机床气密检测功能改善

1、机床气密检测功能改善2014-3-4 GlenWang，TEF3Strictly confidential Chassis Brakes International 2012 - All rights reserved , also regarding any disposal, exploitation, reproduction, editing, distribution, as well as the event of applications for industrial property rights. Air sensor switch ImprovementTEF3目录目录一、

2、什么是气密检测一、什么是气密检测二、气密检测的现状和问题二、气密检测的现状和问题三、更换气密检测模块三、更换气密检测模块-选型选型四、新产品介绍四、新产品介绍-FESTO气检模块气检模块五、预计改善效果五、预计改善效果六、预计投资回报六、预计投资回报七、实验测试结果七、实验测试结果八、全面改进实施计划八、全面改进实施计划FIXTUREStrictly confidential Chassis Brakes International 2012 - All rights reserved , also regarding any disposal, exploitation, reproduct

3、ion, editing, distribution, as well as the event of applications for industrial property rights. Air sensor switch TEF3一、什么是气密检测一、什么是气密检测气密检测功能：通过检测气流变化， 1, 确认加工件是否在夹具上是否在夹具上2, 确认加工件摆放位置加工件摆放位置Air Sensing FunctionStrictly confidential Chassis Brakes International 2012 - All rights reserved , also re

4、garding any disposal, exploitation, reproduction, editing, distribution, as well as the event of applications for industrial property rights. Air sensor switch ImprovementTEF3二、目前我公司机床气密检测的现状和问题二、目前我公司机床气密检测的现状和问题目前我公司气密功能是由机床厂家出厂配置的，是以SMC 的ISA15 气密模块为核心的一套组件（如右图）。其目前存在主要问题：1、能耗损失大，能耗损失大，一台机床全年消耗压缩空

5、气11，803CNY2、功能相关问题功能相关问题 精度差，不稳定，需反复调整排气口一直排气Strictly confidential Chassis Brakes International 2012 - All rights reserved , also regarding any disposal, exploitation, reproduction, editing, distribution, as well as the event of applications for industrial property rights. Air sensor switch Improvem

6、entTEF3二、目前我公司机床气密检测的现状和问题二、目前我公司机床气密检测的现状和问题 气密检测孔容易堵塞旋钮式调整方式，无法观察到量的变化，调整困难旋钮位置很容易被人为改动而导致功能失效模块不坚固，容易损坏Strictly confidential Chassis Brakes International 2012 - All rights reserved , also regarding any disposal, exploitation, reproduction, editing, distribution, as well as the event of applicatio

7、ns for industrial property rights. Air sensor switch TEF3 MAWOMATIC GmbHEnergy save relatedQuality relatedOthersBrandControl unitPurge airpressure displayValue setupPriceQualityServiceCKDNoNoNoNoLowNo sureNot sureSMCNoNoNoNoLowBadno serviceIFMNoNoNoYesHighGoodGoodMawo.NoNoNoNoHighGoodNo serviceNorgr

8、enYesYesYesYesHighGoodNo serviceRexrothYesYesNoNoHighNot sureGoodFestoyesyesyesyeslowGoodGood三、更换气密检测模块三、更换气密检测模块-选型选型Strictly confidential Chassis Brakes International 2012 - All rights reserved , also regarding any disposal, exploitation, reproduction, editing, distribution, as well as the event o

9、f applications for industrial property rights. Air sensor switch ImprovementTEF3四、新产品介绍四、新产品介绍-FESTO气检模块气检模块Strictly confidential Chassis Brakes International 2012 - All rights reserved , also regarding any disposal, exploitation, reproduction, editing, distribution, as well as the event of applicat

10、ions for industrial property rights. Air sensor switch ImprovementTEF3四、新产品介绍四、新产品介绍-FESTO气检模块气检模块Strictly confidential Chassis Brakes International 2012 - All rights reserved , also regarding any disposal, exploitation, reproduction, editing, distribution, as well as the event of applications for i

11、ndustrial property rights. Air sensor switch ImprovementTEF3四、新产品介绍四、新产品介绍-FESTO气检模块气检模块FESTO气密模块所需配件少，结构紧凑Strictly confidential Chassis Brakes International 2012 - All rights reserved , also regarding any disposal, exploitation, reproduction, editing, distribution, as well as the event of applicati

12、ons for industrial property rights. Air sensor switch ImprovementTEF3四、新产品介绍四、新产品介绍-FESTO气检模块气检模块Festo可以在更大量程下提供更好的检测精度Strictly confidential Chassis Brakes International 2012 - All rights reserved , also regarding any disposal, exploitation, reproduction, editing, distribution, as well as the event

13、of applications for industrial property rights. Air sensor switch ImprovementTEF3四、新产品介绍四、新产品介绍-FESTO气检模块气检模块FESTO气检模块检测方式A：2个检测压力个检测压力1、SOPA 工作时有两个压力，一个是清洁时的高压清洁时的高压，一个是检测时的低压检测时的低压；2、其他品牌始终是一个低压力在检测；B：由于高低压不同，产生了不同的检测效果及能耗1、SOPA清洁时的高压清洁时的高压可以将堵在气检口的铁屑等杂质吹净，保证检测点的洁净保证检测点的洁净；2、其他品牌气检工作时始终是低压，如果检测口堵塞

14、，可能输出错误信号；C：能源消耗1、SOPA气检工作顺序是清洁 检测 停，故停止时节能节能；2、其他品牌气检一直吹气，故将消耗更多的压缩空气能源。Strictly confidential Chassis Brakes International 2012 - All rights reserved , also regarding any disposal, exploitation, reproduction, editing, distribution, as well as the event of applications for industrial property rights

15、. Air sensor switch ImprovementTEF3五、预计改善效果五、预计改善效果能耗降低刀具损失较少1、费用降低气密检测改善1/34/52,382元/台/年2-3万元/年Strictly confidential Chassis Brakes International 2012 - All rights reserved , also regarding any disposal, exploitation, reproduction, editing, distribution, as well as the event of applications for ind

16、ustrial property rights. Air sensor switch ImprovementTEF32、功能更优五、预计改善效果五、预计改善效果精度更高,更稳定更坚固耐用有高压清扫,不堵了数字显示,容易调整,还可以锁定看着是不是有高度大气上档次的感觉？看着是不是有高度大气上档次的感觉？一套价格只比SMC多了600元Strictly confidential Chassis Brakes International 2012 - All rights reserved , also regarding any disposal, exploitation, reproductio

17、n, editing, distribution, as well as the event of applications for industrial property rights. Air sensor switch ImprovementTEF3六、预计投资回报六、预计投资回报Change SMC air sensor switch to Festo air sensor switch Energy cost save: 150,000 CNY/yearBroken tool cost save: 20,000-30,000 CNY/year Quality risk reducti

18、on: 180 times/yearMaintenance cost save:130,000 CNY/yearPay back: 1.3 yearProject: Benefit: Strictly confidential Chassis Brakes International 2012 - All rights reserved , also regarding any disposal, exploitation, reproduction, editing, distribution, as well as the event of applications for industrial property rights. Air sensor switch ImprovementTEF3七、实验测试结果七、实验测试结果在我公司实验机床上测试FESTO气密检测模块，完全达到了预期效果。基于该模块的强大功能，我们采用了新的检测方法，循环时间内检测+清扫时间缩短到1分钟，在节能上远远超出预期，可以达到7,000/台/年的能耗节省。节能效果超出预期7000/2382=293%Strictl