装配过程中的总体拥有成本(TCO)计算


Throughout industry, the Total Cost of Ownership (TCO) principle is a critical factor in decisions on procuring new machinery or plant. The actual procurement costs are not the only factor that a business must consider if it aims to manufacture competitively in the long term. It's equally important to factor in all the direct and indirect costs incurred before, during and after the procurement. This is the way to identify solutions that are most favorably priced and cost-effective. This principle also applies to joining and press-fit processes in industrial manufacturing: investments in electromechanical joining systems can pay off in the long run here – in terms of energy balance and maintenance expense as well as product scrap costs.

In May 2012, the University of Kassel published a study that compares the energy efficiency of hydraulic, pneumatic and electromechanical processes. The results highlight and emphasize the savings potential of electromechanical joining systems. With conventional hydraulic applications, the energy required is 4.4 times more than for electromechanical technology – and pneumatic processes actually use up to ten times more energy. With an electromechanical solution, greater efficiency means that savings of 77 percent are possible as compared to hydraulic systems; in relation to pneumatic applications, as much as 90 percent can be saved.

Electromechanical NC joining systems from Kistler – total control thanks to monitoring and regulation of joining and press-fit processes.
Electromechanical NC joining systems from Kistler – total control thanks to monitoring and regulation of joining and press-fit processes.

在整个工业行业中,总拥有成本(TCO)原则是决定购置新机器或工厂的关键因素。实际的采购成本并不是一个企业在长期竞争性生产中必须考虑的唯一因素。同样重要的是采购前、采购期间和采购后所产生的所有直接和间接费用。这是找出最优惠价格和成本效益的解决方案的方法。这一原则也适用于工业制造中的连接和压装过程:从长远来看,机电数控压装系统的投资可以从能源平衡和维修费用以及产品报废成本方面获得回报

2012年5月,德国卡塞尔大学发表的一项研究中比较了液压,气动和机电数控三种压装系统的能耗。研究结果表明了机电数控压装系统的节能潜力。在传统的液压应用中,所需的能量是机电数控技术的4.4倍,而气动压装实际上要消耗十倍以上的能量。使用机电数控压装解决方案,可比液压系统节省77%,比气动压装系统节省多达90%能耗。

降低运营成本

机电数控压装系统的维修和维修费用最低。为什么?因为不需要更换机油或处理液压油,所以不会出现像气动过程中可能出现的泄漏危险。在气动压装应用中,此类事故可能造成额外费用高。机电数控压装系统的用户也可以消除油和压缩空气的成本。低维护成本也增加了生产时间和工厂生产率。其结果是:根据具体的案例情况,投资在不到两年的时间内便可迅速摊销。

提高生产效率

使用伺服驱动器,可以非常精确地控制压装过程-由于位移、速度和力均可精确地控制从而也提高了系统的安全性和可靠性,并且可以大大降低废品率。可视化的在线评估功能保证了生产过程一致性和质量可靠性。好处:可及时发现不合格件,并从产线中剔除,不再流入下一环节。通过这些优势,机电数控压装系统全面提高了生产效率。

避免额外投资成本

越来越多的制造商选择能够在同一个工厂执行不同的连接步骤的系统。在这里,机电应用也提供了主要优点:快速设置和灵活适应不同的测量范围。这意味着可以在一台机器上生产不同的部件。好处:总体设备减少,节省额外的设备投资费用。

装备面向未来的设备

因此,制造商可以充分利用这些优势的潜力,奇石乐提供一体化的机电数控压装系统集成力传感器和高性能的力-位移监控系统–实现端到端的监测和记录所有测量值。由于用户友好的界面和可视化直观的操作,制造商可以通过早期发现有缺陷的部件来优化生产。maXYmos监控系统与伺服电缸和IndraDrive伺服驱动器相配套可对装配过程进行在线评估并可导出历史曲线文件。高度的控制和过程监控的优势意味着可以达到最佳的循环时间和最大的过程重复性。精确定位确保一致精确的结果。