Mechanical innovation Reducer technology from general-purpose equipment to industrial robots
Intelligent equipment upgrade: unveiling the reducer innovation from industrial machine tool to robot
This paper comprehensively analyzes the application and development trend of key technologies such as general equipment, industrial machine tools, injection molding machines, cutting tools, reducers, industrial control, and construction machinery. It focuses on the contribution of the digitalization of industrial machine tools to the upgrading of the manufacturing industry, the application of injection molding machine automation technology in the production of plastic products, and the improvement of machining efficiency due to the high wear resistance of tools. At the same time, the types of reducers for industrial robots and their development trends were concerned. The article emphasizes the core position of technological innovation in promoting the transformation and upgrading of the manufacturing industry, and demonstrates the development potential of the field of intelligent equipment.
1. General equipment, industrial machine tools (machine tools), injection molding machines, cutting tools, reducers, and industrial control systems
General equipment, industrial machine tools (machine tools), injection molding machines, cutting tools, reducers, industrial control systems and construction machinery are all indispensable key components in the manufacturing industry, each of which plays a central role in different fields, and technological progress is closely related to industrial development. The following will provide an in-depth analysis of the technical applications, cases, industry characteristics, professional technical knowledge points and development trends in these fields.
1.General equipment: General equipment refers to equipment that is widely used in multiple industries, such as motors, reducers, conveyor belts, etc. Technical applications for these devices include automation control, energy-saving technologies, and intelligent monitoring. Examples include automated production lines and logistics systems in smart factories. Industry trends include digital transformation, intelligence, and energy efficiency.
2.Industrial machine tools: Industrial machine tools are the basic machines that make other machines, such as machine tools. Its technical applications include high-precision machining, numerical control technology, and flexible manufacturing systems. Examples include component machining in the aerospace sector and mould making in automotive manufacturing. Technical expertise includes cutting principles, machine dynamics and error compensation. Trends include high-speed machining, multi-axis linkage, and smart manufacturing.
3.Injection molding machines: Injection molding machines are used to manufacture plastic products. Its technical applications include injection molding technology, mold design, and materials science. Examples include housing manufacturing for consumer electronics and manufacturing for automotive parts. Expertise includes melt flow analysis, injection molding process parameters, and mold cooling. Trends include lightweight design, composite applications, and automated production.
4.Tools: Tools are used in machining for cutting and forming. Technical applications include advanced tool materials, tool geometry design and cutting process optimization. Examples include high-speed cutting and precision machining in metalworking. Technical expertise includes tool wear mechanisms, tool coatings, and cutting force analysis. Trends include nanotechnology coatings and intelligent tool management.
5.Reducer: The reducer is used to reduce the rotational speed and increase the torque. Technical applications include gear design, lubrication technology and transmission efficiency optimization. Examples include reducers in industrial robots and drive systems for wind turbines. Technical expertise includes gear meshing theory, dynamic analysis, and reliability design. Development trends include high-precision reducers and permanent magnet synchronous reducers.
6.Industrial control: Industrial control involves automation systems and process control. Technology applications include PLCs (Programmable Logic Controllers), industrial networks, and human-machine interfaces. Cases include the control system of an automated production line and the overall control of a smart factory. Technical expertise includes control algorithms, system integration, and data acquisition and analysis. Development trends include the application of industrial Internet, edge computing and artificial intelligence in industrial control.
7.Construction machinery: Construction machinery includes heavy equipment such as excavators and cranes. Technical applications include hydraulics, power transmission and remote control technology. Examples include large-scale engineering projects in infrastructure construction. Technical expertise includes structural mechanics, hydraulic control, and mechanical design. Trends include electrification, intelligence, and environmental protection.
Overall, trends in these areas are driven by digitalization, intelligence, automation, and sustainability. Technological innovation and the need for increasing efficiency have led to the evolution of these areas. For example, Industry 4The 0 concept promotes the application of smart manufacturing and IoT technology in various fields. In addition, advances in materials science are also influencing these areas, such as the application of new tool materials and lightweight materials.
Second, what is the specific development trend of the reducer?
As a key equipment in transmission technology, reducer plays an important role in the field of modern industry and automation, and its development trend is mainly reflected in the following aspects:
1.Efficiency and precision:
High level and high performance: The design and manufacture of reducers tend to be higher precision levels and better transmission efficiency. Through the use of carburizing quenching, gear grinding and other advanced processing technology, the bearing capacity and service life of the gear are improved, while the volume is reduced, the noise is reduced, the operation stability and the overall transmission efficiency are improved.
2.Modular & Integrated Design:
Building block combination design: In order to meet the individual needs of different industries and customers, the reducer is developing in the direction of modularization, with strong versatility of components, which is convenient for rapid selection, assembly and maintenance, and can flexibly expand the product series, shorten the production cycle and reduce costs.
3.Intelligence and Digitalization:
The deep integration of the reducer and the intelligent control system realizes functions such as accurate speed control, condition monitoring and fault diagnosis, as well as remote operation and maintenance services.
Industry 4 is supported by embedding sensors and communication modules0 and data acquisition and interconnection in the intelligent manufacturing environment.
4.Lightweighting and miniaturization:
With the application of new materials and the optimized design of structure, the reducer is constantly pursuing a lighter and more compact product form to adapt to the application scenarios with strict volume and weight restrictions in the fields of robotics, aerospace, and new energy vehicles.
5.Diversification & Customization:
Diversified types and variant designs: In order to cope with different working conditions and use requirements, the product categories of reducers are increasingly rich, including planetary reducers, worm gear reducers, harmonic reducers and other different types, and the installation methods are diverse, such as hollow shaft suspension, floating support base, integrated connection between motor and reducer, etc., which expands the application range in various complex environments.
6.Environmental protection and energy saving:
Considering the needs of sustainable development, the research and development of reducers also focuses on improving energy efficiency, reducing mechanical losses, and meeting green manufacturing standards.
7.Independent and controllable and domestic substitution:
In the context of the restructuring of the global industrial chain, China and other countries are actively developing and promoting high-end reducers produced in China to break the monopoly of foreign technology and realize the independent controllability and localization of core components.
3. What is the working principle of the injection molding machine?
The working principle of the injection molding machine is based on the thermoplastic properties of the plastic, through a series of successive process steps, the solid plastic particles are heated and melted, injected into the mold, and cooled into the desired shape and size of the plastic product. Here are the detailed steps of the working process of the injection molding machine::
1.Raw material pretreatment:
The plastic pellets are fed from the hopper into the barrel of the injection molding machine.
2.Material melting:
The outside of the barrel is heated by a heating ring, so that the plastic particles inside are heated and gradually melted into a flowing state.
3.Screw conveying and plasticizing:
The barrel is equipped with a screw that is driven by a motor to rotate, and the screw exerts shear force and pressure on the molten plastic during rotation, causing it to be further evenly mixed and pushed forward.
4.Metering & Storage:
When the screw continues to move forward, under the action of the injection cylinder, the head of the screw forms a closed storage space to complete the measurement and storage of a certain amount of molten plastic.
5.Injection Phase:
The injection cylinder pushes the screw forward quickly, and the molten plastic in the storage chamber is injected into the closed mold cavity through the nozzle at high pressure at high pressure.
6.Holding pressure and cooling:
After the injection is completed, the injection molder maintains a certain pressure (holding pressure) to ensure that the plastic is fully filled and compacted in the mold cavity, and the mold is cooled by a cooling system to gradually solidify the plastic.
7.Mould opening and ejection:
After the plastic is completely cooled and hardened, the mold is opened, and the product is pushed out of the mold through the ejection mechanism.
8.Cycle Preparation:
While the part is removed, the injection molding machine begins the preparation of the next cycle, which includes the steps of cleaning up the remaining plastic, re-closing the mold, and refilling the molten plastic.
The entire injection molding process is a cyclical cycle that stops after a set number of products have been produced. This process is suitable for both high-volume production of a single product and small batch production of many different types of plastic products.
4. What are the coatings of tools?
There are several main types of tool coatings:
1.Diamond-like coating (DLC).
The DLC coating has an extremely low coefficient of friction, good adhesion resistance, and high hardness and wear resistance. Divided into different subtypes, such as:
Gray-black plain DLC coating.
The TAC hydrogen-free DLC coating, which can be as hard as 5000HV, is one of the hardest known DLC coatings and may exhibit a seven-color appearance.
2.Titanium nitride coating (TIN).
The golden yellow color of the TIN coating is one of the most common tool coatings, providing good resistance to high-temperature oxidation and some wear resistance, making it suitable for a wide range of general purpose cutting applications.
3.Titanium carbide coating (TICN).
The ticn coating is silver-gray and has low internal stress, so it has high toughness, excellent lubricity and wear resistance, especially suitable for use in occasions with high requirements for toughness and wear resistance, such as punching dies and stretch molding.
4.Other composite coatings and multi-coatings.
Composite coatings include, but are not limited to: TiALN (titanium aluminium nitride), CRN (chromium nitride), ZRN (zirconium nitride), ALCRN (aluminum-chromium nitrogen), and even multi-layer or multi-component nanocomposite coatings.
These coatings often combine the advantages of different elements to form gradient or composite structures to adapt to more complex working conditions and higher mechanical performance requirements, such as improving thermal stability, reducing the coefficient of friction, and enhancing wear resistance and high temperature oxidation resistance.
With the development of technology, coating materials and processes are continuously optimized, and new high-performance coatings such as nanostructure coatings, ultra-thin multi-layer coatings, doped modified coatings, etc. are also emerging, which further improve the performance of tools under various harsh machining conditions such as high-speed cutting and dry cutting.
5. What are the applications of energy-saving technology for general equipment?
Energy-saving technologies for general equipment are widely and varied, and the following are a few major areas and specific technologies:
1.Power System Energy Saving Technology:
Frequency conversion speed regulation technology: the motor speed is adjusted through the frequency converter to match the load demand and avoid ineffective energy consumption, especially in fans, pumps and other equipment.
High-efficiency transformer: The use of low-loss silicon steel sheet and optimized design of the winding structure reduces the iron and copper loss at no load and load.
Power factor correction: Improve the power factor through reactive power compensation to reduce energy loss in grid transmission.
2.Energy saving of lighting systems:
LED lighting replaces traditional light sources: LED luminaires have higher light efficiency and longer lifespan, significantly reducing power consumption.
Intelligent lighting control system: Automatically adjust the light intensity according to the ambient light intensity and personnel activities to reduce unnecessary energy waste.
3.Energy Saving for Building Equipment:
Air conditioning system: Adopt high-efficiency inverter air conditioning, thermal ** system and intelligent temperature control strategy to improve energy efficiency ratio (COP).
Heating system: the use of ground source heat pump, solar heat collection, low-temperature radiant heating and other technologies to replace the traditional high-energy heating methods.
Building envelope insulation technology: reduce the loss of cold and heating and save energy by improving building materials and adding insulation layers.
4.Energy saving of industrial production equipment:
Combined heat and power technology: Waste heat from the production process** is converted into electricity or heat energy for reuse.
Industrial boilers and kilns: Efficient combustion technology and waste heat ** systems are used to improve thermal efficiency.
Equipment upgrades: energy-efficient electric motors, compressors and other power units, as well as efficient production lines with intelligent control systems.
5.Energy Saving for Office and Household Appliances:
Energy-saving label products: Buy appliances that meet energy efficiency standards, such as energy-efficient refrigerators, washing machines, TVs, etc.
Standby energy management: Develop low standby power consumption technology and intelligent power management system to reduce the power loss of electrical appliances in standby mode.
6.Automation and information energy-saving technology:
Industrial Internet and Internet of Things technologies: Optimize equipment operation through real-time monitoring and data analysis to avoid over-operation and unnecessary energy consumption.
Energy Management System (EMS): Integrates the management of the overall energy consumption of the enterprise, provides decision support and optimization solutions.
The above are just some of the applications of energy-saving technologies for general equipment, and there are more innovative technologies and solutions in actual scenarios, which are constantly being updated with the development of technology.
6. How does the digitalization of industrial machine tools promote the upgrading of the manufacturing industry?
The digitalization of industrial machine tools refers to the integration of advanced information technology, computer technology, network technology and control technology to traditional machine tools and equipment, so as to realize the whole process of intelligent and networked from design, production, processing, testing and management and service. Its role in promoting the upgrading of the manufacturing industry is reflected in the following aspects:
1.Increase productivity:
The digital industrial machine can precisely control the toolpath and motion parameters through the advanced CNC system, reducing non-productive time and increasing the output rate of a single machine.
Real-time monitoring and optimization of the production process, automatic adjustment of cutting parameters to adapt to changes in workpiece material and condition, thereby reducing cycle time.
2.Improve product quality
High-precision digital control ensures consistent part size and shape, reducing scrap rates and return costs.
Through real-time monitoring and intelligent diagnosis, errors can be prevented and maintenance can be carried out in a timely manner to ensure product quality.
3.Enhance the ability of process innovation:
Digital technology has made it possible to manufacture complex surfaces, multi-axis simultaneous machining, and difficult parts such as composite materials, and broadened the product line and market space of the manufacturing industry.
Simulation** technology simulates the actual machining process in a virtual environment in advance, helping engineers optimize the design and process.
4.Promote flexible production and customized manufacturing
The digitalization of industrial machine tools enables it to have the ability to quickly change, flexibly respond to changes in market demand for small batches and multiple varieties, and realize the lean production mode of on-demand production.
Integrated in the intelligent manufacturing system, the industrial machine can seamlessly connect with ERP, MES and other information systems to realize order-driven automatic scheduling and execution.
5.Resource Conservation and Environmental Protection:
Digital management and optimization reduce material waste, improve energy efficiency, and help enterprises achieve green manufacturing goals.
Maintenance** and remote monitoring capabilities reduce downtime and repair costs, extend equipment life, and indirectly reduce resource consumption.
6.Building a Smart Factory Ecosystem:
Industrial machine tools as "Industry 4.."0" or "Made in China 2025" framework under the framework of the core equipment, through the Internet of Things, cloud computing and other technologies interconnected with other production equipment, logistics systems and management systems to form a collaborative intelligent manufacturing system.
In short, the digitalization of industrial machine tools is one of the key links in the manufacturing industry towards intelligent manufacturing, which can not only greatly improve the technical level and comprehensive competitiveness of the manufacturing industry, but also support the transformation and upgrading of China's high-end equipment manufacturing industry.
7. Application of injection molding machine automation technology in the production of plastic products?
The application of injection molding machine automation technology in the production of plastic products is extremely extensive and in-depth, which significantly improves the production efficiency, product quality and stability of the overall production process. The following are the specific applications and advantages of automation technology for injection molding machines:
1.Automatic Feeding System:
Centralized feeding system: realize the automatic conveying and measurement of raw materials through the first-class feeding system, reduce manual intervention, ensure the uniform mixing of raw materials, and improve the accuracy of proportioning.
2.Robots & Manipulators:
Equipped with a manipulator around the injection molding machine for automatic loading and unloading operations, including taking out the molded plastic parts and putting a new mold into the injection molding machine, which greatly reduces the time and labor cost of manual operation, and reduces the labor intensity of workers and the risk of work-related injuries.
3.Closed-loop control system:
The injection molding machine adopts an advanced closed-loop control system to monitor and accurately control the injection speed, pressure, temperature and other process parameters in real time to ensure the stability and consistency of the injection molding process and improve product quality and yield.
4.Intelligent Process Optimization:
Computer-aided design (CAD) and computer-aided manufacturing (CAM) software, combined with injection simulation** technology, pre-optimize the process plan to reduce the number of mold trials and scrap rates.
5.Remote Monitoring & Diagnostics:
Through the Internet of Things technology and the industrial Internet platform, the operation status of the injection molding machine can be remotely monitored, equipment failures can be warned in advance and maintenance suggestions can be provided to effectively prevent production interruptions.
6.Auto-Tune Function:
The automatic injection molding machine has the ability of self-learning and self-adjustment, and can automatically adjust various parameters according to the actual working conditions to adapt to the needs of different materials or products.
7.Integration with MES ERP system:
The injection molding machine automation system can be seamlessly integrated with the factory's information management system to realize real-time production data collection, order tracking, production plan execution, quality traceability and other functions, and support lean production in an intelligent manufacturing environment.
8.Post-processing automation:
For plastic parts that need to be processed later, a series of processes such as cooling, trimming, testing, and packaging of parts are completed through automated equipment such as conveyor belts and sorting robots, so as to realize the unmanned operation of the whole production line.
To sum up, the automation technology of injection molding machine not only improves the overall efficiency of the production line, but also greatly improves the working environment, and enhances the rapid response ability and market competitiveness of enterprises to changes in market demand. With the development of new technologies such as artificial intelligence, big data analysis and edge computing, the automation of injection molding machines is continuing to evolve in the direction of more intelligence and refinement.
8. How to improve the machining efficiency with high wear resistance of the tool?
The high wear resistance of the tool means that the tool can maintain excellent cutting performance during long-term machining, and is not easy to wear or has a slow wear rate. Improving the wear resistance of the tool can directly improve the machining efficiency, which is reflected in the following aspects:
1.Longer tool life: Tools with high wear resistance can make more cuts in the same machining time, reducing the number of tool changes, resulting in increased productivity.
2.Reduced downtime: Reduced tool change and readjustment times due to tool wear ensure continuity and stability of the machining process and improve the overall efficiency of the production line.
3.Improve machining quality: Tools with good wear resistance can maintain high cutting accuracy, reduce dimensional tolerances in the machining process, and improve product quality and consistency.
4.Reduced machining costs: While the initial cost of a highly wear-resistant tool may be higher, in the long run, it can reduce the cost per part due to its long service life.
5.Improved material removal rate: Highly wear-resistant tools maintain good cutting performance at higher cutting speeds, resulting in higher material removal rates and shorter machining times.
6.Reduced reliance on coolant: Tools with good wear resistance are less dependent on coolant during machining and can operate in dry or semi-dry cutting conditions, reducing coolant use and associated environmental concerns.
7.Increased machine utilization: Due to the extended tool life, the running time of the machine is fully utilized, and the utilization rate of the machine tool is improved.
In order to improve the high wear resistance of the tool, the following measures can be taken:
Use high-quality tool materials such as carbide, ceramic, cubic boron nitride (CBN), etc.
Advanced tool design, such as design with good heat dissipation performance and reduced cutting resistance.
Apply suitable tool coatings, such as titanium alloys, alumina, etc., to improve the hardness of the tool surface and reduce friction.
Optimize machining parameters such as cutting speed, feed, and depth of cut to reduce tool wear.
In short, improving the wear resistance of tools is one of the key factors to improve machining efficiency, and it is of great significance to achieve efficient, economical and high-quality modern machining.
9. What are the effects of miniaturization of reducer on construction machinery?
The impact of reducer miniaturization on construction machinery is mainly reflected in the following aspects:
1.Improved compactness
The miniaturization of the reducer means that its size and weight are reduced, which is conducive to a more compact drivetrain layout when designing construction machinery. This reduces the overall size of the equipment and allows the construction machine to be more flexible in confined spaces or limited work sites.
2.Performance Optimization:
Despite the reduced size, the miniaturized reducer can maintain or even improve its original performance, such as output torque and transmission efficiency, by adopting advanced materials, design methods, and manufacturing processes. This makes the power transmission of construction machinery more efficient after miniaturization.
3.Energy Conservation and Emission Reduction:
The lighter small reducer helps to reduce the energy consumption of the whole machine, so as to achieve the purpose of energy saving and emission reduction. At the same time, due to the reduced mass, the vehicle's dynamics will also improve, such as faster acceleration and more responsive handling.
4.Load capacity and load carrying capacity:
Although miniaturization will bring limitations to physical size, if properly designed, the small reducer can also ensure sufficient load transmission capacity and bearing capacity, and ensure the stability and reliability of construction machinery when completing complex working conditions.
5.Ease of assembly and maintenance:
Miniaturized reducers are generally easier to install, disassemble and repair, shorten the maintenance cycle and time cost, and improve the availability and efficiency of the equipment.
6.Application field expansion:
The progress of reducer miniaturization technology has provided the possibility for the development of micro and light construction machinery, enabling it to play a greater role in urban construction, landscaping, pipeline maintenance and other scenarios that require refined operations.
7.Cost control and market competitiveness:
Through miniaturized design, it is possible to reduce material consumption and production costs, thereby reducing the overall cost of construction machinery products and enhancing market competitiveness.
In summary, the miniaturization of the reducer not only affects the structural design, performance and adaptability of the working environment of construction machinery, but also relates to the cost control, energy conservation and environmental protection requirements of the whole machine and the application prospects in emerging market segments.
10. What are the reducers used in industrial robots?
There are three main types of reducers commonly used in industrial robots:
1.RV reducer (rotary vector): RV reducer is a precision transmission device, especially suitable for the power transmission of multi-joint robots. It has the characteristics of high precision, high torque, strong rigidity, etc., which can effectively ensure that the robot maintains good dynamic performance and position repeatability when moving at high speed. The RV reducer is designed by combining a cycloidal pinwheel with a planetary gear mechanism to achieve a compact structure at a large speed ratio, and has a high load capacity and long life.
2.Harmonic drive gearbox: Harmonic drive gearbox works by the principle of elastic deformation, which is mainly composed of wave generator, flexible wheel (elastic wheel), rigid wheel and bearing. When the input shaft drives the wave generator to rotate, the flexible wheel produces a controllable radial deformation, which realizes the contact and transmission with the rigid wheel. Harmonic reducer is characterized by small size, light weight and high transmission efficiency, but compared with RV reducer, its bearing capacity is smaller, and it is often used in light robots with small loads or occasions that require extremely high positioning accuracy.
3.Planetary gearbox: Planetary gearbox is a widely used precision gearbox, its structure includes sun gears, planetary gear carriers (including multiple planetary gears), internal ring gears, etc. The planetary gears rotate around the sun gear and rotate around their own axis, reducing the rotational speed of the input shaft and amplifying the output torque. Planetary reducers also have the advantages of high precision, high efficiency and strong bearing capacity, and are mainly used in applications that require large torque or wide speed ranges in the field of industrial robots, and are also widely used in servo motors and other mechanical equipment that require precise speed control.
To sum up, this article introduces the diversified selection and application of industrial equipment such as general equipment, industrial machine tools, injection molding machines, cutting tools, reducers, industrial control and construction machinery. In actual production, choosing the right equipment according to specific needs can improve production efficiency and reduce production costs. For example, the application of injection molding machine automation technology in the production of plastic products can improve production efficiency and product quality; Choosing tools with high wear resistance is conducive to improving machining efficiency; The miniaturization of reducer has many positive effects on construction machinery. In the field of industrial robots, RV reducers, harmonic reducers, planetary reducers, etc. play an important role in the joint drive of robots. Choosing the right reducer can improve the overall performance and economy of the equipment.