The main technical characteristics of roller production line
Time：2025-12-08
The BCNAP-I CNC automated roller production line reconstructs the traditional manufacturing model with breakthrough technology. The production line realizes the whole process of automation from raw material processing to finished product assembly through the integration of CNC technology, intelligent control and environmental protection technology, and its core innovation points can be summarized in the following technical dimensions:1. Precision manufacturingBreakthrough in shaft machining and assembly accuracyThe CNC machining center is used to achieve micron-level precision control of the roller
shaft (±0.02mm), combined with dynamic positioning technology, so that the axial symmetry of the roller skin and shaft exceeds the national standard. By introducing the roller skin rust removal and rounding process, the radial runout is compressed to 0.15mm, which is 3-5 times higher than the traditional process and significantly reduces the operating vibration of the equipment.Spinning connection technology replaces weldingThe innovative spinning method is used to connect the bearing housing and the roller skin, and the metal is cold-deformed through mechanical force. This process not only eliminates the impact of welding thermal deformation on accuracy, but also reduces energy consumption by more than 30%, while avoiding welding fume pollution, which is in line with the trend of green manufacturing.2. Surface treatment: double breakthrough in anti-corrosion and cleaningUltra-long pipe body sandblasting technologyIn view of the problem of treating the inner wall of steel pipes above 6 meters, a vertical sandblasting mechanism was developed to achieve uniform rust removal of the inner wall through the synergy of high-pressure airflow and abrasives. This technology lays the foundation for subsequent anti-corrosion spraying, so that the roughness of the inner wall of the steel pipe reaches the process requirement of Ra12.5μm.Instant curing spraying systemThe horizontal sprayer uses a fast-curing resin to form a dense anti-corrosion layer on the inner wall of the steel pipe. The coating has been tested to block dust from entering the bearing cavity, solving grease contamination and extending the service life of the roller
by 40%.3. Intelligent equipment: patented technology cluster applicationThe roller skin processing center has four innovationsThe 3-station 4-point manipulator realizes fast positioning of the workpieceMulti-flute forming boring knives improve hole processing efficiencyThe spinning riveting process ensures the strength of the connectionMulti-knife concentric rounding technology eliminates ellipticity deviationRotary double-head machining centerIntegrated 6-station CNC system, it can automatically complete the whole process of roller
shaft. By intelligently identifying the size of the blank, continuous operation from turning to deburring is realized, and the processing efficiency is increased by 60%.4. Automation and precision synergyAutomatic shaft threading technologyBased on the precise calculation of the length-to-diameter ratio i=0.0022 (i=(D-d)/L), a pneumatic push mechanism was developed to replace manual shaft threading. This technology shortens the assembly cycle time to 8 seconds/piece, which is 8 times more efficient than the traditional method, and ensures the accuracy of shaft hole fitting.Double-head pressing centerIt adopts a 6-station rotary platform and integrates an automatic installation device for elastic retaining rings. The pressure sensor monitors the press-fitting process in real time to ensure that the bearing assembly interference is controlled within the range of ±0.01mm.5. Intelligent controlA distributed control system with Siemens S7-300PLC as the core is built, and 32 intelligent nodes are connected through the PROFIBUS bus. The system integrates data acquisition card and SCADA monitoring platform to realize real-time optimization of production parameters. The control system has been tested to increase the overall effectiveness (OEE) of the equipment to 92%.6. Economic benefits and environmental protection valueThe annual output of a single roller production line is 1.1 million idlers, and the cost of a single piece is reduced by 5 yuan and the quality premium is increased by 10 yuan through process optimization. Based on annual production, it can create value-added income of 16.5 million yuan. The coating process adopts a waste heat recovery system to convert the spraying and curing heat into domestic hot water, saving 120 tons of standard coal per year.The roller production line has passed ISO 9001 quality system certification, and its innovative technology has obtained 12 national patents. According to the appraisal of the China Machinery Industry Federation, the overall technology has reached the international advanced level, providing replicable intelligent solutions for the field of heavy equipment manufacturing.
