Intelligent Production Line For Magnesium Alloy Motor Housings

Analysis of the Application of Magnesium Alloys in Products Such as Motor Enclosures:

Process Introduction:
1.Semisolid injection molding

Although magnesium alloy can follow the aluminum die-casting process, to balance safety, environmental protection, oxidation burn-off, and high density requirements, semi-solid injection molding has become the preferred technical route for large structural components. In the semi-solid injection molding process, the solid phase ratio has a significant impact on the forming ability and defects. An appropriate solid phase distribution can promote the improvement of magnesium alloy performance. Compared with magnesium alloy cold chamber die-casting and hot chamber die-casting, semi-solid injection molding has been proven to have the best microstructure and performance in thin-walled parts.

2. Automation of deburring

This project introduces professional automated deburring robots and flexible grinding tools. It uses a high-precision visual recognition system to scan and position the surface of the castings. Then, through specially designed cutting tools or grinding tools, it precisely removes burrs according to the preset path and force. This not only makes the surface of the castings smooth and flat, but also improves the processing efficiency by tens of times compared to traditional methods. Unlike the traditional deburring process that requires a large number of workers to perform long-term grinding, this automated process only requires a small number of technicians to perform equipment maintenance and parameter monitoring. The labor cost is significantly reduced. It is expected to reduce by approximately 100% - 200% compared to the traditional method. This process lays a good foundation for subsequent processes by conducting hourly sampling inspections and two-hour quality inspections.

3. Automated Milling

Robots can automatically pick up castings, install them onto the corresponding cutting equipment, and carry out precise machining operations such as turning and milling on the castings according to the pre-programmed cutting processes. They strictly control the dimensional tolerances and meet the complex shapes and high precision requirements of different customers' designs, ensuring the high quality output of the final products. In addition, the addition of robotized feeding in this process saves labor costs by 5-10 times compared to manual labor. Traditional cutting processing requires multiple operators to perform tasks such as workpiece clamping, equipment debugging, and process monitoring. However, our automated cutting system only requires a small number of professionals to do programming and daily equipment management. Compared with the traditional mode, the labor cost has also shown a significant reduction, ranging from 100% to 200%. Conducting hourly production inspections and quality inspections every two hours fundamentally changes the situation where manual reliance was high and costs were high.

4. Automated passivation treatment

Passivation treatment is of vital importance for enhancing the corrosion resistance of magnesium-aluminum alloy castings. In this process, the automated production line precisely transports the castings to the passivation treatment area through an automated conveying system. Using intelligent-controlled chemical treatment equipment, the concentration of the passivation solution, the processing time, and temperature are precisely adjusted to achieve a stable and uniform passivation effect. This effectively extends the service life of the castings and improves the overall quality of the products. Previously, the passivation treatment often required manual handling, soaking, and inspection, involving numerous cumbersome operations, which consumed a lot of manpower. Now, the automated process only requires a few personnel for remote monitoring and system maintenance. Compared to traditional methods, the labor cost can be reduced by 100% - 200%. Additionally, hourly production inspections and quality inspections conducted every two hours ensure the advantages of cost control throughout the production process.

Project objective :

1. Build an AI automated die-casting production line with international advanced standards, achieving high-level automation and intelligence in die-casting production.
2. Enhance the production efficiency and quality of die-castings, with a product qualification rate of over 98%.
3. Reduce production costs, with energy consumption reduced by 20% compared to traditional die-casting lines, efficiency increased by 10-30%, and labor costs decreased by 30-60%, significantly increasing net profit by 10-15%.
4. Through technological innovation and equipment upgrading, promote the intelligent development of the die-casting industry and set new benchmarks for the industry.

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Layout Of Magnesium Aluminum Alloy High-pressure Casting Fully Automatic Production Line: