Manhole Cover Grinding Machine Center

I.  Overview

We have a professional team of engineers specializing in molding, cutting, and grinding. With years of design and practical experience, we solve real-world problems for our clients.

The equipment we design uses internationally renowned brand components, such as Yaskawa servo motors, Keyence, Schneider, Omron, IKO, and ABB, ensuring stable, reliable, safe, and efficient operation. This equipment is user-friendly and designed according to ergonomic principles. Our main products include fully automatic riser grinding machines, fully automatic gate cutting machines, and fully automatic molding lines.

WUXI SMART CNC primarily helps clients achieve the best results with minimal investment. We provide high-precision and high-quality equipment to our clients; we offer superior service and the best solutions to save  significant  human   and  material  resources   for   enterprises  and  greatly  improve  their  production efficiency and quality.

II.  Solution Design

1.  Project Description:

Polishing Objects (8 items):

The following solution is mainly for the above 8 types of manhole covers.

2.  Customer Requirements:

1 ，Remove the sprue and riser from the manhole cover casting.

2 ，Grind the flash and burrs around the exterior of the manhole cover casting.

3 ，Grind the flash and burrs inside the inner hole of the manhole cover casting.

4 ，Drill installation holes in the manhole cover casting, with a diameter of approximately 10-20 mm.

3.  Equipment Parameter Introduction

Based on your company's products and parameters, our designed machine parameters are as follows:

4.  Device Description

(I) Equipment dimensions (height 2700)

(II) Description of the overall layout of the equipment

Schematic diagram of overall equipment layout

Grinding Process:

I.  Manually hoist the manhole cover onto the fixture of the four-axis robotic arm.

II.  The four-axis robotic arm enters the grinding chamber and the safety door closes. III. Proceed in the following sequence:

1 ，Use the sawing machine to remove the gating system.

2 ，Grind the gates and the burrs around the outer periphery on the grinding machine. 3 ，Use the central hole grinding machine to remove burrs from the inner bore.

4 ，Drill holes using the drilling machine.

IV. The safety door opens, and the finished manhole cover is manually removed.

(III). Equipment Composition Description

The  fully  automatic  grinding  machine  mainly  consists  of  a  six-axis  robotic  arm,  grinding  wheel  unit, automatic feeding system, automatic tool alignment, workpiece clamping fixture, frame sheet metal, and electrical control modules. Each component module is installed within the frame according to the grinding trajectory to complete the grinding tasks. During operation, the operator only needs to stand outside the equipment and place the workpiece to be ground in the fixture position.

1 、 Four-Axis Robotic Arm

Function: Move the workpiece to the sawing machine, grinding machine, wheel grinding machine, and drilling machine for the respective cutting and grinding processes according to the programmed instructions.

Load Capacity: 200 kg, Movement Range: 2400 mm,

X-Axis Linear Movement Stroke: 3.5 meters, Fourth Axis: Capable of 360-degree rotation 

2 、Sawing Machine + Gating System Discharge Conveyor

Function: Remove the gating system from the manhole cover and uniformly convey it to the waste container outside the machine. The sawing machine can perform arc cutting.

3 、Grinding Unit

Equipped with large grinding wheels and grinding heads, targeting the removal of burrs and excess material on the gating system, outer perimeter, and inner bore of workpieces. The grinding tools are made of electroplated diamond, ensuring safety, efficiency, and minimal dust.

Additional Features: The grinding wheel and head units are equipped with a floating mechanism designed specifically for workpiece grinding. Due to the unique nature of the casting process, workpieces may exhibit deformations and size discrepancies, leading to inadequate or excessive grinding, causing significant abrasive wear. This may necessitate re-grinding or result in scrap. The floating mechanism addresses these issues effectively by allowing the grinding wheel to move back and forth. If the grinding amount is excessive, the grinding wheel will automatically retract. The force is adjustable, allowing different grinding pressures to be set for various positions.

4 、Safety Lock

Grinding is a high-risk industry. The equipment is equipped with Euchner safety locks,  significantly enhancing safety. These locks adhere to European IV standards, ensuring comprehensive safety for both the equipment and the operators.

5 、Cooling System

The equipment features a comprehensive cooling system, ensuring stable operation in harsh environments and significantly extending the equipment's lifespan.

Details:

① Grinding Wheel Spindle Cooling: All grinding wheel spindles are water-cooled using a chiller, maintaining the spindle temperature below 25°C, allowing for continuous, stable operation for 24 hours.

② Electrical Cabinet Cooling: The electrical cabinet is equipped with an air conditioning unit with a temperature display panel and adjustable settings, keeping the temperature below 35°C.

6 、Lubrication System

The equipment includes an oil injection system that automatically lubricates the internal guide rails and cylinders at set intervals and quantities. This not only significantly extends the equipment's lifespan but also simplifies maintenance, making it more convenient.

7 、Touch Screen Control Panel(English Version Available)

①Touch Screen Shot(English Version Available)

②Teaching Navigation(English Version Available)

The system is equipped with teaching navigation. The operator follows the step-by-step prompts for teaching and related signal settings. The operation is simple, easy to learn, and the thinking is clear.

③Alarm Record(English Version Available)

All alarms of the equipment will be recorded in the system, which can be viewed by staff for easy supervision of equipment usage.

8 、Grinding Force Perception System

The equipment is equipped with a grinding force perception system, allowing for control over the grinding force applied to the workpiece during the grinding process. Coupled with the grinding wheel floating system, it prevents the occurrence of "hard grinding," thereby improving the quality of the workpiece grinding and significantly extending the lifespan of the grinding wheel.

Working Principle:

The system uses various high-precision sensors to collect data during the grinding process involving the four-axis robotic arm, such as grinding resistance, spindle torque, and floating torque. This data is processed using an embedded function to establish a linear relationship between the movement speed W=kV (W: effective grinding power; k: speed linear coefficient; V: four-axis swing arm movement speed)  According to the above equation, by real-time monitoring of the effective grinding work W, when the effective grinding work W is greater than the limit value Wmax (grinding suddenly encounters a large burr), the four-axis swing arm will automatically slow down the movement speed, the effective grinding work W will decrease, and it will return to the stable range. When the effective grinding work W is less than the limit value Wmin  (the grinding of large burrs is completed, and small seams continue to be polished), the four-axis swing arm will automatically speed up the movement speed, the effective grinding work W will increase, and it will return to the stable range. Through the above process, it is ensured that the effective grinding work W fluctuates within the specified range. Thereby ensuring that when grinding irregular burrs, seams, and gates, the four-axis swing arm automatically adjusts the feed to ensure the grinding quality.

(I) Clamping Scheme

Workpiece Clamping and Positioning (Refer to the Above Diagram)

For cutting and grinding manhole covers of different models, simply replace the fixture. The fixture is designed for quick change. Under the action of the cylinder, the pressing head clamps the workpiece for cutting and grinding.

(II) Cutting and Grinding Process Illustration (Using the Largest Model 1150*1150 as an Example)

① Cutting the Gating

② Cutting the Outer Protruding Gating System (Cutting Allowance)

③Grinding the Flash and Burrs in the Central Hole

④Drilling Holes

6 、Features of the Automatic Grinding Machine

1）Grinding Machine Patents:"A Grinding Equipment," Patent No.: ZL 2016 2 1172249.1   "An Automatic Floating Grinding and Cutting Device," Patent No.: ZL 2016 2 1172551.7

2）Safety Level: The equipment meets EU IV safety standards.

3）Collision Prevention System: Equipped with a four-axis robotic arm collision prevention system to ensure the equipment's longevity.

4）Program Storage: The equipment can store 1~200 programs to meet the grinding needs of different products.

5）Automatic Alarm Display and Storage: Abnormal alarms are automatically displayed and stored for later review.

6）Guided Operation: Easy for employees to operate, requiring minimal training.

7）Fully Enclosed Equipment: Equipped with dust extraction ports to improve the working environment, reducing dust by 99% compared to manual grinding.

8）Easy Fixture Change: Simplifies fixture change, reducing preparation time.

III. After-Sales Service and Warranty

1. Installation, Commissioning, and Operator Training

Our trained engineers will install the machine at your factory. During all installation phases, your staff must assist our engineers and provide meals.

Our engineers will commission and test-run the equipment and provide training to operators and maintenance personnel. Although the automatic grinding machine is user-friendly and comes with detailed operation manuals, providing proper operation skill demonstrations will make the operation  even more convenient and enhance the user experience. Maintenance personnel will also gain a thorough understanding of troubleshooting and preventive maintenance. The machine is equipped with a remote diagnostic system for program diagnostics; ifyou have any questions, contact our engineers.

For your company's multiple products, we will program and debug one product; the rest will be arranged by your company's engineers. If you need our engineers to debug, travel and other expenses will be charged.

Installation Period:

-Installation Time: 1 week

-8 hours/day, excluding weekends

After completing the installation and training, our engineers will submit an installation and training report for your staff's signature, confirming that we have completed the installation and training as required.

2. Exclusions

The following items are not included in our supply scope and must be paid by your company:

-Site preparation for the automatic belt grinding machine (ground reinforcement and cleaning, etc.)

-Site preparation for the automatic belt grinding machine (ground reinforcement and cleaning, etc.)

-Providing lifting equipment for installation, including various materials and driver services (e.g., forklifts and lift platforms)

-Construction and installation to fix the machine

3. Warranty

WUXI  SMART  CNC  Co.,  Ltd.  guarantees  that the  equipment provided  is  of high  quality  in  terms  of materials and workmanship, with a warranty period of 12 months.

The warranty period will commence upon meeting any of the following conditions:

-After machine acceptance

-When the machine starts production -3 months after machine delivery

The warranty for the machine or any part of it is void in the following circumstances:

-Any part of the automatic grinding machine is modified or replaced without authorization.    -Changes are made to the control structure's standard tolerances or operational specifications.

-Damage to the  equipment  due  to  improper use  or neglecting  the  operational  knowledge  stated  in  the manual.

WUXI SMART CNC will provide continuous telephone and remote fault support, and if trained personnel are still unable to resolve the issue, the seller will respond within 8 hours. In rare cases where telephone service and remote fault support cannot solve the problem, engineers will provide on-site support as quickly as possible.

© This proposal is the copyright of WUXI SMART CNC!

All technical and commercial secrets, such as the technology and prices obtained from this proposal, must comply with Chinese laws on copyright, patents, trademarks, and other intellectual property, and follow the relevant provisions of confidentiality regulations. It must not be disclosed, transferred, licensed, exchanged, gifted, or used improperly by any other organization or individual in any way. If violations cause losses to the supplier, the buyer will be liable for related legal responsibilities.

In addition to continuously improving the performance of existing products, our company also constantly introduces new products. Therefore, our company reserves the right to change technical specifications and content without further notice.

The implementation of the contents involved in this proposal is subject to the final technical solution.