Technical information, technical services and technical training
1. Technical information
We will supply general drawing, foundation drawing, Layout drawing, water and electricity cost, interface position, pipe diameter, etc to the buyer, so that they can plan and design their factory within 15 days after execution of the contract.
Equipments drawings (general assembly drawing and main parts drawings), Hydraulic schematic diagram, Electrical schematic diagram, Circuit drawings, Lubricating schematic diagram, Operating manual, Software and program, Installation guide manual, Operation manual of purchased parts, Quality certification, and Manufacturer name
Operating manual should meet the requirements of using, maintain, operating, installation and adjustment Binding is norms and tidy. It includes Use characteristics, main technical parameter, Structure, Electrical System, Lubricating system, testing, Troubleshooting methods, Safety rules, etc.
Attached drawings of operation manual includes General assembly drawings, Main parts schematic, Electrical schematic diagram, Circuit drawings, Electric wiring diagram (includes hammer, electric cabinet, operating panel), Lubricating schematic diagram, main gas cylinder parts diagram, etc
2 .The technical service that our company will provide to customers as follows,
Responsible for field planning and layout
Responsible for design foundation drawing of various parts
Responsible for technical service
Responsible for installation and debugging of forging hammer
Responsible for training customer to operate and maintain forging hammer free of charge
Responsible for supplying spare parts and wearing parts, which price is favourable
Provide technical guidance for life
3. Technical training
Training during installation, commission and test running, which is taught by engineers on-site including mechanical engineer and electrical engineer.
The detailed technical training is as following:
Study the working principle of numerical control hydraulic closed die forging hammer
Study the operation methods of numerical control hydraulic closed die forging hammer
Study the operating maintenance and schedule maintenance of numerical control hydraulic closed die forging hammer
Study common fault analysis and handle of numerical control hydraulic close die forging hammer
Study the replacement of wearing parts of numerical control hydraulic close die forging hammer
Study die installation and fixing means of numerical control hydraulic close die forging hammer
5/03/2009
Quality control of numerical control hydraulic closed die forging hammer
Quality control of numerical control hydraulic closed die forging hammer
1. Quality management system
Our company has passed ISO9001:2000 quality certificate on 31 Dec, 2001, and the certificate No is 4100/200110088.
It includes “Quality manual”, “Program file”. “ Program file” includes “ File control regularization”, “Quality inspection control regularization”, “Management examine & comment regularization”, “Management regularization of Training, Evaluating,Selecting staff” etc nineteen files.
2、Quality policy & Objectives
Quality policy:
Customer first, quality first
Keeping Innovating New Products, and supplying best service，
Keeping developing, Prevention first,
Quality Objectives
Pass percent of inspection : 95%
Pass percent of leaving factory: 100%
Percent for customer’s feedback: 100%
3. Set up assembly lines of the key parts of quality management guidance points and assemble direct manual
The processing and assembly of all the key parts for numerical control hydraulic closed die forging hammer is in four plants, in order to ensure the quality of the products, our factory set up 35-point quality management in four plants. At the same time, the preparation of each key parts of homework guide book, tolerances for each process than drawings enhance the 1/3, spare parts fabrication, assembly instructions in strict accordance with requirements of processing, the requirements of key parts are 100% qualified
4 . Set up the quality record cards of the key parts
We set up the quality records cards for key parts respectively In accordance with the AD/AGC-4.0-02-2001.8, finally a summary to the whole file, convenience of the query and retrospective
5. Set up the quality record cards of the main parts
The main parts of numerical control hydraulic closed die forging hammer have quality record card, and the parts must comply with the requirements of drawings.
It is we adopt the above measures that guarantees parts assembly, final assembly and test running of numerical control hydraulic closed die forging hammer getting 98% one time, and the percent of pass for machine leaving factory, field installation and test running was 100 %.
6. Quality Inspection and laboratory of spare parts
Quality inspection system is as following:
Inspecting raw materials entering factory→Inspecting working procedure→Inspecting semi-finished product warehouse→Inspecting assembling→Inspecting before leaving factory
All the dimension of key parts should be inspected, and it ensures 100% inspection. Hardness of quenched and tempered inspection, surface roughness inspection, Nondestructive test inspection etc.
The main detection and laboratory apparatus: Physical and chemical experiments, Metallographic analysis, two stage measure, Rockwell Hardness Tester, Surface roughness instrument, Ultrasonic Flaw Detector, Magnetic Flaw Detector, etc
7. The distribution points of quality control for numerical control hydraulic closed die forging hammer
Products
Quality control points in workshops
Team Name
Quality control items
Numerical control hydraulic closed die forging hammer
Small-middle parts machining workshop
Grinding machine team
Hit valves
Small machine team
Below seal
Large parts machining workshop
Machining center
Hammer head
Machining center
Valve block
Machining center
Die seat
Grinding machine team
Cylinder bush
Grinding machine team
Hammer rod
Heat treatment workshop
A team
Heat treatment of hammer head and hammer rod
Assembly workshop
Assembling team (B team)
Assembling and test forging
Painting team
Painting
1. Quality management system
Our company has passed ISO9001:2000 quality certificate on 31 Dec, 2001, and the certificate No is 4100/200110088.
It includes “Quality manual”, “Program file”. “ Program file” includes “ File control regularization”, “Quality inspection control regularization”, “Management examine & comment regularization”, “Management regularization of Training, Evaluating,Selecting staff” etc nineteen files.
2、Quality policy & Objectives
Quality policy:
Customer first, quality first
Keeping Innovating New Products, and supplying best service，
Keeping developing, Prevention first,
Quality Objectives
Pass percent of inspection : 95%
Pass percent of leaving factory: 100%
Percent for customer’s feedback: 100%
3. Set up assembly lines of the key parts of quality management guidance points and assemble direct manual
The processing and assembly of all the key parts for numerical control hydraulic closed die forging hammer is in four plants, in order to ensure the quality of the products, our factory set up 35-point quality management in four plants. At the same time, the preparation of each key parts of homework guide book, tolerances for each process than drawings enhance the 1/3, spare parts fabrication, assembly instructions in strict accordance with requirements of processing, the requirements of key parts are 100% qualified
4 . Set up the quality record cards of the key parts
We set up the quality records cards for key parts respectively In accordance with the AD/AGC-4.0-02-2001.8, finally a summary to the whole file, convenience of the query and retrospective
5. Set up the quality record cards of the main parts
The main parts of numerical control hydraulic closed die forging hammer have quality record card, and the parts must comply with the requirements of drawings.
It is we adopt the above measures that guarantees parts assembly, final assembly and test running of numerical control hydraulic closed die forging hammer getting 98% one time, and the percent of pass for machine leaving factory, field installation and test running was 100 %.
6. Quality Inspection and laboratory of spare parts
Quality inspection system is as following:
Inspecting raw materials entering factory→Inspecting working procedure→Inspecting semi-finished product warehouse→Inspecting assembling→Inspecting before leaving factory
All the dimension of key parts should be inspected, and it ensures 100% inspection. Hardness of quenched and tempered inspection, surface roughness inspection, Nondestructive test inspection etc.
The main detection and laboratory apparatus: Physical and chemical experiments, Metallographic analysis, two stage measure, Rockwell Hardness Tester, Surface roughness instrument, Ultrasonic Flaw Detector, Magnetic Flaw Detector, etc
7. The distribution points of quality control for numerical control hydraulic closed die forging hammer
Products
Quality control points in workshops
Team Name
Quality control items
Numerical control hydraulic closed die forging hammer
Small-middle parts machining workshop
Grinding machine team
Hit valves
Small machine team
Below seal
Large parts machining workshop
Machining center
Hammer head
Machining center
Valve block
Machining center
Die seat
Grinding machine team
Cylinder bush
Grinding machine team
Hammer rod
Heat treatment workshop
A team
Heat treatment of hammer head and hammer rod
Assembly workshop
Assembling team (B team)
Assembling and test forging
Painting team
Painting
The description of technology progress and rationality of Numerical control hydraulic close die forging hammer
The description of technology progress and rationality of Numerical control hydraulic close die forging hammer
1. The automatic monitoring of failure and the distributing of monitoring point of Numerical control hydraulic close die forging hammer
The automatic monitoring system includes：Hydraulic oil temperature control、hydraulic oil pressure control、main motor temperature control etc，set through touch screen，to achieve close loop auto monitoring.
Except the auto monitoring, this machine also have automatic alarming function，and the alarming history record，the failure screen will automaticly eject to show the failure place when failure happen，make the product repair fast and facility，this screen will close after the failure remove.
2. The description of eject part and hit time control of Numerical control hydraulic close die forging hammer
Eject part and hit part at the same step set by touch screen，when the machine in continuous working，press automatic eject button，and adjust hit time interval make the equipment hit step and automatic eject working in the same step.
This product also can adjust the hit time interval，let the forging hammer and other assistant equipments working in same step to achieve the automatic control.
3. The hit energy numerical control description of Numerical control hydraulic close die forging hammer
Hit energy control is facility，it can be adjust according to percentage of general hit energy.
For example：When the general hit energy is 50KJ, now need set hit energy is 25KJ, just input 50% in the percentage of hit energy can come true hit energy 25KJ.When the set hit energy not fit the actual set hit energy, also can mend the hit energy according to the actual condition.
This equipment established "product data base" for user, user can access hit energy, time interval, eject time etc of product hit step by themselves
VII The manufacture ability description of Anyang Forging Press Machinery Industry Co., Ltd.
The 98% of worker, the inspector, the assembler that take part in the manufacturing the Numerical Control Hydraulic close die forging hammer of our company are masters, and has participated in the electro hydraulic forging hammer training class which the company conducts, understanding the structure of electro hydraulic forging hammer, the performance and each components' importance. Among them, the technical school students occupies 68% of first line worker, the university student occupies 30%, other account for 10%.
·The machining precision of hammer frame is important，especially the degree of symmetry of “X” Type guide rail side and the uprightness degree of coattail side，affect the assemble quality directly，in order to ensure the precision，technologist study out the detail machining project and check method，use the large CNC floor type boring machine completed the relate machining step，achieved the requirement of drawing set.
·The precision of hit valve and two stage lead valve is the key for energy precision control，all the key machining completed with CNC machine.
·The precision of oil cylinder jacket is very high，for inside and outside circle same column degree、inner hole's column degree、surface roughness degree are strict，the degree of difficulty of process is very large. Our company adopt deep hole boring machine process first, then use precision inside diameter rolling head rolling，ensured boring hole precision，and also ensured the surface intension at last complete outside circle process on grinding machine.
·Hammer head, main valve block etc machined on CNC machining center，ensured the machining quality .of hammer head
The manufacture equipment of Numerical Control Hydraulic Close Die Forging Hammer
Serial number
Name
Type
Quantity
Main technical feature
Other explain
1
Multi aspect
mill machining center
LP4021
1
Dragon gate wide 2.3M
Made in Taiwan
2
Numerical display
boring milling machine
TX6213
1
X：6m，Y：2m，Z：1m
ANHUI WUHU
3
Numerical display boring milling machine
TX6922
1
X：8，Y：4，Z：2.1
Crane 125T、
Crane 50T
4
Dragon Gate numerical control hammer milling machine
YK42200-400
1
X：4.5m，Y：2.6m，Z：1.4m
5
Russian floor type boring machine
Main axis Φ160
1
The largest height of work piece2.7m、main axis flex 1.2m、the largest length of work piece 9.3m
floor area 15*8m Crane 15T、30T
6
NC flame cutting machine
CNCDG-3500×12000
1
Effective cutting width
2.7m、cutting speed 50-750mm/min，cutting thickness 220mm。
Shanghai general
7
Floor type boring machine
T615K
1
Main axis Φ150 flex 1M
Floor area 10*6m Crane 15T、30T
8
Double housing planer
B2020Q 6
3
Working plate 1.8*6 Largest width of work piece 2m
Crane 30T、15T
9
Double housing planer
B201
1
Working plate 1.6*4 Largest width of work piece 1.7m
Crane 15T、5T
10
open-side planer
B1016
3
Working plate1.4*6 Largest width of work piece1.6m
Crane 15T
11
Parallel Lathe
C61100
1
Max length of workpiece φ1000mmm
1 x3m 1x5m crane 10T 5T
12
CNC Lathe
CKA6163
1
Max swing diameter of work φ630mm
Max length of workpiece 1500mm
ANYANG XINGSHENG GROUP
13
CNC Lathe
CKJ6152
1
Max swing diameter of work φ520mm
Max length of workpiece 1000mm
ANYANG XINSHENG GROUP
14
CNC Lathe
CAK6150Dj
1
Max swing diameter of work φ520mm
Max length of workpiece 640mm
SHENYANG MACHINE TOOL (GROUP)
15
Vertical Lathe
C5225
1
Max turning diameter φ2.5m
Crane 15T
16
Vertical Lathe
C5116
2
Max turning diameter φ1.6m
Crane 5T
17
Vertical Lathe
C5112A
1
Max turning diameterφ1.2m
Crane 5T
18
cylindrical grinding machine
H147
1
Max grinding diameter φ630
Max length of workpiece 4m
Crane 5T，
Max carrying capacity1.2T
19
boring machine
T612A
4
Spindle diameterφ125，Max carrying capacity on the worktable 4T
Crane 5T
20
boring machine
T68
1
Spindle diameter φ85，
1 digital display and 3 common
Crane 10T
21
coordinate setting boring
T4163C
1
Coordinate precision 4mm,
Max boring diameter φ250
Crane 5T
22
drilling machine
Z30100
1
Max drilling diameter φ100
Crane 30T、15T
23
drilling machine
Z3080
1
Max drilling diameter φ80
Crane 15T
24
Lathe
C616、CA6140、C6163 ,etc many sets
25
milling machine
X53K、X52K、X63W , etc many sets
26
planing machine and Drilling machine
B665、B690，Z340、Z3050 , etc many sets
27
cylindrical grinder, surface grinder, plano grinder , etc many sets
28
Heat treatment equipments
180KW vertical furnace
1
φ1200mm×210mm
125KW vertical furnace
1
φ800mm×1850mm
225Kw vertical furnace
1
φ800mm×4000mm
75KW box furnace
2
40KW box furnace
1
35KW box furnace
1
75KW salt furnace
1
Frange slot
1
100KW Double-frequency quenching equipments
1
1. The automatic monitoring of failure and the distributing of monitoring point of Numerical control hydraulic close die forging hammer
The automatic monitoring system includes：Hydraulic oil temperature control、hydraulic oil pressure control、main motor temperature control etc，set through touch screen，to achieve close loop auto monitoring.
Except the auto monitoring, this machine also have automatic alarming function，and the alarming history record，the failure screen will automaticly eject to show the failure place when failure happen，make the product repair fast and facility，this screen will close after the failure remove.
2. The description of eject part and hit time control of Numerical control hydraulic close die forging hammer
Eject part and hit part at the same step set by touch screen，when the machine in continuous working，press automatic eject button，and adjust hit time interval make the equipment hit step and automatic eject working in the same step.
This product also can adjust the hit time interval，let the forging hammer and other assistant equipments working in same step to achieve the automatic control.
3. The hit energy numerical control description of Numerical control hydraulic close die forging hammer
Hit energy control is facility，it can be adjust according to percentage of general hit energy.
For example：When the general hit energy is 50KJ, now need set hit energy is 25KJ, just input 50% in the percentage of hit energy can come true hit energy 25KJ.When the set hit energy not fit the actual set hit energy, also can mend the hit energy according to the actual condition.
This equipment established "product data base" for user, user can access hit energy, time interval, eject time etc of product hit step by themselves
VII The manufacture ability description of Anyang Forging Press Machinery Industry Co., Ltd.
The 98% of worker, the inspector, the assembler that take part in the manufacturing the Numerical Control Hydraulic close die forging hammer of our company are masters, and has participated in the electro hydraulic forging hammer training class which the company conducts, understanding the structure of electro hydraulic forging hammer, the performance and each components' importance. Among them, the technical school students occupies 68% of first line worker, the university student occupies 30%, other account for 10%.
·The machining precision of hammer frame is important，especially the degree of symmetry of “X” Type guide rail side and the uprightness degree of coattail side，affect the assemble quality directly，in order to ensure the precision，technologist study out the detail machining project and check method，use the large CNC floor type boring machine completed the relate machining step，achieved the requirement of drawing set.
·The precision of hit valve and two stage lead valve is the key for energy precision control，all the key machining completed with CNC machine.
·The precision of oil cylinder jacket is very high，for inside and outside circle same column degree、inner hole's column degree、surface roughness degree are strict，the degree of difficulty of process is very large. Our company adopt deep hole boring machine process first, then use precision inside diameter rolling head rolling，ensured boring hole precision，and also ensured the surface intension at last complete outside circle process on grinding machine.
·Hammer head, main valve block etc machined on CNC machining center，ensured the machining quality .of hammer head
The manufacture equipment of Numerical Control Hydraulic Close Die Forging Hammer
Serial number
Name
Type
Quantity
Main technical feature
Other explain
1
Multi aspect
mill machining center
LP4021
1
Dragon gate wide 2.3M
Made in Taiwan
2
Numerical display
boring milling machine
TX6213
1
X：6m，Y：2m，Z：1m
ANHUI WUHU
3
Numerical display boring milling machine
TX6922
1
X：8，Y：4，Z：2.1
Crane 125T、
Crane 50T
4
Dragon Gate numerical control hammer milling machine
YK42200-400
1
X：4.5m，Y：2.6m，Z：1.4m
5
Russian floor type boring machine
Main axis Φ160
1
The largest height of work piece2.7m、main axis flex 1.2m、the largest length of work piece 9.3m
floor area 15*8m Crane 15T、30T
6
NC flame cutting machine
CNCDG-3500×12000
1
Effective cutting width
2.7m、cutting speed 50-750mm/min，cutting thickness 220mm。
Shanghai general
7
Floor type boring machine
T615K
1
Main axis Φ150 flex 1M
Floor area 10*6m Crane 15T、30T
8
Double housing planer
B2020Q 6
3
Working plate 1.8*6 Largest width of work piece 2m
Crane 30T、15T
9
Double housing planer
B201
1
Working plate 1.6*4 Largest width of work piece 1.7m
Crane 15T、5T
10
open-side planer
B1016
3
Working plate1.4*6 Largest width of work piece1.6m
Crane 15T
11
Parallel Lathe
C61100
1
Max length of workpiece φ1000mmm
1 x3m 1x5m crane 10T 5T
12
CNC Lathe
CKA6163
1
Max swing diameter of work φ630mm
Max length of workpiece 1500mm
ANYANG XINGSHENG GROUP
13
CNC Lathe
CKJ6152
1
Max swing diameter of work φ520mm
Max length of workpiece 1000mm
ANYANG XINSHENG GROUP
14
CNC Lathe
CAK6150Dj
1
Max swing diameter of work φ520mm
Max length of workpiece 640mm
SHENYANG MACHINE TOOL (GROUP)
15
Vertical Lathe
C5225
1
Max turning diameter φ2.5m
Crane 15T
16
Vertical Lathe
C5116
2
Max turning diameter φ1.6m
Crane 5T
17
Vertical Lathe
C5112A
1
Max turning diameterφ1.2m
Crane 5T
18
cylindrical grinding machine
H147
1
Max grinding diameter φ630
Max length of workpiece 4m
Crane 5T，
Max carrying capacity1.2T
19
boring machine
T612A
4
Spindle diameterφ125，Max carrying capacity on the worktable 4T
Crane 5T
20
boring machine
T68
1
Spindle diameter φ85，
1 digital display and 3 common
Crane 10T
21
coordinate setting boring
T4163C
1
Coordinate precision 4mm,
Max boring diameter φ250
Crane 5T
22
drilling machine
Z30100
1
Max drilling diameter φ100
Crane 30T、15T
23
drilling machine
Z3080
1
Max drilling diameter φ80
Crane 15T
24
Lathe
C616、CA6140、C6163 ,etc many sets
25
milling machine
X53K、X52K、X63W , etc many sets
26
planing machine and Drilling machine
B665、B690，Z340、Z3050 , etc many sets
27
cylindrical grinder, surface grinder, plano grinder , etc many sets
28
Heat treatment equipments
180KW vertical furnace
1
φ1200mm×210mm
125KW vertical furnace
1
φ800mm×1850mm
225Kw vertical furnace
1
φ800mm×4000mm
75KW box furnace
2
40KW box furnace
1
35KW box furnace
1
75KW salt furnace
1
Frange slot
1
100KW Double-frequency quenching equipments
1
Subscribe to:
Posts (Atom)