Application of intelligent manufacturing in hose clamp production: analysis of the entire process technology from automated stamping to online detection

Keywords: hose clamp intelligent manufacturing, automated stamping, online detection, digital twin

abstract

Traditional clamp production relies on manual operation, which has problems such as low efficiency (single piece processing time>15 seconds) and high defect rate (>3%). This article takes a certain clamp factory as an example to analyze its intelligent transformation path.

3.1 Automated stamping production line

High speed servo press: Adopting a 1000 ton servo press, the stamping speed reaches 300 times/minute, the positioning accuracy is ± 0.02mm, and it is suitable for clamp strips with a thickness of 0.5-3mm.

Progressive die design: Integrated processing of material dropping, punching, forming, and cutting is achieved through 16 station progressive dies, increasing material utilization from 65% to 85%.

3.2 Robot Welding and Assembly

Laser welding process: IPG 2kW fiber laser is used, with a welding speed of 10m/min and a weld strength of 95% of the base material, suitable for precision welding of titanium alloy clamps.

Collaborative robot assembly: The UR10e robot is used to automatically load and tighten screws and nuts, with a torque accuracy of ± 2%. The single shift production capacity has been increased from 800 pieces to 3000 pieces.

3.3 Online Testing and Quality Traceability

Machine vision inspection: Deploy the Cognex In Sight 7000 series camera to detect clamp tooth defects (such as burrs and cracks) with an accuracy rate of 99.8% and a detection speed of 200 pieces per minute.

Digital twin system: Through the Siemens MindSphere platform, real-time monitoring of equipment status (such as pressure, temperature), energy consumption, and OEE (overall equipment efficiency) is achieved, with fault warning time advanced by 72 hours.

3.4 Flexible Production and Customization

Modular production line design: Through a fast mold changing device (mold changing time<10 minutes), it supports mixed production of different specifications of clamps (diameter 10-100mm).

3D printing assisted development: SLM metal 3D printing is used to produce clamp prototypes, and structural verification is completed within 48 hours, reducing the development cycle by 60%.

conclusion

Intelligent manufacturing has shifted the production of hose clamps from "batch manufacturing" to "flexible customization", achieving a dual improvement in quality and efficiency through the integration of automation, digitization, and networking.