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UNIFLEX – Hydraulik GmbH
Machines for insulator manufacturing
1 www.uniflex.de October 2015
Technology Innovations for Crimping of Composite Insulators CARSTEN - - PowerPoint PPT Presentation
Technology Innovations for Crimping of Composite Insulators CARSTEN - - PowerPoint PPT Presentation
Technology Innovations for Crimping of Composite Insulators CARSTEN BAUMGARTNER UNIFLEX Hydraulik GmbH Machines for insulator manufacturing October 2015 www.uniflex.de 1 Welcome Carsten Baumgartner Head of engineering and production
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Welcome
Technology innovations for crimping of composite insulators
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Carsten Baumgartner Head of engineering and production Uniflex Hydraulik GmbH, Karben, Germany
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Content 1. Introduction 2. Current technology 3. Development objectives 4. Development milestones 5. Basic principles 6. Evaluation of test results 7. Forecast 8. Summary and conclusion
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Introduction Composite longrod insulators are used as state of the art for several applications. Radial crimping machines are used for joining of longrod insulators. Different process control systems are market used for reliable and continous product quality.
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Current technology Longrod composite insulators
- Near term customized design for flexible adaption
to individual requirements
- Reliable technology
- Approved ratio between weight, lifetime, costs and
performance
- Wide market availabilty of suppliers
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Current technology Uniflex crimping machines
- Machines up to 20000KN crimping force
- Slide bearing technology
- Fixed 6 o‘clock master die
- Simple process implementation
- In-house Engineering, design and service
- Uniflex expericence since over 40 years
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Current technology Process control systems and related limits
- Crimp to diameter
- Simple – but no inference of product quality
- Pressure controlled crimping
- Product optimized crimping speed
- Force related to product behaviour
- Crack detection possible
- Real crimping force dependent on equipment condition and
environment
- Impact sound analysis for crack detection
- Complicated for installation and operation
- Sensitive against environmental influences
- Frequently detection errors
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Development objectives Improvement of crimping process for approved insulator manufacturing, based on experience and knowledge Detection of faulty insulators without additional quality costs effort Cycle time reduction for insulator manufacturing Easy installation and operation Independency of environmental influences
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Development milestones Evaluate system for detection and control of real crimping force translated to workpiece Search for applicable and reliable components
- Sensors
- Control unit
- Actuator unit
Review system function at field test conditions
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Establish basic principles Hardware
- Uniflex HM 380 crimping machine
- Measuring processor unit: sampling
rate 10KHz
- High speed proportional valve for
fast response
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Establish basic principles Sensor
- Force measuring pin / type full
bridge
Sensor application
- 6 o‘clock master-dies
- Crimping dies
Quantity of sensors
- 2 sensors: front and back
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Evaluation of test results
– Symmetric force transmission to crimping dies
- Master-die can be used for qualified measurement
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Evaluation of test results
Linearity between pressure and force
- Hydraulic pressure is not linear to real crimping forces
- Pressure is no reliable indicator for insulator failure
- Pressure cannot be used for qualified evaluation of crimping process
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Evaluation of test results – Repeatability at serial production
- Crimp to pressure: force variation up to +/- 25%
- Crimp to force: specified force transmission to workpiece
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Evaluation of test results – Failure detection at manufacturing process
- Sample batch analysis for force range detection
- Continous and reliable process control while manufacturing
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Evaluation of test results – Real force calibration
- Load cell sensor for reference forces
- Required work-piece forces can be
translated between different machines
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Forecast
– Detection of
- Correct positioning at master-die
- Proper preassembling of work-pieces
- Regular combination of rod and fitting
- Inhomogeneity of insulators raw material
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Summary and conclusion
– Real force controlled crimping for qualified process control – Optimized crimping result and reduced cycle time – Fixed 6 o‘clock master die for permanent and protected sensor application – Symmetric force transmission to crimping dies Independency of environmental influences, such as friction, temperature, noise or machine service situation – Redundancy by application of two force sensors – Mechanical insulator crack detection without absorption by hydraulic oil – Easy installation and operation – Approved crimping parameters exchangeable between different machines by force calibration
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Uniflex Hydraulik GmbH
Thank you for your kind attention.
- see you at booth S1-
www.uniflex.de
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