As the core component of the construction machinery track system, the chain rail links require strict accuracy, efficiency and stability.This article focuses on the automation practice of chain and track projects, starts from the entire process, analyzes how automation reshapes the production model, and provides the industry with a referenced intelligent upgrade path.
Chain Rail Link Production Process
Chain rail link double-sided milling machine
- Machine tool processing stroke: meets 135-280 pitch;
- The equipment’s continuous machining changes in dry milling shall not exceed 0.05mm; parallelism and flatness are <0.2;
- The equipment comes with 2 truss robots, which can automatically load and unload the workpiece from the conveyor belt.
- Automation does not add beats
- Equipment is divided into left and right section equipment, one set requires 2 equipment
| Serial No. | Production Line Name | Product Model | Number of Production Lines | Equipment Model | Number of Equipment | Equipment Production Cycle (s/pair) | Automatic Production Cycle (s/pair) |
|---|---|---|---|---|---|---|---|
| 1 | 190 Chain Track Link Production Line | 190 | 3 | 135~190 Double – sided Milling Machine | 6 | 50S | 50S |
Quenching and tempering complete set of equipment
- 135-216 tempering adopts a pass-through induction furnace (rated power 200W, frequency 2000Hz), with advantages: small space, short time about 10min, and 6 meters in length of the furnace body;
- One unit can produce left and right sections at the same time
| Serial No. | Production Line Name | Product Model | Number of Production Lines | Equipment Model | Number of Equipment | Equipment Production Cycle (s/pair) | Automated Production Cycle (s/pair) |
|---|---|---|---|---|---|---|---|
| 1 | 190 Chain Track Link Production Line | 190 | 3 | Small Pitch 135 – 190 Chain Track Link Quenching and Tempering Equipment | 3 | 40S | 40S |
Chain and rail production process and traditional pain points
1) Overview of traditional production processes
Chain rail section manufacturing covers five core links: blank preparation (forging/casting), precision machining (milling, boring, broaching, etc.), heat treatment strengthening, quality inspection, and logistics distribution. Each link relies on manual operation and stand-alone operation, and the process is separated.
2) Traditional model pain points
- Large accuracy fluctuations: manual clamping and single-machine machining lead to difficult control of dimensional tolerances (such as the traditional process shaft hole tolerance ±0.2mm), and discrete shape and position tolerances (up to 0.5mm), affecting the adaptability of the track system.
- The efficiency bottleneck is obvious: the process connection depends on manual handling, the replacement time is long (2-4 hours/variety), and the 190-pitch chain rail link shift production is only 150-200 sets, which is difficult to meet the needs of large-scale orders.
- Difficulty in quality traceability: manual detection leakage detection rate is high (magnetic powder defect detection leakage detection rate exceeds 5%), data is not effectively related, defect traceability is time-consuming and labor-intensive, and the defect rate is 10%-15%.
- High energy consumption and cost: equipment idle and energy waste, single-set chain rails save energy 15-20kWh, labor costs account for more than 30%, and production economy is limited.
Automation solution architecture of chain track link project
(I) Overall design ideas
With the deep integration of “process + automation + digitalization” as the core,
we will build a three-in-one system of “intelligent processing unit + automated logistics + digital management and control” to achieve seamless process connection, full data linkage, and real-time quality control.
(II) Core subsystem composition
| Subsystem | Functional Positioning | Key Technology Support |
|---|---|---|
| Intelligent Processing Unit | Achieve automation of processes such as milling, boring, and broaching | Multi-axis linkage, in-line inspection, tool life management |
| Automated Logistics System | Ensure material flow between processes | AGV scheduling, intelligent buffering, robot loading and unloading |
| Digital Management Platform | Data collection and decision-making for the entire production process | MES system, digital twin, AI algorithms |
Full process practice of automation solutions
(I) Intelligent processing unit: a double breakthrough in precision and efficiency
1.Double-sided milling automation
- Equipment configuration: Ubright Solutions custom double-sided milling machine, dual milling heads are synchronized, equipped with servo drive slide table + high-precision grating scale, positioning accuracy ±0.015mm.
- Automation logic: The blank posture is recognized through a 3D visual system (recognition accuracy ±0.2mm), the truss robot automatically loads and unloads (beat ≤15 seconds/piece), the CNC system performs processing according to preset parameters (such as 190 pitch chain rail links, milling speed 800mm/min, and back-eating tool 2mm). The online detection module feedbacks the plane degree in real time (controlled within 0.05mm).
2.Coarse fine boring automation
- Process innovation: Six-spindle linkage boring machine integrates automatic tool changing magazine (tool change time ≤8 seconds) + cutting force monitoring system, rough boring and fine boring are clamped in one go.
- Data support: The shaft hole tolerance is stable at ±0.05mm (traditional process ±0.2mm), and the center distance tolerance is ±0.1mm. Through the tool life prediction algorithm (based on cutting force and temperature data), the tool loss warning accuracy is ≥95%, reducing burst shutdown by 70%.
3.Brushing and machining automation
- Flexible adaptation: The vertical pull-up bed is equipped with quick-replacement tool fixture (change time ≤5 minutes), compatible with 135-228 pitch chain rail links.
- Efficiency improvement: broaching speed is 6m/min, single-station double-piece processing (beat 40 seconds/pair), surface roughness Ra≤12.5μm, 100% higher efficiency than traditional horizontal pulling beds.
(II) Automatic logistics system: an efficient engine for process connection
1.Robot loading and unloading
- Multi-model collaboration: FANUC robot is responsible for loading and unloading precision processes (such as boring machines, pulling machines), loading 165kg, repeat positioning accuracy ±0.2mm; truss robot is adapted to high-temperature processes (such as heat treatment), and uses high-temperature resistant magnetic claws (temperature resistant to 300℃), and the handling beat is ≤20 seconds/piece.
- Visual guidance: 3D laser profile sensor scans the material frame (recognition accuracy 0.05mm/pixel), AI algorithm plans the optimal grasping path, and the workpiece posture recognition accuracy is ≥99.5%, solving the problem of disorderly loading of blanks.
2.AGV intelligent scheduling
- Logistics Network: Latent AGV (load 500kg, speed 1.2m/s) builds a “processing – detection – cache” closed loop, and realizes material flow between processes through SLAM navigation (accuracy ±10mm), and the logistics time is reduced from 15 minutes/batch to 5 minutes/batch.
- Dynamic cache: Elastic cache magazine (capacity 20 – 30 pieces) balances the process beat (such as when changing tool of the boring machine, AGV is preferred to withdraw materials from cache), and OEE (comprehensive equipment efficiency) of the production line has been increased from 65% to 85%.
Plan implementation effectiveness and industry value
(I) Comparison of core indicators
| Dimension | Traditional Process | Results of Automated Solution | Improvement Margin |
|---|---|---|---|
| Machining Precision | Dimensional tolerance ±0.2mm | Dimensional tolerance ±0.05mm | 75% |
| Production Efficiency | 150 – 200 sets per shift | 356 sets per shift (190 pitch) | 80% |
| Yield Rate | 85% – 90% | Above 99.5% | 10 – 15 percentage points |
| Changeover Time | 2 – 4 hours per variety | ≤30 minutes per variety | 80% |
| Energy Consumption per Set | 15 – 20kWh | 8 – 10kWh | 50% |
Summary
The automation solution of the chain track project is based on process, automation as the wing, and digital as the soul, reshaping the traditional manufacturing process and achieving all-round breakthroughs in accuracy, efficiency and flexibility.
