Optimizacija galvanizacijske linije in nadgradnja izdelave nikljanih reber

Kuhar, Blaž (author), Nedeljković, David (mentor)

Diplomsko delo obravnava proces izdelave nikljanih reber za potrebe montaže na mehanizem za registratorje. Del procesa je površinska obdelava reber v galvanski liniji obešal, kjer se rebra nikljajo. Proces je ozko grlo proizvodnje, zato sem imel nalogo, da preučim delovanje in z izboljšavami povečam učinkovitost linije in nato celotnega procesa izdelave reber. Z delom na galvanski liniji sem začel v letu 2004, kjer sem zgolj iz elektro načrtov, programa na krmilniku in navodil za uporabo popisoval obstoječe stanje linije. S pomočjo upravljavcev sem spoznaval, na kakšen način linija dela in spremljal, s kakšnimi težavami in zastoji se soočajo na liniji. Največ zastojev so povzročali transportni vozički. Z manjšimi programskimi in mehanskimi spremembami sem odpravil počasno spuščanje nosilcev reber v pozicijo, spuščanje do spodnje končne lege, optimiziral hitrost vožnje in pozicioniranje transportnih vozičkov. Posredno sem skrajšal cikel linije in dosegel večjo zanesljivost delovanja linije. Izkazalo se je, da je učinkovitost galvanske linije obešal odvisna predvsem od človeškega faktorja. Ključen preboj je bil prehod na izdelavo reber iz nikljane žice. Pozornost sem preusmeril v izboljšavo procesa in iskanju rešitev za večjo produktivnost. Proces izdelave reber se je postopno spreminjal; Najprej z uvedbo neposrednega šaržiranja nikljanih reber, prestavitvijo strojev za izdelavo reber in zaustavitvijo galvanske linije obešal. Sledila je izdelava šaržiranja na tri postaje. Uvedla se je napredna kontrola lukenj v nikljanem rebru in izdelal transportni sistem reber. Vse spremembe so bile izvedene do konca leta 2014. V primerjavi z letom 2004 se je produktivnost procesa izdelave reber potrojila. Z višjim nivojem avtomatizacije in boljšim obvladovanjem proizvodnega procesa dosegamo tudi višjo kakovost izdelkov.

• Language: Slovenian
• Keywords: galvanska linija, PLC, merilni sistem, transportni sistem, produktivnost.
• Work type: Undergraduate thesis
• Organization: FE - Faculty of Electrical Engineering
• Year: 2016
• PID: 20.500.12556/RUL-85178
• Publication date in RUL: 14.09.2016

Secondary language

• Language: English
• Title: Optimization of galvanizing line and an upgrade of the nickel-plated ribs manufacture

Abstract

The thesis discusses the manufacturing process of nickel-plated ribs to be mounted on the lever arch mechanism for files. Part of the process consists of surface coating of ribs in an galvanic line of hangers in which the ribs are nickel-plated. This process is a bottleneck of production, therefore I was assigned to examine the functioning of the line and by implementing adequate improvements, I had to improve its efficiency and later to optimize the whole process of rib production. In 2004 I started working at galvanic line, where my job was to describe the current state of the line with electro plans, program on the controller and operating instructions. With the help of operators I became familiar with the ways of how the line is operated and I monitored the problems and delays on the line. Most delays were caused by transport carts. By minor software and mechanical changes I eliminated the slow lowering of rib carriers into a position. I optimized lowering of rib carriers to the lower end position. I increased running speed and positioning of transport carts. The line cycle was indirectly shortened and higher reliability of operation was achieved. It turned out, that the effectiveness of the galvanic line of hangers primarily depends on the human factor. Transition to nickel-plated wire was the breakthrough. My attention was drawn to finding the ways to improve the process and to increase productivity. The process of ribs production was gradually changing. First by introducing direct charging of nickel-plated ribs, relocation of rib-production machinery and by shutting down the galvanic line of hangers. The implementation of three-station charging followed. Advanced control of holes in nickel-plated rib was introduced and a transport system of ribs was put into operation. All the changes were carried out by the end of 2014. The productivity of rib-production process has tripled compared to 2004. With higher level of automatization and management of production process, higher quality of products is achieved.

• Keywords: galvanic line, PLC, measuring system, transport system, productivity.