilization due to inconsistent pressure repeatability each time.

Under the cooperation of server and plc program, the hydraulic press can control the critical point of signaling pressure well under the high sampling frequency and high-speed scanning cycle.

Thanks to the research results of hydraulic team of Dekuma for years, the set target value can be achieved under cooperated control of the server and the plc program. In the pressure holding stage, the pressure fluctuation is controlled within 1 bar, which can also maintain long-time operating of oil pump without damage.

Due to the specific characteristics of PTFE powder, after the initial pressurization to the set pressure and entering the holding pressure stage, the volume can still be compressed continuously. Once the volume is compressed, the pressure shall be reduced and the press will supplement pressure. Therefore, the pressure holding stage of PTFE product serves as a process of hydraulic system continuous pressure dropping and supplementing.

The stability of hydraulic press is realized based on years of application experience. Under the perfect coordination of high response of servo hydraulic PID and discharge flow of hydraulic oil circuit, the pressure fluctuation reaches almost zero.

 

For accurate pressure output, the hydraulic press engineers continuously optimize the hydraulic system and program. In application of servo system, sometimes a single PDI parameter is often not sufficient for the pressure range of the whole area. With the PID parameters set with low pressure, it will be still not applicable when reaching medium and high pressures.

After finding this situation in practical application, the hydraulic press combines with years of application experience, adopts multiple sets of PID parameters, corresponding to the multi-stage signaling pressure of the hydraulic press, and avoids the inapplicability of a single PID parameter to different pressure stages.

 

 

(3)After completion of pressing, the pressure relief time is controllable

For pressing of PTFE powder blank products, sometimes the pressure holding time takes dozens of minutes, with the purpose of obtaining a blank product with uniform density after reaching a certain compression ratio. However, after reaching the pressure holding time, in case of pressure relief instantaneously for some products, it is easy to cause the quality problem of hidden cracks inside the product.

To solve the problem of pressure relief, the hydraulic engineers have developed the function of slow pressure relief process and controllable time, and the pressure relief time can be controlled from several seconds to dozens of minutes.

For this, the pressure relief process can be considered as an inverse process of pressurization. During pressure relief, the pressure is output according to the time ratio for the purpose of reducing pressure until the final pressure relief in place. Conventional hydraulic presses have no such function.

 

 

(4)Convenient setting of process parameters

Adopt PLC + touch screen + servo drive control, for intuitive and efficient setting of technological process and parameters.

Most PTFE blank molding methods require two-sided pressurization + product demolding, and one product forming requires pressing twice + demolding once. However, the pressing parameters of the three times are not the same, and common hydraulic presses require repeated manual filling of different parameters three times.

Based on the special process of PTFE, the hydraulic press has compiled the parameter setting method for this process, allowing the customers to input parameters that conform to the product for one time, and the pressing can be completed with only operation controller. The operation is simple and fast, which reduce the probability of errors, improves reliability, and significantly reduces the technical threshold of operators.

 

 

For products that require to maintain pressure and exhaust for a certain period of time under different pressures to ensure transmission of pressure to all parts of the resin, it provides a free parameter setting function. (As shown in figure below)

 

 

For commonly used product parameters, after completion of debugging and passing inspection, it can be saved as a recipe, which supports one-key save and recall. (As shown in figure below)

 

 

(5)Energy saving and environmental protection

Common hydraulic presses produce large noises when working, which can easily pollute the production environment and affect the health of operators. The Datong hydraulic press adopts a servo motor as the power source, whose noise level is only about 70 decibels when working, and is almost silent under standby state. When operating, the torque is output according to the size of immediate load. The power loss is small, which can save 30%-50% of electric energy compared with common hydraulic presses, with significant energy saving effect.

Note that the pressing and holding time of PTFE powder blank products is long. For high precision, the user shall basically maintain the pump on and holding pressure. In this process, the servo motor system of the press only needs a dozen or so percent of output to conform to the pressure holding requirements. The hydraulic system produces less heat, reduces the cooling cost, and extends the service life of oil pump.

Common hydraulic presses require full speed output when the pump is on and pressure is holding. The actual utilization rate is only about 10%, and the machine is doing useless heating work for the rest time. The power loss is large, the energy utilization rate is low, and the oil pump service life of each hydraulic component is reduced.

 

 

04 Conclusion

For PTFE powder molding, accurate and stable pressure serve as the key factor to molding; for investment income, machines with energy-saving, energy conservation and environmental protection and high-utilization features are the key to cost recovery and realization of benefits; for operators, simple and efficient operation mode is the key point; the hydraulic press meets all the above key points, which can meet customer needs, and help customers solve problems from the root.

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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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Chinese Creation of German Heritage | DEKUMA Brand Story

1. Hardship in plastic machinery development

 

Since 2002, with China’s reform and opening-up policy, its economy rapidly grew and there was a strong demand for rubber and plastic machinery and equipment from different industries. The Chinese manufacturing industry’s knowledge and technical skills in the rubber and plastic machinery industry was well behind other foreign countries’, causing local domestic manufacturing companies to be dependent on imported machines. European and American equipments were more advanced, but they were expensive. Shipments were also slow and after-sales services were mostly unresponsive. If the machines or components were damaged when received and required re-ordering, the lead-time usually took at least one or two months for another shipment. This greatly hindered China’s rapidly growing manufacturing industry.

 

 

Some European manufacturers realized the opportunity for business development in China, and decided to invest and set up factories in China. Only a few of them were successful in setting up their manufacturing facilities and developing their own brands in China, most of them were unable to take any market shares in the Chinese market due to a lack of understanding of Chinese law, culture, the market, etc.

 

2. Awakening of the industry

 

There are always pioneers in the market.
 
Some of these ‘pioneers’ of the local rubber and plastics machinery industries invested a vast sum to buy blueprints from European companies hoping to gain some breakthroughs.
Some of them chose to produce the machinery strictly according to the blueprint, but the products were way below the acceptable standards when comparing to the imported ones.
While other pioneers chose to use the blueprints as a reference which ended up making products which were just similar to those they produced locally.
 
A number of pioneers even tried the reverse-engineering upon purchasing of those overseas machinery, tools and products, aiming to integrate others’ advance technologies into their production but in vain. The essence of materials, engineering and techniques were not captured.
3.  Journey to Germany technology

Amid the industry’s development, we questioned if a machine with high performance and reasonable production cost was really impossible, and whether high-end rubber machines can only be used in niche markets.

 

For several years, the core management team of Cosmos Machinery Enterprises Ltd. (Cosmos) had been searching for solutions.

Cosmos is a Hong Kong listed company with more than 40 years of  experience in machine manufacturing, industrial product trading, and manufacturing of plastic products. Cosmos has been one of the market leaders in machine manufacturing in China Mainland, with an ample source of quality customers and suppliers. Our strong sense of brand awareness and quality control have demonstrated asuccessful model more capable than our mainland counterparts. In addition, Cosmos has an advanced and extensive capacity forproducing and processing rubber machinery as well as the rich experiences in collaborating with some international partners. More importantly, the core team in Cosmos could communicate well and exchange ideas with Europe counterparts, which would help us understand and develop necessary knowledge and skills in advancing our technology.

 

With Cosmos recognizing the importance of manufacturing its rubber machineries on its own, it then built a machining center in the 1990s, which has possessed a strong processing and production capacity.

 

 

In order to enhance the competitiveness of China’s rubber and plastics machinery and equipment industry, and reduce the dependency on imported equipments, it was important to develop the ability to build our own high-end equipments, that is why Cosmos’ executives have conceived a uniquesolution.

 

DEKUMA GmbH Deutsche Kunststoff Maschinen

 

At the beginning of 2002, Cosmos leaders formed a small team of experts in Germany with knowledge of Chinese cultures and the machine industry.
With mutual understanding among the team members, they dedicated themselves to establish along-term collaborating relationship aiming to develop state-of-the-arttechnologies in the machine manufacturing industries in the Chinese market. Hence, this team in Europe founded “Dekuma GMBH” (“Dekuma” is short for German plastic machinery), a small tech company.
They rapidly started designing and producing their first Dekuma rubber equipment. It is worthwhile to mention that Cosmos leaders did not relocate the team back to China as they recognized the importance of having an independent R&D team in Germany, where it could enjoy a strong and positive atmosphere in technological research, and thus allowing its designs to carry German’s attributes.
4. The foundation of extraordinary quality
“Dekuma GMBH” had the European team working in different components in R&D. Such as creating the design, digital application, equipment optimization, etc. Their design was then manufactured in China Mainland, with the European team completing the testing for the equipments to ensure strict quality control. Dekuma’s first generation of rubber machines were repeatedly designed, tested and amended. After 2 years or so, they were able to find a perfect balance between ‘Made in China’ and ‘Designed in Germany’, and the German-designed products at Cosmos at that time was produced and its quality and performance was also recognized by German experts.
 
After the success of having the first-generation equipment, the entire Dekuma GMBH team officially brought their research results to China in 2004, and jointly established “Dekuma Rubber & Plastic Technology (Dongguan) Co.,Ltd.” with Cosmos in a way that Dekuma GMBH was investing their technological expertise to this Joint Venture.
Since the integration of the German team into the company, workers in Cosmos frequently heard the word ‘rubbish’ from their German counterparts (the quality standards between countries were different backthen). Germans are extremely strict with manufacturing qualities, down to the smallest step of using the specific tool for a specific part. For example, during installation, each screw should be screwed in with it’s specific screwdriver, each bolt must be marked and tightened a second time, slits must be measured with a specific measuring tool, all equipments’ corefunctions must undergo a 24 hour no-fail checkup (all must be redone if thetest fails at the last second).
 
It is precisely because of the strict requirements of the German team that Dekuma can gradually grow through their constant guidance. Subsequently we understood the importance of precision in each of the workflow in their production plants, many starproducts such as the first pipe extrusion production line, China’s largest 2800-ton horizontal rubber injection machine, and a full-section rubber track forming machine were continuously produced in Dekuma and could be exported internationally with positive response. Since then, the soul of German engineering has been integrated into Dekuma’s DNA.
5. Towards the niche market

With the continuous competitive environment across all industries, the competitive edge of Dekuma’s standard was being challenged, and more importantly, both domestic and foreign customers urgently needed customized equipment to enhance their competitiveness.

In order to satisfy the upgrading needs of customers, Dekuma turned its attention to the niche market segments in 2012 and began actively paying attention to theirneeds by continuing the technological innovation and continuous research and development.

 

Although there was still a gap between Dekuma’s equipment and imported equipment, the gap was narrowing rapidly. Comparing with foreign branded equipment, some of Dekuma’s most significant competitive edges are rapid response, effective technical exchanges in early stages, timely equipment delivery, equipment installation and  optimization, and quick solutions to problems encountered by customers… These characteristics could be the real solution for problems of efficiency encountered during the rapid development of all Chinese manufacturers.

 

Among different niche market application, Dekuma has been highly recognized by our users such as from automobile nylon tubing, rubber track, the microduct cables, hydraulic press for brake pad sectors thanks to our strong R&D, perseverance and our willingness to customize products for our clients.

 

6. China’s smart manufacturing journey

 

Germany’s “Industry 4.0” strategy is the fourth industrial revolution led by smart manufacturing, using the “Internet+” approach to push traditional manufacturing towards smart manufacturing, especially in the fields of equipment manufacturing, drive and electrical engineering.
 
For example, structural designs, material used, craftsmanship and precision are some of the factors that made superb mechanical parts of the plastic equipments, the truly determining component has to be the drive and motion control system, it decides the equipment operation, coordination of the machine processing, compatibility and  specifications.
 
Relying on Cosmos’ technology in digital engineering and automation, Dekuma has become a leading manufacturer in the industry by transforming the term ‘Made in China’ into ‘Smart manufacturing in China’. Dekuma has a strong R&D team in drive and motion control. The quality control algorithm for each equipment produced by the company is continuously optimized by the team according to their deep understanding of users’ procedures, product conditions, etc. This program is also a core technology in Dekuma. Compared with the general control algorithms, self-developed algorithms can greatly improve the overall performance of the equipment.

 

With the continuous investment in research and development in smart manufacturing and automation, Dekuma’s “Smart manufacturing result” has been highly recognized by customers, industries and even awarded by the nation.
Dekuma was subsequently awarded with the “Top 30 Comprehensive Strength Enterprises of China Plastics Machinery Manufacturing Industry”, “Chinese National Science and Technology Progress Award”, “Guangdong Province new Specialized Enterprise”, “First (set) key technical equipment certification”and other honors.
Most of Dekuma’s customers are high-end users in the industry, and its products are exported around the globe such as the United States, Europe, Latin America, the Middle East, and Southeast Asia, and are used in different fields including auto parts, building materials, energy transmission, and electronic communications. This helps the technological innovation and facilitates “smart manufacturing” of  various industries.
With continuous innovation, state-of-the-art technology and strict quality control, Dekuma is advancing in the high-end  plastics and  rubber machinery industry as a visionary market leader locally and internationally in the future to come.
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How Dekuma microduct extrusion line is pushing the limit?

近日,畅销产品DEKUMA微管挤出生产线通过验收,实现多项性能突破!

DEKUMA微管挤出生产线远销欧洲、中东、东南亚等地,可生产用于光缆网络建设和扩建的硅芯管和集束管。自2011年推出以来,DEKUMA与客户合作,不断优化升级,打造四大优势:

 

01.高输出

 

6-14mm硅芯管DEKUMA微管挤出生产线生产速度可高于100m/min。

凭借DEKUMA高产量挤出主机、优化设计的多层模头、高性能下游设备、自主研发的PCC全线电脑控制系统和多年的细节优化,其生产速度实现了世界级速度。

 

02.高稳定性

 

在管材的高速生产中,生产线的各个环节都可能成为生产速度的瓶颈。

主机挤出量的波动,真空度的突然变化,甚至冷却中的摩擦,都可能随时中断管材的生产。

DEKUMA知道用户的想法并为用户考虑。在原有高品质挤出生产线的基础上,对微管的生产进行了针对性的优化,实现了生产速度的不断突破。

现在,100m/min 的速度仅仅是个开始。我们将继续挖掘DEKUMA挤出线的潜力,立志成为微管生产设备的最佳选择。

 

 

03.操作方便

 

先进的PCC电脑控制系统,实现全线自动化控制。

主机配有米重控制装置,实现生产速度和挤出量的自动调节。

收卷机配有积放架,并设计有自动换卷功能,使紧张的换卷工作变得轻松可控。

 

 

04.交钥匙解决方案

 

2011年,为满足意大利客户的要求,DEKUMA自主研发了该设备。

在与客户的不断合作中,德库玛逐渐加深了对微管生产需求的理解,并不断对设备进行优化升级。

DEKUMA已经掌握了微管生产的交钥匙解决方案,并取得了多项突破。挤出生产线可达到同类设备的世界一流水平。

微管挤出生产线不仅帮助意大利客户成为当地最大、欧洲领先的通信网络解决方案提供商,还成功协助沙特阿拉伯、埃及、南非、泰国等地区的客户从传统管材生产升级到微管生产.

 

随着通信技术的不断发展,特别是5G网络的高速普及,网络运营商需要增加新的光缆网络以满足用户日益增长的数据需求。城市大规模光缆网络的建设依赖于充足的地下管道资源。因此,通信管道管孔资源的短缺是不可避免的。

传统的扩管方式需要挖路,成本高,施工难度大。在国外,基于硅芯管和集束管的微导管和微光缆系统技术是解决“最后一公里”问题最流行的方法。德库马与国外客户合作开发的微管挤出生产线,为客户提供高产能、高稳定性、人性化操作的一整套解决方案,帮助客户轻松实现微管生产的转型和产能升级。

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