Multiple processing processes are completed at one time. Help factory beat speed by 50%
Today, as the manufacturing industry is gradually moving towards "efficient collaboration" and "flexible production", the traditional multi-machining and multiple clamping process process is difficult to meet the high requirements of modern manufacturing for efficiency, quality and response speed. Especially in the field of heavy-duty parts processing, complicated processes, frequent handling, and large clamping errors have become the "invisible bottleneck" that restricts the improvement of production line efficiency.
In order to solve this problem, Shandong DONGS CNC Equipment Co., Ltd. is guided by customer needs, focusing on efficient processing of medium and large parts, and launches a medium and large horizontal turning center solution of "one-time clamping and composite completion", which helps the factory achieve a significant speed-up of production beats, and some customers have increased the beats by up to 50%.
一、The efficiency dilemma of traditional processing methods
Taking typical large shaft or flange parts as an example, traditional processing methods often require switching between multiple machine tools to complete multiple processes such as rough trucking, precision trucking, drilling, tapping, and chamfering. Each process conversion means one disassembly and assembly, one handling, one re-correction and positioning.
These operations may seem subtle, but they greatly reduce the overall efficiency in total, which not only wastes manpower and time, but also gradually amplifies the error during the clamping and positioning process, ultimately affecting the product yield rate and delivery stability. What's more serious is that in the current context of tight labor and rising labor costs, the traditional model of multi-person collaboration is obviously unsustainable.
二、DONGS solutions: one-time clamping, composite processing
DONGS CNC's medium and large horizontal turning center has systematically designed solutions to this pain point. With the core concept of "multi-process integration + one-time clamping processing", DONGS enables customers to continuously complete a variety of processes such as turning, drilling, tapping, end-face processing, etc. on a single machine tool through high-torque spindle, large-size guide rail structure, high-rigid turret configuration, and optional power tool system.
No need for disassembly and handling, no need for secondary clamping, the workpiece can complete all the processes from the blank to the finished product after one fixation, the processing rhythm is significantly shortened, and the product accuracy is simultaneously improved.
【Configuration Highlights】
Modular expansion of the power turret,Supports complex cavity processing
Large through hole spindle structure,It can stably clamp long shaft and large pipe diameter parts;
High rigidity bed and screw system,Ensure high accuracy is maintained under heavy load conditions;
Optional automatic loading and unloading system,Optional automatic loading and unloading system.
三、Customer case: The beat is shortened from 8 hours to 4 hours
A large mechanical processing enterprise located in Europe, mainly engaged in the processing of heavy-duty parts such as wind power spindles and engineering pipe fittings. Its original process is the cooperation of three equipments: "lathe + drilling machine + vertical plus". It takes about 8 hours to process a large workpiece, and the work intensity is high and the process connection is tight.
Starting from 2024, the customer will introduce two DONGS medium and large horizontal turning centers to complete all processes using composite processing methods. After the new equipment was put into production, the beat of a single piece was compressed to 4 hours, the production capacity increased by more than 50%, and the labor consumption was reduced from 4 people to 2 people. More importantly, due to the reduced number of clamping times, the product size consistency and surface quality have significantly improved, and the rework rate has dropped by more than 70%.
四、one machine is multi-energy, unleashing the flexibility potential of the factory
Today's manufacturing factories not only pursue "fast", but also pursue "stability" and "flexibility". The composite processing model advocated by DONGS can not only bring about a rhythm improvement, but also improve the factory's production response and flexibility level as a whole by reducing the number of equipment, reducing the handling frequency, and optimizing the layout.
Customers can flexibly switch processing tasks on the basis of a more compact production line layout to meet the complex needs of multiple varieties, small batches and even order-interspersed production. This "short beat + high quality + strong flexibility" model is a key link in the upgrade of intelligent manufacturing.
Complete multiple processes at once is not only a breakthrough at the technical level, but also an embodiment of the philosophy of efficiency. DONGS CNC has always adhered to the actual needs of customers as the starting point, and has continued to deepen its efforts in the field of medium and large horizontal turning, providing solid equipment support for the high-quality development of China's manufacturing industry.
In the future wave of manufacturing upgrades, DONGS will continue to work with more customers to help factory speed up, improve quality and leap in competitiveness with more efficient, smarter and more reliable equipment solutions