With the rapid development of science and technology, it has become a general trend to accelerate the development of manufacturing industry towards digitalization, networking and intelligence. In the ceramic bathroom industry, it has become a consensus to move from "manual production" to automatic and intelligent production. In order to promote the transformation, upgrading and innovative development of the ceramic bathroom industry, and improve the current situation of the industries with low production efficiency, high labor intensity, and harsh production environment, the Equipment Automation Business Department of the Institute of Intelligent Manufacturing, Guangdong Academy of Sciences has made technological innovations and tackled key problems in the division of labor in the production and manufacturing process, and has successively broken through the robot and intelligent technologies in the key processes of ceramic bathroom industry, such as glaze spraying, polishing, high-pressure molding, etc, We have earlier developed automation equipment such as "enamel spraying robot production line" and "polishing robot system" in China, promoting the transformation and upgrading of ceramic sanitary industry with intelligent technology solutions.
In an automatic production line, one ceramic blank is transmitted to the corresponding position by the conveyor belt. After the robot receives the induction signal, it immediately adjusts the joint arm to aim at the ceramic blank for glaze spraying. With a hissing sound, the glaze spraying process is completed in a flash. Intelligent production has brought great changes to ceramic manufacturing.
In order to promote the transformation, upgrading and innovative development of the ceramic bathroom industry in Chaozhou City, in recent years, the Institute of Intelligent Manufacturing has signed an industry university research cooperation agreement with Hengjie Sanitary Ware and other enterprises. The launch of this flexible production line for enamel spraying robots in the ceramic bathroom industry is just one of the major achievements of the above industry university research cooperation.
This production line is the first in China to realize the full process robot glazing, including toilet elbow, inside and outside of water tank, water ring, internal and external surface of body, and intelligent cleaning glaze. It is a flexible production line with multiple robots working together. It adopts multiple 6-joint industrial robots, and is equipped with special machines such as transplanting positioning machine, automatic taking and placing water tank cover machine, pipe glazing machine, and bottom wiping machine. It is very suitable for the production of bathroom industry. According to the enterprise accounting, the monthly wage income of a skilled enamel spraying worker is between 8000 and 10000 yuan. After the production line is put into trial production, the production efficiency is increased by 80%, the number of workers is reduced by 70%, and the qualification rate is increased by 10%, greatly reducing the production cost of the enterprise.
In recent years, more and more industrial robots are used for grinding instead of manual work. However, sanitary products have problems such as complex curved surface, low green body hardness, high dust equipment protection, etc., which make it difficult to obtain stable process effect.
In order to solve the practical problems in processing, the scientific research team of the Institute of Intelligent Manufacturing carried out technical breakthroughs in the grinding process of ceramic bodies, broke through the above technical problems, developed complete sets of grinding automation equipment such as "robot constant flange, constant grinding machine, automatic dust removal", and took the lead in realizing industrial applications in China.
Development and application of multiple intelligent production lines
In order to better promote the transformation and upgrading of the ceramic sanitary ware industry, the research team of the Institute of Intelligent Manufacturing continued to deepen the ceramic sanitary ware industry, continued to innovate and develop in the high-pressure forming of sanitary ceramics, the upper and lower kilns of green bodies, the finished inspection and digital manufacturing of intelligent toilets, and developed and promoted several intelligent production lines for sanitary ware enterprises. The high-pressure forming system realizes automatic grouting, mold opening and closing, demoulding, robot slurry coating, bonding, etc.
In view of the high temperature and labor intensity of the upper and lower kilns of ceramic bodies, a double-layer, dual robot upper and lower kiln system with multiple product lines was developed.
At present, relevant scientific and technological achievements have been promoted and applied in Chaozhou, Foshan, Fujian, Hebei, Chongqing, Hengjie, Jiumu, Kohler, Huida, Biguiyuan and other sanitary enterprises, making positive contributions to the transformation and upgrading of China's ceramic sanitary industry.