Research on the core parameter configuration and cost-effectiveness optimization of the middle plate three-in-one leveling feeder in the shipbuilding industry
Publish Time: 2025-04-15
In the large-scale production of the shipbuilding industry, the middle plate three-in-one leveling feeder is a key equipment, and its parameter configuration directly affects the production efficiency and cost. In view of the wide demand of the shipbuilding industry for material thickness of 0.5-4.5mm and width of 400-1500mm, it is necessary to build an optimization plan from three aspects: material specifications, equipment performance, and cost-effectiveness.The material parameters of the middle plate three-in-one need to match the characteristics of the shipbuilding process. The thickness range of the marine middle plate covers 0.5-4.5mm, the typical yield strength is 245-355N/mm², and the material is mainly low-alloy high-strength steel such as Q235B and Q345B. The equipment needs to support coil specifications with an inner diameter of Φ450-530mm and an outer diameter of ≤1400mm, and the weight of a single coil is 2-6 tons. For example, for the shipbuilding segment manufacturing scenario, a machine with a material width of ≥1200mm is required to meet the large-format processing requirements of hull structural parts.The performance of the middle plate three-in-one equipment needs to break through the bottleneck of traditional technology. The feeding speed needs to reach above 22m/min, and the feeding accuracy is controlled within ±0.15mm to meet the accuracy requirements of the hull linear lofting. The leveling roller is made of high-alloy bearing steel, and after quenching and tempering-high-frequency treatment-hard chrome plating and other processes, the surface finish reaches Ra0.4μm, which can eliminate the internal stress of the material. For example, the machine with a four-worm gear adjustment structure can achieve 0.1mm adjustment of the pressing amount by rotating the handwheel, and with the double-cylinder eccentric relaxation structure, the relaxation speed is increased by 30%.Cost-effectiveness optimization needs to focus on the full life cycle cost. Equipment selection needs to balance procurement cost and use cost:Power system: The servo motor power configuration needs to match the material specifications. For example, the model with a material width of 800mm uses an AC4.4kW servo motor, and the model with a material width of 1500mm is upgraded to AC7.5kW to avoid power redundancy.
Automation configuration: Standard touch screen human-machine interface, photoelectric material arc control system, optional hydraulic automatic loading trolley, material straightening capacity detection device to improve operating efficiency.
Maintenance cost: Key components adopt modular design, such as leveling roller group, feeding roller and other wearing parts need to support fast replacement to reduce downtime.
Based on the case of a shipbuilding company, the middle plate three-in-one model with a material width of 1200mm and a feeding speed of 25m/min was selected. Compared with traditional split equipment, the floor space is reduced by 40%, the labor cost is reduced by 60%, and the equipment comprehensive cost (TCO) is reduced by 25%. By optimizing material utilization (material loss rate ≤1.5%) and improving equipment utilization (OEE≥85%), the construction cycle of a single ship is shortened by 15 days.Future development trends need to focus on intelligent upgrades: integrating digital twin technology, building equipment virtual models for performance prediction; using AI visual systems to monitor material surface quality in real time; integrating the Industrial Internet of Things (IIoT) to achieve remote monitoring of equipment status and predictive maintenance. For example, by collecting more than 100 parameters such as feeding speed and leveling pressure, an equipment health assessment model is established to increase the accuracy of fault warning to 95%.The parameter configuration of the middle plate three-in-one leveling feeder needs to be closely linked to the shipbuilding industry's needs for cost reduction and efficiency improvement. Through the three-dimensional linkage of material specification adaptation, performance breakthrough, and cost optimization, a cost-effective solution is built to support the high-quality development of the shipbuilding industry.
