A company's air compressor station was built in 1955. There are currently 9 air compressors of the same type, 5L-40/8, which are used by 31 departments for compressed air. They are mainly used for pneumatic tools, pneumatic instruments and wind control devices. Wind blown device (cleaning the surface of the aluminum plate). The supply wind radius is up to 3 3 km and the supply wind branch points are up to 188. The air supply volume of the air compressor station is 117 m 3 / min. Due to the long running time, the compressed air pipe network often leaks. According to estimates, the total leakage of compressed air in the production workshop is 15 20 m 3 / min, and the leakage rate is 12 8% 17%. Since the air compressor station only supplies air, it cannot control the entire pipe network system, and often the unit pressure is insufficient. The phenomenon that the wind unit is seriously wasted. It is often not enough to start five units during the peak hours during the day, and there are still some spares for starting the six units. The excess wind can only be discharged. The total air supply of air compressors is 61.42 million m 3 per year, while the actual air volume is 53.16 million m 3 , the loss is 81.86 million m 3 , and the wind rate is only 86 6%. Control, waste serious problems, the company's patented technology wireless remote control air distribution device has achieved good results.

1 wireless remote control air distribution device working principle Wireless remote control air distribution device consists of four parts: main engine (air compressor end), adapter, extension (terminal) and electronically controlled pneumatic valve. Remote control technology is used to remotely control each windmill, and the valve without the wind point is closed in time to avoid wind leakage; and the air compressor unit's working capacity is adjusted in time according to the required air volume of each wind point. The system can solve the problem that the company has long compressed air pipelines, many wind supply branch points and serious leakage, and truly realizes effective monitoring and production of the air supply system, so that the air compressor is in the best economic operation state. To achieve maximum energy savings.

The host is the core of centralized control, located in the centralized control room, which sends remote start and stop control commands to the extensions located at each use point. The electromechanical control pneumatic valve is installed on the indoor air supply pipe of the production site, and executes the air distribution command sent by the host. The number of host control extensions can reach hundreds, the control distance is 5 km, and the power supply of the device is AC220V.

The device utilizes advanced microelectronic technology to give full play to the high efficiency and flexibility of the microcontroller in industrial control. It is a high-performance, intelligent industrial monitoring system. Its technical feature is that the host and extension use the international radio enthusiast channel 144 MHz band bidirectional dual working conditions. The electronically controlled pneumatic valve is an automatic valve that realizes the opening of the valve by means of the wind pressure inside the air supply pipe and the power loss of the electromagnetic reversing valve. The opening pressure is 0 25 M Pa, the working pressure is 0 6 1 M Pa; the national standard shut-off valve size, there are 12 kinds of specifications of DN2 5 DN300; the remote control distance is 0 3 km in the plant area, the transmitting power is 0 5 W, electronic control The pneumatic valve has a power of 15 W and is fully compliant with the company's requirements.

2 Installation of wireless remote control air distribution device On April 10, 2004, the wireless remote control air distribution device was installed. Specifically do the following work: (1) replace the valve. Remove the original manual valve and install the remote control valve.

(2) Install the extension. Install the extension near the remote control valve, fix the extension to the wall, and extend the extension antenna to the outside. In order to ensure the receiving quality, the extension is connected to the electric valve through the line, and the extension is connected to the power supply to control the electric valve.

(3) Host and computer systems. The main transmitting antenna is fixed on the roof of the air compressor station, and the antenna is connected to the adapter. The adapter is connected to the industrial control host, and control software is installed on the host to ensure that the remote electric valve is controlled by the computer system.

The computer system is connected to the local area network, and the power adjustment personnel and technicians can realize the monitoring and management of the wind through the network to achieve centralized control and planned supply. The air compressor station prepares the kinetic energy supply schedule according to the weekly wind time and air volume of each wind unit, and reasonably arranges the start time of the air compressor.

3 economic benefits 3 1 input costs computer system 70,000 yuan; extension system 85,000 yuan; valve 105,000 yuan; demolition, installation labor costs, etc. 80,000 yuan; a total of 340,000 yuan.

3 2 Application effect After nearly one year of operation, the device solves the phenomenon of large horse-drawn car, solves the problem of insufficient pressure at the end of the air supply, guarantees normal production; can plan to use, special-purpose supply wind; thoroughly solve the use of wind unit The phenomenon of uneven sales; centralized control; saving manpower and saving electricity consumption.

Originally, the annual loss of compressed air was 818,600 m 3, and now there is no leakage and no loss. Calculated according to the internal price of air pressure 0 065 yuan / m 3, the annual loss of 532,000 yuan; In addition, after using the system, the air compressor unit running time reduced by 8 640 h (original operation 43 200 h, now the actual operation 34 560 h), air compressor operation is safer and more economical.

At the same time, the power, circulating water, spare parts and spare parts consumed by the air compressor are also reduced accordingly. Before the change, the annual average power consumption was 75.47 million kWh. After the change, the actual electricity meter reading was 659.88 million kWh, and the annual electricity saving was 94.59 million kWh. The power saving rate was 12 53%, and the electricity price was 0 52 yuan / kWh. The annual electricity saving fee is 49.19 million yuan. The annual operating cost of the air compressor is about 1.98 million yuan. Therefore, the annual savings can be 82.59 million yuan.

4 Conclusion (1) The wireless remote control air distribution device is technically advanced, economically reasonable, and easy to operate and operate. The device is used to ensure that the wind units are used to balance the wind and prevent leakage.

(2) Remote control of each on-site valve through the wireless remote control air distribution system to minimize the effective volume and leakage point of the air supply pipe network, thereby reducing the boot capacity and boot time, and saving an annual cost of 82.59 million yuan. In the case of concentrated supply of wind and uneven production, the energy-saving effect is more obvious.

(3) Reduce the non-productive waste by planning the opening and closing control of each wind point; the wind control system provides the wind operation record report of each wind control terminal, and can perform inquiry, print preview and print operation.

(4) Through effective control and management of each wind unit, energy consumption is reduced and energy is effectively utilized, thereby achieving the goal of reducing costs and improving the competitiveness of enterprises.

Gravity Casting Parts

"Gravity Die Casting. A permanent mould casting process, where the molten metal is poured from a vessle of ladle into the mould, and cavity fills with no force other than gravity, in a similar manner to the production of sand castings, although filling cn be controlled by tilting the die."

Gravity Die Casting

Sometimes referred to as Permanent Mould, GDC is a repeatable casting process used for non-ferrous alloy parts, typically aluminium, Zinc and Copper Base alloys.

The process differs from HPDC in that Gravity- rather than high pressure- is used to fill the mould with the liquid alloy.

GDC is suited to medium to high volumes products and typically parts are of a heavier sections than HPDC, but thinner sections than sand casting.

There are three key stages in the process.

  1. The heated mould [Die or Tool] is coated with a die release agent. The release agent spray also has a secondary function in that it aids cooling of the mould face after the previous part has been removed from the die.
  2. Molten metal is poured into channels in the tool to allow the material to fill all the extremities of the mould cavity. The metal is either hand poured using steel ladles or dosed using mechanical methods. Typically, there is a mould [down sprue" that allows the alloy to enter the mould cavity from the lower part of the die, reducing the formation of turbulence and subsequent porosity and inclusions in the finished part.
  3. Once the part has cooled sufficiently, the die is opened, either manually or utilising mechanical methods.

Advantages

  • Good dimensional accuracy
  • Smoother cast surface finish than sand casting
  • Improved mechanical properties compared to sand casting
  • Thinner walls can be cast compared to sand casting
  • Reverse draft internal pockets and forms can be cast in using preformed sand core inserts
  • Steel pins and inserts can be cast in to the part
  • Faster production times compared to other processes.
  • Once the tolling is proven, the product quality is very repeatable.
  • Outsourced Tooling setup costs can be lower than sand casting.

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