How is a non-standard automation line for pipe fitting processing designed from scratch?

In the field of processing and manufacturing, pipe fittings are very common components, from household appliance water pipes to engineering machinery hydraulic systems. However, many small and medium-sized processing plants are still in the stage of manual single process operation for processing multiple varieties and small batches of pipe fittings, with low efficiency and unstable qualification rates. To upgrade production capacity, standard automation equipment often cannot meet personalized needs, so a customized non-standard automation processing line is needed.

How was the non-standard automation line for pipe fitting processing designed and implemented from scratch?

The first step is to sort out the requirements and thoroughly understand the real needs of the customer. Many novice designers are prone to drawing blueprints as soon as they enter the industry, resulting in equipment that either cannot fit or cannot meet production capacity. The problem lies in not understanding the requirements clearly.

At the beginning of building this pipe fitting processing line, we first followed the project team to the customer's workshop for a day to record the customer's existing process: the customer wanted to make hydraulic system pipe fittings, and the processing flow was raw material cutting → chamfering at both ends → hole expansion forming → high-pressure cleaning → air tightness testing. Originally, each of the five processes was assigned one worker for manual transportation, and the daily output was only 800 pieces, with a pass rate of about 92%. The customer's demand was to increase the daily output to over 2000 pieces, with a pass rate of 98%, and only a site of 12 meters long and 3 meters wide could be freed up for installation. It was also necessary to accommodate the production of three different diameter specifications of pipe fittings in the future, and change specifications quickly.

We compiled a list of these requirements one by one, checking everything from production capacity budget to power supply voltage and workshop entrance channel width, before entering the design phase.

The second step is to design a plan that balances practicality and cost-effectiveness. After the requirements are clarified, the first step is to make the overall layout. As the site is only 12 meters long, we arrange the five processes in a straight line, and use double speed chains to transport between each process, matched with customized fixtures and jigs. Each fixture is fixed with one pipe fitting and follows the rhythm of the workstation, without the need for manual transportation.

Next, we will do detailed design for each workstation: for the cutting workstation, which used to be manually fed, we have designed an automatic layered material bin. After the raw material bars are fed in, they will be automatically divided and fed in, matched with a servo pipe cutting machine, with an accuracy controlled within 0.1 millimeters; Chamfering and reaming stations, because they need to be compatible with different specifications, we have designed the fixture as a quick change structure. When changing specifications, only the clamp head needs to be replaced, and the adjustment can be completed in 10 minutes without disassembling the entire station; We have installed an automatic sorting mechanism at the inspection station, where qualified parts automatically flow into the next process and unqualified parts are automatically removed without manual sorting.

We have selected a commonly used PLC control system for the electrical part, paired with a touch screen, which makes it easy for workers to operate. We have also reserved an interface for docking with the customer's MES system, which can upload real-time production and qualification rate data. After the initial draft of the plan was released, we also conducted a 3D simulation demonstration for the client to confirm that the layout, rhythm, and operational logic were all correct before finalizing the final plan.

The third step is pre debugging at the factory to solve the problem before shipment. After the plan is finalized, it is about procurement and processing. Standard components such as PLCs, motors, and cylinders are directly purchased from qualified suppliers, while non-standard parts such as frames and fixtures are handed over to the machining workshop for production. After all the parts are in place, we will assemble them in our own workshop first, and the most important step next is pre debugging.

We took three different specifications of pipe fittings provided by the customer and ran them continuously for three days, totaling more than 6000 pieces, in order to identify issues such as material jamming, insufficient precision, and substandard rhythm. For example, during this trial run, we found that the chamfering station occasionally had burrs caused by excessive chamfering allowance due to slight differences in the hardness of the bar material. Later, we adjusted the variable speed logic of the tool feed and automatically adjusted the feed speed according to the actual hardness, and the problem was solved.

If these issues are left to the customer's site for modification, it will not only delay the customer's production, but also affect the project schedule. Pre commissioning is an important buffer for the implementation of non-standard lines.

Step four, on-site installation and acceptance, and ensure proper delivery and after-sales service. After passing the pre commissioning, the equipment is disassembled and transported to the customer's site, reassembled and repositioned, connected to electricity and gas, and then tested and adjusted on site. The next step is to train the customer's operators and maintenance personnel on how to change specifications, perform daily maintenance, and handle common minor faults. Finally, according to the acceptance criteria stipulated in the contract, run continuously for three working days to verify that the output, qualification rate, and pace meet the requirements, and the acceptance is considered complete.

After delivery, we will follow up on the operation of the equipment once a week for the first month. If there are any minor issues, we will promptly make on-site adjustments to ensure the stable operation of the equipment.

After the delivery of this non-standard automation line for pipe fittings processing, the customer originally required a process of 5 workers. Now, only one worker needs to replenish the material every hour, and the rest of the time is fully automated. The daily output is stable at over 2200 pieces, and the pass rate is stable at 98.5%. After more than a year, the equipment cost can be recovered.

In fact, the core of non-standard automation lines is never to pursue high-end configurations, but to meet the real needs of customers from beginning to end, and to do every detail well, which can truly help customers achieve cost reduction and efficiency improvement.