The people’s point of view has always been that long-term production of batch products can only be processed on specialized equipment to achieve the best economics. Such a device is designed for this kind of workpiece to meet all the requirements. However, today's product variety changes very frequently, and the characteristics of the produced workpieces also change frequently. Therefore, the processing plan gradually requires the equipment to be flexible.

Figure 1 In the investment analysis of machine tools, the greatest flexibility and good economy has always been a pair of mutually opposing factors. Reconfigurable manufacturing systems can resolve this contradiction, especially in high-precision mass production

Reconfigurable machine tools are getting more and more applications. It is obviously cheaper than general-purpose equipment. This is because some modules and processing options are not necessary, but they are purchased and replaced when needed. . On the other hand, higher flexibility compared to special equipment or special equipment can make the overall processing of small batches or medium batches of workpieces more outstanding economic benefits.

Machine reconfigurable solutions can ensure optimal processing of real-time workpieces by purchasing new modules to meet new requirements. Since there is no need to pay for unnecessary parts, the price of the equipment becomes correspondingly lower.

The prerequisite for successful reconfigurable manufacturing is to have a suitable interface. This interface technology allows all process modules or axes to be replaced. In contrast to current equipment solutions, the replacement of manufacturing processes, from milling to grinding or the installation of additional rotary or linear shafts, does not require the equipment to be shut down for several weeks. In an ideal situation, the replacement of the process can be done by the user within one day. The machine tool manufacturer provides the corresponding technology or pre-installs and pre-commissions the module. For reconfigurable manufacturing, these components need only be accurately assembled to the device through the mechanical interface on the device.

Interfaces are rigid and standardized

In addition to the good rigidity of the interface, the long-term replaceability of the module and the standardization of the equipment must also be achieved. The bolt connection method is common, but the bolt needs to apply tension after calibration. The module must be repeatedly measured and adjusted by means of a bolt.

Using a so-called static interface is most suitable. The principle is similar to that of the HSK tool connector, and the user can obtain a rigid interface with strong biting force. Tensioning can be done hydraulically or manually. If you add modules to the equipment in a narrow production space, you only need to fit the module into the 4 mm centering taper.

The XG series powertrain (Figure 2) was designed for technical improvements or product changes that were implemented due to cost pressures and continuous optimization of workpieces in mass production. The new production technology is integrated into the equipment through the interface, so that the equipment can be maintained at the latest technology level. In addition, the equipment can also respond quickly to new requirements for mass production. In the past, even minor changes to the parts often required large amounts of modification.

Figure 2 The XG series MAG powertrain is mainly used for the mass production of power hinged components. This machine can be reconfigured for this series

Integration of new technologies

Product changes make reconfigurable manufacturing necessary (Figure 3). This requires a great deal of intervention in the equipment: from the automation of the equipment in the workshop, to the workpiece holder to the shaft arrangement (Figure 4).

Figure 3 The processing module is equipped with a static interface that enables replacement between the articulated joint (upper) and the differential housing (lower). Changes to the required workspace have been taken into account

Fig. 4 The working space changes greatly when the articulated joints and the differential housing are replaced. The replacement part can be the automated part of the equipment, it can also be the clamping device of the workpiece, it can also be the layout of the shaft

In order to achieve this, a static interface is provided on the processing module, and at the same time when the interface is defined, it can still be replaced on the installed device. To do this on some modules is very time consuming, especially on large and heavy components such as the B-axis module, mainly because of the limited working space. When replacing parts, some parts must have special openings for easy transport.

With the help of the interface, the processing module is pre-adjusted at the equipment manufacturer, which can reduce the on-site replacement workload and speed up the work completion. The fixture system and automation part of the workpiece can also be replaced via the interface. This enables fast and easy reconfiguration in two working areas of two different workpieces. In order to ensure ideal rigidity, each module has a corresponding number of interfaces.

Grinding replaces milling and turning

Another case is the extremely simple reconfigurability of the XG series machine tool: change the hard milling and turning process to grinding. By replacing the milling spindle with a grinding spindle with a rotation speed of 60 000 r/min and replacing the turning tool holder with a grinding spindle with a rotation speed of 30 000 r/min. Due to the standardized interface from the connecting element to the plug, this measure does not require a large amount of work. In addition, the module can also be fixed to the equipment rack via a standard interface (Figure 5).

Figure 5 From the geometry of the connecting element up to the plug, the device is fitted with standard components. In addition, it is possible to exchange, for example, the turning axis module with the milling axis module.

This practice is very meaningful if the replacement process has a major impact on the equipment, as is the case when switching from hard milling and hard turning to soft machining. In this case, the milling axes for roughing and finishing can be used on the device. With the modular solution, the replacement of parts is very simple. Since both modules use the same interface, releasing the tensioner allows the module to be removed from the device. The milling module can be roughly positioned and then held in place by the clamping force of the interface. In this way, the exchange process can be greatly shortened.

Smaller purchase costs and better economic benefits

Reconfigurable manufacturing is an ideal way to improve the economics of the machine and extend the service life of the machine. New interface technologies can also be quickly and easily integrated into the device.

In terms of economics, a study has been conducted to compare a conventional device with a reconfigurable device of the same type: during 15 years of use, a total of three reconfigurable manufacturing operations have been performed ( From the milling process change to the grinding process, the different machine shafts are removed or mounted), confirming that the new equipment scheme is more than about 20% economical. Due to the long service life of the equipment, there is no need to spend a lot of procurement funds. This advantage is obvious.

Benzene series intermediates

Benzene, an organic compound, is the simplest aromatic hydrocarbon with a chemical formula of C6H6. At room temperature, it is a sweet, flammable, colorless and transparent liquid with carcinogenic toxicity and a strong aromatic odor. It is insoluble in water, easily soluble in organic solvents, and can also be used as an organic solvent itself. The ring system of benzene is called benzene ring, and the structure after removing a hydrogen atom from the benzene ring is called phenyl, which is represented by Ph, so the chemical formula of benzene can also be written as PhH. Benzene is a basic petrochemical raw material, and its output and production technology are one of the symbols of a country's petrochemical development level.

On October 27, 2017, the list of carcinogens published by the World Health Organization's International Agency for Research on Cancer was preliminarily sorted out for reference, and benzene was included in the list of Class I carcinogens.

Foreign name: Benzene, benzol, benzeen

Alias: Rest oil

Chemical formula: C6H6

Molecular weight: 78.11

CAS login number: 71-43-2

EINECS accession number: 200-753-7

Melting point: 5.5℃

Boiling point: 80.1℃

Water soluble: insoluble

Density: 0.88 g/cm³

Flash point: -11℃

Application: Used as spices, dyes, plastics, medicines, explosives, rubber, etc.

Security description: S36/37; S45; S53

Hazard description: R11; R36/38; R45; R46; R48/23/24/25; R65

UN Dangerous Goods Number: 1114/1115

The benzene ring is the structure of the benzene molecule. It is a plane regular hexagon, each vertex is a carbon atom, and each carbon atom is combined with a hydrogen atom. The carbon-carbon bond in the benzene ring is a unique bond between single and double bonds, with a bond angle of 120° and a bond length of 1.40Å

Benzene Series Intermediates,2 4 6-Trimethylbenzaldeliyde,4-Iodo-3-Nitrobenzoic Acid Methyl Ester,4-Iodo-3-Nitrobenzoic Acid

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