BCNAP-I CNC automatic idler production line

BCNAP-I CNC automatic idler production line (hereinafter referred to as "idler production line") is a benchmark equipment for idler manufacturing independently developed by our company, integrating 4 dedicated CNC machining centers, 18 proprietary processes and 34 patented technologies to realize the automation of the whole process from raw materials to finished products. The idler production line has been highly praised by experts in many industry conferences in 2011-2012, and has been recognized as a domestic advanced technology, and the spinning process idler accuracy it produces reaches 1/2-1/5 of the MT821-2006 standard, meeting the needs of high-speed and large-capacity belt conveyors. 

1. Core technical advantages

The idler production line adopts a modular design, integrating the Siemens S7-300PLC master control system and PROFIBUS bus technology, and supports on-site and remote dual-mode control. Core innovations include: 
High-precision machining: the accuracy of the idler shaft is ±0.02mm, the radial runout of the roller skin is 0.15mm (standard 3-5 times), and the axial symmetry is improved by CNC positioning technology; 
Patented spinning process: replace welded connection bearing housings with spinning method, reduce energy consumption by 30%, and significantly improve environmental protection; 
Inner wall treatment technology: vertical/horizontal sandblasting spraying machine solves the problem of inner wall treatment of steel pipes above 6m and extends the life of idlers; 
Automatic assembly: The five-degree-of-freedom manipulator and self-clamping spreader realize the automatic loading and unloading of the roller skin, and the efficiency of shaft threading is increased by 8 times. 

2. The whole process process 

The idler production line covers 8 major processes to achieve "zero manual intervention" production: 
Roller skin blank treatment: the sandblasting machine removes the rust of the inner wall, and instantly cures the sprayer to form an anti-corrosion layer; 
Roller skin machining center: servo feeding→ boring→ spinning bearing seat→ outer diameter rounding, four-point manipulator to complete station switching; 
Painting and drying line: automatic loading → spraying by manipulator→ heating → cooling of tunnel furnace, and heat energy recovery for domestic hot water; 
Idler shaft processing: the six-station rotating double-head machine tool completes 7 processes such as milling groove and drilling, and automatically grinds burrs; 
Threading assembly: the reversing manipulator realizes precise alignment of the axle skin, and the axial positioning error ≤ 0.05mm; 
Press-fit center: double-head 6-station mechanism synchronously completes sealing, bearing lubrication and retaining ring installation; 
Online inspection: automatic inspection machine detects different axes, resistance and axial movement, and defective products are automatically eliminated; 
Finished product packaging: The manipulator transports the qualified idlers to the packing line, and the whole process of data traceability. 

3. Economic benefits 

Efficiency improvement: 1,000 pieces per shift (1.1 million pieces per year in 3 shifts), the efficiency is 16 times that of traditional equipment, and only 5 people per shift are employed; 
Cost optimization: the production cost of a single idler is reduced by 5 yuan, the quality premium is increased by 10 yuan, and the annual revenue is increased by 16.5 million yuan; 
Environmental protection and energy saving: The spraying heat energy recovery system saves 30% energy, and the spinning process reduces welding pollution. 

4. Industry application and market prospects 

The idler production line has passed the scientific and technological novelty check (report number 201214B1917499), and its technical indicators meet the needs of large-capacity conveyors during the "Twelfth Five-Year Plan" period. In coal, ports, mines and other fields, the idler production line can be adapted to the idler processing of Φ20-Φ40mm and the length of less than 6m, customer feedback shows: 
After adopting it in a coal mining enterprise, the failure rate of idlers decreased by 60% and the maintenance cost was reduced by 40%; 
In the application of port projects, the idler production line has been running continuously for 12 months without failure, and the production capacity has reached 100%. 
The BCNAP-I idler production line takes "high precision, high efficiency, and high efficiency" as the core, redefining the idler manufacturing standards. We sincerely invite industry partners to explore intelligent manufacturing solutions to help enterprises achieve capacity upgrading and green transformation. For customized solutions or technical consultations, please feel free to contact our expert team.