机床气密检测功能改善

机床气密检测功能改善2014-3-4GlenWang，TEF3Strictlyconfidential–ChassisBrakesInternational2012-Allrightsreserved,alsoregardinganydisposal,exploitation,reproduction,editing,distribution,aswellastheeventofapplicationsforindustrialpropertyrights.AirsensorswitchImprovement–TEF3目录一、什么是气密检测二、气密检测的现状和问题三、更换气密检测模块-选型四、新产品介绍-FESTO气检模块五、预计改善效果六、预计投资回报七、实验测试结果八、全面改进实施计划FIXTUREStrictlyconfidential–ChassisBrakesInternational2012-Allrightsreserved,alsoregardinganydisposal,exploitation,reproduction,editing,distribution,aswellastheeventofapplicationsforindustrialpropertyrights.Airsensorswitch–TEF3一、什么是气密检测气密检测功能：通过检测气流变化，1,确认加工件是否在夹具上2,确认加工件摆放位置AirSensingFunctionStrictlyconfidential–ChassisBrakesInternational2012-Allrightsreserved,alsoregardinganydisposal,exploitation,reproduction,editing,distribution,aswellastheeventofapplicationsforindustrialpropertyrights.AirsensorswitchImprovement–TEF3二、目前我公司机床气密检测的现状和问题目前我公司气密功能是由机床厂家出厂配置的，是以SMC的ISA15气密模块为核心的一套组件（如右图）。其目前存在主要问题：1、能耗损失大，一台机床全年消耗压缩空气11，803CNY2、功能相关问题→精度差，不稳定，需反复调整排气口一直排气Strictlyconfidential–ChassisBrakesInternational2012-Allrightsreserved,alsoregardinganydisposal,exploitation,reproduction,editing,distribution,aswellastheeventofapplicationsforindustrialpropertyrights.AirsensorswitchImprovement–TEF3二、目前我公司机床气密检测的现状和问题→气密检测孔容易堵塞→旋钮式调整方式，无法观察到量的变化，调整困难→旋钮位置很容易被人为改动而导致功能失效→模块不坚固，容易损坏Strictlyconfidential–ChassisBrakesInternational2012-Allrightsreserved,alsoregardinganydisposal,exploitation,reproduction,editing,distribution,aswellastheeventofapplicationsforindustrialpropertyrights.Airsensorswitch–TEF3MAWOMATICGmbHEnergysaverelatedQualityrelatedOthersBrandControlunitPurgeairpressuredisplayValuesetupPriceQualityServiceCKDNoNoNoNoLowNosureNotsureSMCNoNoNoNoLowBadnoserviceIFMNoNoNoYesHighGoodGoodMawo.NoNoNoNoHighGoodNoserviceNorgrenYesYesYesYesHighGoodNoserviceRexrothYesYesNoNoHighNotsureGoodFestoyesyesyesyeslowGoodGood三、更换气密检测模块-选型Strictlyconfidential–ChassisBrakesInternational2012-Allrightsreserved,alsoregardinganydisposal,exploitation,reproduction,editing,distribution,aswellastheeventofapplicationsforindustrialpropertyrights.AirsensorswitchImprovement–TEF3四、新产品介绍-FESTO气检模块Strictlyconfidential–ChassisBrakesInternational2012-Allrightsreserved,alsoregardinganydisposal,exploitation,reproduction,editing,distribution,aswellastheeventofapplicationsforindustrialpropertyrights.AirsensorswitchImprovement–TEF3四、新产品介绍-FESTO气检模块Strictlyconfidential–ChassisBrakesInternational2012-Allrightsreserved,alsoregardinganydisposal,exploitation,reproduction,editing,distribution,aswellastheeventofapplicationsforindustrialpropertyrights.AirsensorswitchImprovement–TEF3四、新产品介绍-FESTO气检模块FESTO气密模块所需配件少，结构紧凑Strictlyconfidential–ChassisBrakesInternational2012-Allrightsreserved,alsoregardinganydisposal,exploitation,reproduction,editing,distribution,aswellastheeventofapplicationsforindustrialpropertyrights.AirsensorswitchImprovement–TEF3四、新产品介绍-FESTO气检模块Festo可以在更大量程下提供更好的检测精度Strictlyconfidential–ChassisBrakesInternational2012-Allrightsreserved,alsoregardinganydisposal,exploitation,reproduction,editing,distribution,aswellastheeventofapplicationsforindustrialpropertyrights.AirsensorswitchImprovement–TEF3四、新产品介绍-FESTO气检模块FESTO气检模块检测方式A：2个检测压力1、SOPA工作时有两个压力，一个是清洁时的高压，一个是检测时的低压；2、其他品牌始终是一个低压力在检测；B：由于高低压不同，产生了不同的检测效果及能耗1、SOPA清洁时的高压可以将堵在气检口的铁屑等杂质吹净，保证检测点的洁净；2、其他品牌气检工作时始终是低压，如果检测口堵塞，可能输出错误信号；C：能源消耗1、SOPA气检工作顺序是清洁检测停，故停止时节能；2、其他品牌气检一直吹气，故将消耗更多的压缩空气能源。Strictlyconfidential–ChassisBrakesInternational2012-Allrightsreserved,alsoregardinganydisposal,exploitation,reproduction,editing,distribution,aswellastheeventofapplicationsforindustrialpropertyrights.AirsensorswitchImprovement–TEF3五、预计改善效果能耗降低刀具损失较少1、费用降低气密检测改善1/3↘4/5↘2,382元/台/年↘2-3万元/年↘Strictlyconfidential–ChassisBrakesInternational2012-Allrightsreserved,alsoregardinganydisposal,exploitation,reproduction,editing,distribution,aswellastheeventofapplicationsforindustrialpropertyrights.AirsensorswitchImprovement–TEF32、功能更优五、预计改善效果精度更高,更稳定更坚固耐用有高压清扫,不堵了数字显示,容易调整,还可以锁定看着是不是有高度大气上档次的感觉？一套价格只比SMC多了600元Strictlyconfidential–ChassisBrakesInternational2012-Allrightsreserved,alsoregardinganydisposal,exploitation,reproduction,editing,distribution,aswellastheeventofapplicationsforindustrialpropertyrights.AirsensorswitchImprovement–TEF3六、预计投资回报ChangeSMCairsensorswitchtoFestoairsensorswitchEnergycostsave:150,000CNY/yearBrokentoolcostsave:20,000-30,000CNY/yearQualityriskreduction:180times/yearMaintenancecostsave:130,000CNY/yearPayback:1.3yearProject:Benefit:Strictlyconfidential–ChassisBrakesInternational2012-Allrightsreserved,alsoregardinganydisposal,exploitation,reproduction,editing,distribution,aswellastheeventofapplicationsforindustrialpropertyrights.AirsensorswitchImprovement–TEF3七、实验测试结果在我公司实验机床上测试FESTO气密检测模块，完全达到了预期效果。基于该模块的强大功能，我们采用了新的检测方法，循环时间内检测+清扫时间缩短到1分钟，在节能上远远超出预期，可以达到7,000/台/年的能耗节省。节能效果超出预期7000/2382=293%Strictlyconfidential–ChassisBrakesInternational2012-Allrightsreserved,alsoregardinganydisposal,exploitation,reproduction,editing,distribution,aswellastheeventofapplicationsforindustrialprop