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HE-Grinding Machine for Control Orifices

The machine comprises four equal grinding stations. They are able to process parts with and without counter pressure. An operator is needed to load the stations.
The serial number is entered by the installed code reader. After pressing the start button, the station is processing the part automatically and in the end a traffic light shows the part status. The grinding media pumps are driven by a servomotor. Therefore, no hydraulic unit is needed. A GWK tempering unit controls the temperature of the grinding fluid between the supply pump and the station.


Rotary Table for HE Grinding

The fully automated HE-grinding module is used for the flow calibration of fuel injection components. Based on a round table concept  the workpieces pass through the individual processes. During the HE-grinding process an abrasive fluid is pumped under high pressure through the workpiece holes to round them. The flow increases, depending on the application, from 5 % to 45 %.The grinding process is stopped as soon as the correlated target flow has been reached. In front of the round table there is a robot loader with drawers to insert the workpieces on pallets into the machine.
After turning the workpiece with a turn unit, the robot moves the workpieces in front of the camera to read the Dot Code on the part. A second camera checks the orientation of the part to put the workpiece orientated into the EDM machine and into the round table nest.
After finished processing in the turntable the robot moves the workpieces back to the pallets in the drawers.

Rotary table for HE grinding

The fully automated HE-grinding module is used for flow calibration of fuel injection components. Based on a round table concept  the workpieces pass through the individual processes. During the HE-grinding process an abrasive fluid is pumped under high pressure through the workpiece holes to round them. The flow increases, depending on the application, from 5% to 20%.The grinding process is stopped as soon as the correlated target flow has been reached. In front of the round table there is a robot loader with drawers to insert the workpieces on pallets into the machine.
After turning the workpiece with a turn unit, the robot moves the workpieces in front of the camera to read the Dot Code on the part. A second camera checks the orientation of the part to put the workpiece orientated into the round table nest.
The round table includes three grinding, three flushing and three measuring nests to work on three different workpiece holes in one turn on the table. After finished processing in the turntable the robot moves the workpieces back to the outtake pallets in the drawers.


HEG Control Orifice

The fully automatic HE-grinding (hydro erosive grinding) module has been designed for flow calibration of control orifices to a defined target. Based on a rotary table concept the workpieces are processed in sequentially arranged stations of this module – HE-grinding, purging, measurement. The stations have been integrated twice in the machine in order to process the inlet and the outlet hole of the control orifice.
During the grinding process an abrasive fluid is pumped through the orifices of the workpieces in order to radius bore hole intersections. The grinding process is stopped as soon as the flow has reached the correlated target flow value. The loading and unloading of the module takes place automatically and is made by means of a robot.
For the part control the DMC of each part is read in the loader module and the orientation is determined to be able to put the part correctly in the rotary table nest.
The control orifices are loaded into the machine on pallets.
The robot takes the part and drives it over a flip unit before it gets to the DMC reading station. After processing in the rotary table stations, the workpieces get unloaded in the pallet again.


HE-Grinding Machine

The bench enables the adjustment of the static flow of nozzle bores by means of a special fluid grinding method. For the grinding process four plunger pumps are available. The operation of the grinding station is possible with one plunger pump for low grinding flows, three plunger pumps for median flows or four plunger pumps for high flows.
After the grinding process the workpiece is cleaned in a flushing station.
Additionally, a measuring station for the static flow through the nozzle bores is incorporated in the test bench. By the use of adapters it is possible to process various workpieces. The process sequences at the work stations, which run independently from each other, can be adapted to the workpiece type.


HE-Grinder with Loader

The automatic HE-grinding (hydro erosive grinding) module has been designed for flow calibration of diesel injection components to a defined target. Based on a rotary table concept the workpieces are processed in sequentially arranged stations of this module – pre-measurement, HE-grinding, blowoff, purging, measurement, blow-off.
During the grinding process an abrasive fluid is pumped through the orifices of the workpieces in order to radius bore hole intersections. The flow will be increased by 8 – 30 % depending on the process. The grinding process will be stopped as soon as the flow has reached the correlated target flow value. The loading and unloading of the module is done by a 6-axis robot. For safe identification of the parts and for complete data traceability the dot code on the workpieces is read in the loader module.
On the right side an EDM machine can be connected. A moveable control panel with a comfortable user interface is installed. Running processes and results are displayed. The parameters can be easily adjusted in case of changing requirements.


HE Grinding Machine

The semi-automatic hydro erosive grinding module has been designed for flow calibration of injector components to a defined target.

Based on a rotary table concept the work pieces are processed in sequentially arranged stations of this module:

• grinding inlet
• flushing inlet
• measure inlet
• grinding outlet
• flushing outlet
• measure outlet

During the grinding process an abrasive fluid is pumped through the orifices of the work pieces in order to radius bore hole intersections. The flow will be increased and stopped as soon as the flow has reached the correlated target flow value. A moveable control panel with a comfortable user interface is installed. Running processes and results are displayed. The parameters can be easily adjusted in case of changing requirements.

高压液体挤压研磨倒圆角设备

 

利用该设备采用高压液体研磨工艺方法,使工件流量小孔达到所预先设定的流量值。为了满足工艺要求,使用一套机械手系统加载工件托盘部件,在每个托盘部件上配有三个零件的工装夹具。托盘部件通过传送带运送到设备的加工区域。设备由加工研磨模块和测量模块组成。

在加工研磨模块上,由4套可同时加工的工装部件组成,它们利用4个真空吸爪,通过伺服电机控制的线轴来提供加工零件。在研磨加工结束后,零件会设备上配置的冲洗工位上清洗,并放回到工件托盘上,以便将其运送到下一个检测模块内。

在测量模块中有6个工位,可以同时对工件上的两个小孔进行流量检测。在检测模块上,提供零件的方式与在研磨模块上是相同的。 研磨加工后满足所设置参数要求的工件,将在设备上的最后一个工步阶段,利用激光器在工件上打出一个二维码。设备配备的照相监控系统将同时对二维码的质量进行监控。

液体挤压研磨加工生产线

 

该设备用于液体研磨加工柴油喷油器部件,使上面的小孔达到所设定的流量值,并同时将小孔的边缘进行倒圆加工。该设备由多个模块组成,一套机器手系统,负责将工件加载到工件托盘上并进行下料操作。设备配置的传送系统,其最多可由11个加工模块组成,各个模块可分成液体研磨,冲洗和流量检测的功能。另外还有一个组合工位,在它上面集成了一套抽检工位,一套激光打印工位和一套信息读取工位。  机器手系统由一个机器手和2套分别用于上料/下料的部件组成。

生产线的加工模块由下面工位和部件组成,其中包括有工件托盘站,一套上下料机械手数控轴部件以及一套7个工位回转工作台系统 (2套液体研磨工位,2套冲洗工位,2套测量工位和一个吹气工位)。在研磨工位使用研磨介质加工倒圆小孔的尖端毛刺,并同时使小孔的液体流量达到设定数值。在接下来的冲洗工位上,必须将零件中可能残存的研磨介质或者其它杂质清洗掉,然后在测量工位检测液体流量。满足所给定流量值公差范围的工件,会再次放回到工件托盘中,否则会被放入到不合格零件箱内。在抽检工位上对一定比例数量的工件进行检测。借助获取的测量值,加工模块的测量工位将彼此进行流量校准。如果其中有较大的误差,其相应的模块会自动停止检测工作,并马上进行标准件校准。最后,激光打码器会在零件上打印相应的二维码,并同时对这个二维码的可读性质量进行检测。

HE-Grinding of Injector Orifice Components

The automatic HE(= hydro erosive)-Grinding module is used for flow calibration of two orifices within each work piece. The machine is based on a rotary table concept: 2 x grinding station, 2 x washing station, 2 x measuring station and 1 x blow out station

HE-Grinding
The HE-Grinding process calibrates the static flow of diesel fuel injector bore holes by using a special fluid grinding method. An abrasive liquid is pumped under high pressure through the respective bore hole intersections. A specially designed and patented cylinder pump (Active Flow Meter method) generates a constant flow and supplies the work piece with grinding fluid. The bore hole intersections, being initially too lean, generate an inlet pressure higher than the nominal pressure. Due to the abrasive fluid the edges of the intersections are being radiused and the inlet pressure decreases. The process is stopped when the pressure measured upstream has reached the nominal pressure. It is also possible to generate constant pressure and to stop the process after having reached a defined target flow. Variable flow increase is possible.

Washing
After HE-Grinding the work pieces are cleaned from residues of grinding media.

Flow test
To verify the correlation between HE-grinding process and flow test with General view ISO 4113 fluid.

HE-Grinding of Orifice Plates and Nozzle Bodies

The machine is used for processing and testing of orifice plates and nozzle bodies. There are three manually loaded stations (measuring station, flushing station and grinding station). During the grinding process an abrasive fluid is pumped through the orifices of the work piece with high pressure. By means of the abrasive fluid, the inlet edges of the respective holes are radiused until the upstream flow or pressure of the nozzle has reached the nominal value. After the grinding process the work piece is cleaned with air and purged in the flushing station. The final flow control of the machined work piece takes places in the measuring station.

Single Head HE Grinding Machine

The HE-grinding module has been designed for radiusing and deburring bore hole intersections. During the grinding process an abrasive fluid is pumped through the orifices of the work piece with high pressure. By means of the abrasive fluid, the inlet edges of the respective holes are radiused until the upstream flow or pressure of the work piece has reached the nominal value. After the grinding process the work piece is cleaned with air.
The module is designed as semiautomatic machine. The operator loads and offloads the parts manually. The grinding process starts automatically after pressing the start button.
The machining of different parts is carried out by means of variable fixtures which have to be changed manually.


Sonplas GmbH- Sachsenring 57 - D-94315 Straubing - Deutschland - Tel: +49 (0) 94 21 / 92 75 - 0 Fax: +49 (0) 94 21 / 92 75 199 - info(at)sonplas.de

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