Case of Customized Double - Head Pipe Cutting Machine
I. Enterprise Requirement Background
A large automotive parts manufacturing enterprise has been long committed to the production of precision pipe fittings such as fuel pipes and brake pipes for automotive engines. With the continuous expansion of the automotive market, the enterprise's order volume has increased significantly. The original single - head pipe cutting equipment can no longer meet the growing production demand in terms of production capacity. Moreover, the traditional single - head pipe cutting machine has a low processing efficiency. When dealing with pipes of different diameters and wall thicknesses, it is necessary to frequently replace tools and adjust parameters, which seriously affects the production progress. In addition, manual operation of the single - head pipe cutting machine makes it difficult to ensure a high degree of consistency in cutting accuracy, resulting in a high defective rate of products. This not only increases production costs but also affects the enterprise's market reputation. In order to break through the production capacity bottleneck and improve product quality, the enterprise decided to customize a high - performance double - head pipe cutting machine.
II. Customization Process
Requirement Communication and Scheme Design: The enterprise contacted a professional pipe cutting machine Jiuqiang Machinery manufacturer and elaborated on its own production requirements in detail. These requirements included the materials of the pipes to be cut (such as stainless steel, aluminum alloy, etc.), the diameter range (from 10mm to 50mm), the wall thickness (from 0.5mm to 3mm), as well as the expected production efficiency (the number of pipe fittings cut per hour) and cutting accuracy (with an error controlled within ±0.1mm). The technical team of the manufacturer conducted in - depth analysis and research based on these requirements and formulated a preliminary equipment design scheme. The scheme adopted an advanced dual - spindle structure, where two cutting heads can work simultaneously, greatly improving the cutting efficiency. At the same time, high - precision servo motors and ball screw drive systems were equipped to ensure cutting accuracy.
Equipment Manufacturing and Debugging: After determining the design scheme, the Jiuqiang Machinery manufacturer started production. High - quality steel was selected as the body material to ensure the stability and rigidity of the equipment. Special designs and selections were made for the cutting tools. For pipes of different materials, corresponding carbide tools were used to improve the durability and cutting quality of the tools. During the equipment manufacturing process, the quality management system was strictly followed, and every component was strictly inspected and debugged. After the equipment was manufactured, a comprehensive debugging and trial run were carried out in the Jiuqiang Machinery manufacturer's factory. The pipe specifications and cutting requirements in the actual production of the enterprise were simulated, and a large number of cutting tests were carried out. During the test process, the cutting accuracy, cutting speed, stability and other indicators of the equipment were monitored and adjusted in real - time to ensure that the equipment performance met the enterprise's requirements.
Delivery and Training: After the equipment was debugged and qualified, it was successfully delivered to the enterprise. The technical personnel of the manufacturer went to the enterprise site to install and conduct the final debugging of the equipment. At the same time, detailed training was provided for the operators and maintenance personnel of the enterprise. The training content included the operation method of the equipment, parameter setting, daily maintenance knowledge, and diagnosis and troubleshooting of common faults. Through on - site demonstrations and practical operation exercises, it was ensured that the enterprise employees could proficiently master the use and maintenance skills of the equipment.
III. Usage Effects
Significant Increase in Production Efficiency: After the customized double - head pipe cutting machine was put into use, the production efficiency was significantly improved. In the past, the single - head pipe cutting machine could cut at most 50 pipe fittings per hour, while the double - head pipe cutting machine can cut more than 150 pipe fittings per hour, with the production capacity increased by more than twice. The two cutting heads work simultaneously, reducing the clamping and positioning time of the pipes and achieving continuous and efficient cutting operations. This enables the enterprise to easily cope with the growing order demand, complete customer delivery tasks on time, and enhance the enterprise's competitiveness in the market.
Remarkable Improvement in Cutting Accuracy: The high - precision servo motors and advanced drive systems adopted by this equipment enable strict control of cutting accuracy. In actual production, the cutting error can be stably controlled within ±0.1mm, meeting the stringent requirements for pipe cutting accuracy in automotive parts manufacturing. High - precision cutting ensures the dimensional consistency of the pipes, reduces the rework workload in subsequent processing procedures, and improves the overall quality of the products. The defective rate of products has decreased from the original 8% to less than 2%, reducing the enterprise's production costs and enhancing the market competitiveness of the products.
Good Equipment Stability: The high - quality body material and elaborate manufacturing process enable the double - head pipe cutting machine to exhibit good stability during long - term continuous operation. The equipment has small vibration and low noise during operation, reducing the impact on the working environment. At the same time, the stable operation state also extends the service life of the equipment and reduces the equipment maintenance cost. The enterprise only needs to carry out regular maintenance and upkeep of the equipment according to the maintenance plan provided by the manufacturer to ensure that the equipment is always in good operating condition.
Enhanced Ease of Operation and Flexibility: The operation interface of the equipment is designed to be simple and intuitive, and the operators can get started proficiently after simple training. Through the operation panel, cutting parameters such as cutting length and cutting speed can be easily set. Moreover, the equipment can quickly adapt to the cutting requirements of pipes with different diameters and wall thicknesses. Only corresponding parameter adjustments need to be made on the operation panel, without the need for frequent tool replacement and complex mechanical adjustments. This ease of operation and flexibility improve the equipment usage efficiency and reduce the labor intensity of the operators.
Double Head Cutting Machine Final Samples:
