AdvanatgesHMI control panel with PLCTouchscreen to manage control of all the stations of the filling unit.Display of : Status, warnings and alarms, allowing fast diagnostic of failures.Possibility of
One Line. Infinite Diameters. Zero Changeover.
Core Innovation: Magnetic Levitation Mandrel System
Shanghai Guangzhi DAP-500 achieves 5-second diameter switching across 50-250mm products via AI-guided mandrel arrays and robotic tool changers, delivering 120 units/minute with ±0.05mm tolerance. Eliminating traditional line conversions for:
? Automotive drive shafts
? Pharmaceutical tubes
? Food packaging cylinders
? Industrial piping systems
圖片代碼graph LR
A[Raw Material] --> B{AI Vision Diameter Scan}
B --> C[Auto Mandrel Selection]C --> D[Magnetic Levitation Clamping]D --> E[Precision Machining]Raw MaterialAI Vision Diameter ScanAuto Mandrel SelectionMagnetic Levitation ClampingPrecision MachiningPerformance Benchmark:
Parameter | Conventional Line | DAP-500 System |
|---|---|---|
Diameter Change Time | 45-120 min | 5 sec |
Concentricity Error | ±0.1mm | ±0.02mm |
Max RPM | 1500 | 6000 (MagLev) |
Tri-Sync Conveyance:
Module | Technology | Precision |
|---|---|---|
Loading | 3D vision-guided robots | ±0.1mm |
Inter-stage Transfer | Self-adjusting V-belts | Sync ±0.001s |
Sorting | Delta robots + AI inspection | 99.99% accuracy |
Industrial IoT:
OPC UA integration with MES/ERP
Digital twin traceability per unit
Component | Specification | Performance |
|---|---|---|
Processing Range | ?50-250mm × L200-2000mm | Straightness ≤0.03mm/m |
Output | 120 units/minute | ±0.5% speed stability |
Diameter Switching | MagLev mandrel array (32 sets) | 5-sec change |
Positioning | Laser interferometry | ±0.005mm (ISO 230-2) |
Conveyance Speed | 0.5-5m/s variable | Sync precision ±1ms |
Power | 380V/80kW (peak) | Regenerative drives save 35% |
Air Consumption | 600L/min @ 0.6MPa | Centralized supply |
Footprint | 25m(L)×8m(W)×4m(H) | U-layout saves 40% space |
Challenge:
$2.5M for multi-line setup
22% capacity loss during changeovers
DAP-500 Solution:
On-the-fly diameter/length adjustment
Integrated torque testing
Result:
? 12 sizes on one line
? Zero changeover downtime
Challenge:
Separate lines per diameter
Cleanroom space constraints
DAP-500 Solution:
IP69K sealed construction
Sterile air curtains
Result:
? FDA 21 CFR compliance
? 60% higher space utilization
Digital Cockpit Features:
AI Modules:
Dynamic Scheduling:
Change Type | Response Time |
|---|---|
Diameter switch | 5 sec |
Material change | 8 sec (with purge) |
Self-Optimization:
Tool life prediction via historical data
Vibration spectrum anti-resonance control
Auto Parts Manufacturer Case:
Conventional Setup:
? $3.6M for 3 dedicated lines
? $780k/year changeover losses
DAP-500 Implementation:
? $1.8M single-line investment
? Zero changeover waste
ROI:
? $1.54M annual savings
? Payback: 14 months
Module | Swap Time | Key Innovation |
|---|---|---|
MagLev Mandrel | 3 min | Tool-free quick-release |
Drive Motor | 7 min | Hot-swap interface |
Conveyor Section | 4 min | Modular snap-fit design |
Safety: CE EN ISO 13849-1 (PLd)
Food Contact: FDA 21 CFR 177.2600
Medical: ISO 13485 (optional)
Explosion Proof: ATEX Zone 22 (optional)
Titanium Support Package:
24/7 Global Response:
Issue Level | Action |
|---|---|
Full line stoppage | 2h remote + 24h on-site |
Module failure | 4h AR-guided repair |
Lifecycle Management:
10-year spare parts guarantee
Service Age | Upgrade Benefit |
|---|---|
5+ years | Free control system updates |
Redefining Production Flexibility
Shanghai Guangzhi DAP-500: Seamlessly shifting from 50mm to 250mm diameters – where manufacturing agility meets precision engineering. ??