Application Case of Custom Automatic Loading and Unloading Dual - Pipe Head Expanding Machine
A leading agricultural machinery manufacturing enterprise, dedicated to the production of a wide range of agricultural machinery such as irrigation systems, seeding machinery, and harvesting equipment, has long grappled with challenges in pipe processing for its products. Given the complex and diverse requirements of agricultural machinery in different application scenarios, the processing of metal pipes, especially the expansion process, demands high precision, efficiency, and consistency. To address these pain points, the enterprise introduced a custom automatic loading and unloading dual - head expanding machine, which has since revolutionized its production process.
Processing of Pipes for Irrigation Systems
In the production of irrigation systems, the connection of pipes often requires precise expansion at the ends to ensure a secure and leak - proof fit. For instance, when manufacturing the main pipelines of large - scale center - pivot irrigation systems, the diameter of the pipes typically ranges from 100mm to 300mm. Before the introduction of the custom expanding machine, the manual or semi - automatic expansion methods were not only time - consuming but also inconsistent in quality. The error in the expansion diameter could reach up to ±2mm, leading to issues such as poor sealing and potential water leakage during installation and operation.
The custom automatic loading and unloading dual - head expanding machine changed the game. Equipped with an advanced numerical control system, it can accurately control the expansion process. The dual - head design allows for simultaneous expansion of two pipe ends, significantly increasing production efficiency. When processing a 200 - mm diameter pipe for the irrigation system, the machine can precisely expand the pipe ends to the required diameter with an error of within ±0.2mm. The automatic loading and unloading mechanism, integrated with a conveyor belt system, can load raw pipes into the expanding station and unload the processed pipes continuously. This not only reduces the labor intensity of workers but also ensures a smooth and continuous production flow.
In terms of equipment maintenance, for the automatic loading and unloading part, daily checks are carried out on the conveyor belt to ensure there is no wear or misalignment. The sensors that detect the position of the pipes are also calibrated regularly to guarantee accurate loading and unloading. For the dual - head expanding mechanism, the hydraulic system, which provides the main power for expansion, is maintained weekly. The hydraulic oil is checked for contamination and replaced if necessary. The expansion dies, which are in direct contact with the pipes, are inspected after every 1000 processing cycles. If there is any sign of wear or damage, they are promptly replaced to maintain the quality of the expansion process. In case of any equipment failure, the machine is equipped with an intelligent diagnostic system that can quickly identify the problem area, allowing the maintenance team to carry out targeted repairs and minimize downtime.
Processing of Tubes for Seeder Frames
Seeder frames, which are crucial for the stability and accurate seeding operation of agricultural seeding machinery, often require high - strength alloy tubes. These tubes need to be expanded at specific sections to facilitate the connection of various components. For example, in the production of large - scale precision seeder frames, the alloy tubes with a diameter of 30mm - 80mm need to be expanded at the ends to fit into the connecting joints precisely.
The custom dual - head expanding machine proves to be highly effective in this application. It can adjust the expansion force and speed according to the material properties of the alloy tubes. For hard - to - process alloys, the machine can gradually increase the expansion force in a controlled manner to avoid cracking or deformation of the tubes. The numerical control system enables the setting of different expansion diameters and lengths for different parts of the seeder frame tubes. During the production of a particular seeder frame model, the machine can process hundreds of tubes per day with a high degree of accuracy. The expansion diameter error is controlled within ±0.1mm, ensuring that all the tubes can be assembled perfectly, which in turn improves the overall stability and seeding accuracy of the seeder.
Regarding maintenance, due to the high - stress nature of processing alloy tubes, the expansion heads of the machine are made of special wear - resistant materials. However, they still need to be inspected frequently. After every 500 processing cycles, the expansion heads are carefully examined for any signs of wear, and if necessary, they are refurbished or replaced. The electrical control system of the machine, which controls the complex expansion process, is updated regularly with the latest software patches to improve its performance and stability. The mechanical transmission parts, such as gears and shafts, are lubricated weekly to reduce friction and ensure smooth operation. In the event of equipment failure, the enterprise has a dedicated team of technicians who are trained to handle the unique features of this custom - made expanding machine. They can quickly troubleshoot and repair the problem, minimizing the impact on production.
Processing of Conveying Pipelines for Combine Harvesters
Combine harvesters' conveying pipelines, which are responsible for transporting harvested crops, have strict requirements for the inner diameter and smoothness of the pipes. The custom automatic loading and unloading dual - head expanding machine plays a vital role in ensuring the quality of these pipelines. For example, when processing the stainless - steel pipelines with a diameter of 150mm - 350mm for grain - handling combine harvesters, the machine can expand the pipes at specific sections to achieve a seamless connection with other components.
The machine's advanced inner - wall treatment function, in addition to expansion, can also ensure that the inner wall of the expanded pipes remains smooth. This is achieved through a combination of special polishing tools and control algorithms. After expansion, the roughness of the inner wall of the pipes can be reduced to Ra0.4μm or less, which effectively reduces the resistance during crop transportation, preventing blockages and improving the working efficiency of the combine harvester. The automatic loading and unloading system can handle the large - sized and heavy pipelines with ease, ensuring a continuous and efficient production process.
In terms of maintenance, the inner - wall treatment tools of the machine need to be cleaned and calibrated regularly. After each shift, the residues on the polishing tools are removed to maintain their polishing effect. The control algorithms for the inner - wall treatment are optimized periodically based on actual production data to ensure the best possible surface quality. The structural components of the machine that bear the weight of the large pipelines, such as the loading and unloading brackets and the expansion support frames, are inspected monthly for any signs of fatigue or damage. Any potential issues are addressed promptly to ensure the safe and stable operation of the machine. When the machine encounters a malfunction, the enterprise's maintenance team can rely on the detailed operation records and diagnostic data provided by the machine to quickly identify and resolve the problem.
Before the introduction of the custom automatic loading and unloading dual - head expanding machine, the enterprise's production efficiency in pipe processing for agricultural machinery was relatively low, and the defective rate was as high as 15% due to inconsistent expansion quality. After implementing this advanced equipment, the production efficiency increased by over 80%, and the defective rate was reduced to less than 5%. This not only significantly reduced production costs but also enhanced the overall quality and competitiveness of the enterprise's agricultural machinery products, enabling it to better meet the demands of the agricultural market.
Pipe Head Expanding Machine Final Samples:
