English (UK) 
简体中文 How do newbies get their powder up fast? -Ahem, the string stage! But I know the pain of the newbie pipe conveying line too well: why is the production line as silky smooth as Dove, but your line is as stuck as dial-up Internet in the 1990s? Don't worry, today we will break up and crumble to say through!Pipe automation line design those doorwayIt is a speciality for all kinds of running, lagging and inefficiency!
Firstly, understand your pipe: shape and weight determine the design foundation.
Designing a conveyor line is not about buying equipment with your eyes closed.Pipe properties are the starting point! I've seen too many mills drop money on the wrong equipment just because they didn't figure out the temperament of their own pipes:
- Steel pipes, metal pipes, these "tough guys".::
- Heavy weight → must be usedHeavy duty chain or roller linesThe regular belt will be crushed in a minute.
- Surface Slip→V-RollerMust be on! Otherwise you'll slip and spin on the conveyor and wonder about your life.
- PVC pipe, plastic pipe these "brittle"::
- Fear of scratching → selectFlexible chain or accumulation conveyorReducing collisions
- Easily deformed →Reducing the distance between the rollersDon't let the pipe overhang in the middle "flash".
- Extra-long tubing (over 6 metres)::
- turning radiusAt least 8 times tube lengthOtherwise it's stuck in the corner.
- plusIntermediate support framePrevents sagging and deformation during transport
(As a negative example: a factory used a belt line to transport steel pipes, and the pipes rolled and cut a big hole in the belt - two days of shutdown just for repairs!)
Second, the core mechanism design: V-type rollers + pusher system is the soul of the
Don't let the fancy terminology fool you! There are just two at the heart of pipe conveyance.Steady, don't wobble + push with precision.
1. V-roller - the "cradle" of the pipe
Why does it have to be a V-shape? Just look at the picture:
| Roller type | Suitable Tubes | Achilles' heel |
|---|---|---|
| flat roller | Short thick tubes (<2 metres) | Long tubes roll off easily |
| V-Roller | All round tubes | Costly 10% |
| grooved roll | Profiled tubes (square/oval) | Customisation is expensive and maintenance is a hassle |
The inclination angle of the V-roller is also of interest.90° angle is the most versatileBut when you're shipping large-diameter pipe, you'll have to adjust it.120°Otherwise the tube gets stuck in the bottom of the slot and the frictional resistance skyrockets.
2. Actuator systems - the "invisible hand" on the conveyor line
Want the tube to go where it's meant to go? The putter has to match like this:
- Cylinder actuators: Cheap and durable, but accuracy ±5mm - suitable for loading stations with low positional requirements
- Servo motor + screw: Accuracy ±0.1mm, expensive but worth it!Socketing/cutting stationessential
- Anti-Rebound Design: Putter headWith polyurethane padsOtherwise, the pipe hits the baffle and bounces back with a "Duang" sound... (Don't ask me how I know this.)
Third, the pit of space layout: not enough turning radius? Total loss!
What do pipe conveyors fear most? --Corner blocked as a viper! Three guides to avoiding the pit:
- Horizontal turning radius ≥ pipe diameter x 12
- A chestnut: a DN100 pipe has a turning radius of at least 1.2 metres.
- What to do with small spaces? Use45°bevelled rollersSegmented steering, much smoother than sharp turns
- Don't climb more than 30° vertically
- Slope > 30°? Pipe will slip back! Gotta add.Stopper or pawl mechanism
- Transition paragraph should be long enough
- straight line to circular arc agoAllow 1 metre transition sectionSudden bends can "twist" the pipe.
(The most outrageous design I've ever seen: three 90° bends crammed into a 5 square metre corner - resulting in workers having to "dig out" a jammed pipe every half hour...)
Fourth, precision control: difference of 1 mm = scrap of the whole batch
Pipe machining is most afraid of inaccurate positioning! Three key control points:
- axial positioning::
- End stops + photoelectric sensorsCombination: baffle hard limit, photoelectric induction soft trigger
- Precision machininglaser rangefinderReal-time feedback for adjusting the position
- Radial anti-skew::
- Every 3 metresSelf-aligning rollersAutomatic offset correction
- Heavy Duty Tube PlusSide guide wheels, don't expect the tube to go straight on its own!
- synchronicity::
- For multi-stage conveyor linesSame PLC controlTo avoid "infighting" between those who push and those who don't.
- The speed difference is controlled atWithin 5%Otherwise the front and rear tubes collide
V. Safety and security: Save this? Wait to lose your money!
Teacher's blood lesson.Never save money on safety devices.!
- emergency stop button:: One every 10 metres, in a visible location (not hidden behind equipment)
- overload protection: Torque limiter must be fitted! A factory drum jammed still hard to turn, the result of the motor burned even with the production stop...
- Anti-roll off design::
- Climbing section plusratchet stopper
- turnpike mountedNylon guide railMore scratch-resistant than metal
Question and answer time
Q: What is the most important part of the design to drop money on?
A.Positioning accuracy!Saving money on pushrods? Wait until your bushings don't line up right and your cuts are crooked! Go straight to servos for precision work. Don't feel bad--Save 3 commissioning workers for 1 servo systemThe money is paid back in half a year.
Q: How to break the small workshop space?
A: TryMulti-level three-dimensional conveying! The lower level to send raw material pipe, the upper level to transport finished products. A steel pipe factory with this trick in 200 square metres of space stuffed down the whole line, the efficiency of the counter rise of 30%. (But note: the floor height of less than 3 metres don't force it)
Q: Why does my conveyor line always drop tubes?
A: 80%.V-roller inclination is wrong! Plastic tubes are too tight with 90° clamp angle card, change to 120° immediately smooth. And--Roller spacing > 1/2 tube lengthMust drop the pipe! Measure your home equipment quickly.
Editor's view
Engage in pipe conveyor line design.Don't be a block-breaker.! Understanding the characteristics of your own tube is the foundation, V-rollers and servo actuators are the core weapons, and safety protection is the bottom line of life-!I've seen too many people lose out by saving a little money.. Really not sure? Spend 5,000 yuan to hire professional engineers on-site survey, than blindly investing 500,000 yuan to change the production line is worth a lot more! (Don't ask me how I figured out this account)
