Components and Finished Products Display
Components such as inner drum blanks, balance rings, and plastic bases undergo a series of processes to be assembled into a finished drum.
Production Line Overview
This production line is designed for the fabrication of 43L and 57L inner drums. The complete line integrates a series of processes, including fully automatic progressive stamping, edge folding and seaming, flanging, orbital riveting, punching, and automatic countersinking and screw driving. By incorporating automation equipment—such as robotic manipulators—the line achieves highly cost-effective semi-automated production; the entire line requires a workforce of only three operators to maintain a stable production cycle of 25 seconds per unit.
Under the high-precision conveyance of a gripper feeder, the sheet metal blanks synchronize with the inner drum's progressive die to enable variable-pitch feeding, achieving a production cycle time of 12 to 15 seconds per piece. Subsequently, a robotic gripper grasps and transfers the workpiece to an integrated folding and seaming machine, which automatically folds the V-edges at both ends, forms the sheet into a cylindrical shape, and tightly presses the seam together (seam strength: >3500 N/50 mm). The formed drum ring is then automatically ejected and inverted via a pneumatic flipping cylinder; a robotic manipulator performs a lateral transfer to load the ring into the flanging machine, which automatically executes a 90-degree flange on both the top and bottom edges. Finally, a robotic manipulator automatically retrieves and unloads the finished ring. This entire sequence constitutes a fully unmanned production segment. Operators then manually assemble the front cover, drum ring, and flange, placing the assembly onto a contoured positioning plate on the machine; a two-handed safety start initiates the automatic orbital riveting process for both the top and bottom ends. All forming wheel assemblies within the equipment utilize standardized modular components, ensuring high operational stability. Operators then place the riveted drum ring onto the contoured positioning plate of the punching machine; a three-way punching module executes the simultaneous stamping of the screw holes required for the tripod mount. This machine features a specialized material detection mechanism designed to prevent accidental or erroneous punching. Finally, operators place the tripod mount into a dedicated positioning fixture and position the drum ring onto its corresponding contoured plate; the machine then automatically executes the alignment and pressing of the d rum ring onto the tripod mount, completing the countersinking and automatic screw-locking processes. This equipment innovatively incorporates servo motors to manage torque control and provide output feedback, thereby achieving precise control over the screw-tightening torque.
Flow chart
Production Line Parameters
Whether the production line equipment is automated or manual depends on various factors, including the client's specific requirements, cycle time, investment budget, and available facility space. Our projects constitute fully customized, integrated turnkey solutions—encompassing every stage from initial consultation, design, and manufacturing to installation, commissioning, and after-sales support.
|
Equipment Cycle Time |
≤25 seconds per piece |
|
Production Cycle Time |
≤30 seconds per piece |
|
Temperature |
0~40℃ |
|
Humidity |
0~60% |
|
Installation Floor Load Capacity |
5 tons per square meter |
|
Control System Power Supply |
DC24V |
|
Aerodynamic Force |
5.5-7.5kgf/cm² |
Decoiler and straightener
The coiled material is manually hoisted onto the loading trolley at a designated position. Upon manual activation via a push-button, the trolley automatically and slowly advances to the required loading position (ensuring the center of the coil rack aligns within the inner diameter of the coil's liner sleeve). Once the uncoiling support arms automatically expand to secure the coil, the trolley retracts to its home position, leaving the coil in a standby state. Manual operation is then initiated to uncoil and feed the material; once the material reaches the required position for stamping, the uncoiler is switched to automatic mode, thereby entering a fully automated operational state.
Servo feeding machine
The servo feeding machine utilizes a servo motor to control its clamping-style feeding mechanism. It incorporates a limit device to regulate the width of the incoming material, maintaining a limiting precision tolerance of ±0.2 mm, while the feeding step deviation (forward and backward) remains ≤0.2 mm/m. The contact surfaces of the clamping mechanism—specifically those touching the material—are constructed from anti-slip, wear-resistant materials featuring a high-gloss finish, thereby safeguarding the material's surface against damage.
Automatic Stamping
The automated stamping system utilizes a double-point mechanical press (min. 300 tons) to punch, form, and cut inner-cylinder sheet metal blanks. Its tonnage, bolster dimensions, and shut height must match the user's maximum product dimensions. To ensure quality, prevent jamming, and facilitate maintenance, the manufacturer must precisely calculate tonnage based on product drawings and die structures. Additionally, the press must feature an overload protection device for rapid pressure relief and ram recovery during a jam.
Integrated V-bending, Curling and Locking-Seaming machine and Sheet Conveying Device
The integrated V-bending, Curling and Locking-Seaming machine is an automated system comprising an automatic conveying mechanism, a hydraulic system, a positioning mechanism, a flanging mechanism, a rounding mechanism, an automatic riveting mechanism, and a material receiving and conveying mechanism. The machine's operating side must be equipped with a light curtain safety device or an interlocking safety guardrail system; should personnel enter the machine's operational zone, the equipment will automatically halt to prevent bodily injury.
Cylinder Ring 90-Degree Up-and-Down Flanging Machine and Loading/Unloading Mechanism
The automated 90-degree cylindrical ring flanging system consists of loading, positioning, expanding/clamping, rotation, flanging, unloading mechanisms, and a receiving station. During operation, a mechanical device loads the riveted ring into the machine, which automatically positions the workpiece and sets the flanging dimensions. The system then expands to clamp the ring, initiates rotation, and advances the flanging mechanism to simultaneously flange both the upper and lower edges.
Pre-assembly of upper and lower flanges and riveting of the sleeve ring
The rotary riveting of the upper and lower flanges to the cylindrical ring is performed on a standalone machine, which comprises a positioning mechanism, a rotation mechanism, a riveting mechanism, a marking mechanism, and a material receiving station. The connecting centers must be reliably aligned, and the centerline of the lower flange's reinforcing rib must be aligned with the center of the mounting position for the cylindrical ring's lifting rib.
Punching Out Triangular Bracket Mounting Holes on the Cylinder Body
The standalone cylindrical body triangular hole punching unit comprises a hydraulic system, a punching station, and a receiving bay. To operate, the user manually places a spin-riveted cylindrical body onto the station and initiates the cycle from a safe distance. The machine then automatically aligns the workpiece via its lower flange and secures it with a pre-clamping mechanism, allowing three punching cylinders to simultaneously extend and complete the operation.
Automatic Countersinking and Screwing Machine
The automatic countersinking and screwing machine is primarily designed to perform countersinking and bolt-fastening operations on triangular brackets. It must be equipped with a reliable positioning and fixturing mechanism to ensure that the cylindrical component remains stable and securely positioned prior to bolt fastening, with a level of precision that fully satisfies the product's quality capability requirements.
Quality Inspection Fixtures
The inner drum is secured using a clamping mechanism that grips the rotating shaft, thereby enabling the dimensional inspection of the inner drum assembly—specifically its height, radial runout, and axial runout. A dial indicator displays the actual measured values, facilitating the recording and monitoring of quality data. Upon completion of the inspection, the finished inner drum is manually placed onto a transport cart, marking the completion of the inner drum's production process.