In the process of industrial automation production, force sensors play an important role in helping equipment achieve high-precision and high-efficiency automation control. The force standard machine is a standard equipment for transmitting force values, which can ensure the accuracy of force measurement instruments in various industries. Conducting research on ultra-high force sensors and building the capability for ultra-high force testing can help improve the technological level of China's high force sensor field and continuously enhance the overall basic and common technical capabilities of the industry.
Shanghai Industrial Automation Instrument Research Institute Co., Ltd., a subsidiary of Shanghai Yidian, undertook the Shanghai Industrial Strong Foundation Special Project "Development and Application of Ultra High Force Sensor and 100MN Force Standard Measuring Machine" in 2019 to meet the needs of ultra high force measurement and application in the industrial field.
Verification modeling, the main equipment of the force standard machine was successfully lifted in one go!
The total weight of the 100MN standard machine device is about 500 tons, of which the heaviest structural component is about 80 tons, and the length of the four square columns is nearly 12 meters, about 30 tons per column. It needs to be vertically lifted into the site from a 20 meter high installation hole and directly installed in place. Not only is the installation difficulty extremely high, but also due to the heavy weight and long length of structural components, there are significant safety risks in hoisting. The project development team has determined the installation and construction plan as well as the safety protection plan through repeated verification, modeling, and on-site measurement. On January 25, 2021, as four giant transport vehicles arrived at the Songjiang branch of Ziyi Institute, the project ushered in the most important construction phase - the lifting of the main equipment of the force standard machine.
With the full cooperation and guarantee of the project development team, installation technicians, and safety management personnel, the main equipment was lifted into place in just 2 days, ensuring the safety and controllability of the installation process.
Stay on site to ensure the development progress of the international first set of equipment!
At the beginning of 2021, during the construction and commissioning phase of the 100MN standard force measuring machine, the project commissioning process encountered challenges. In order to ensure the progress of equipment development, the R&D team and installation technicians of the Institute of Instrumentation faced difficulties and stayed on site for two consecutive months to carry out continuous debugging.
During a debugging process, when the pressure was released to 3000 tons during the return trip, the hydraulic system suddenly failed to unload normally, which was a very tricky problem. The debugging personnel attempted to unload the hydraulic cylinder by loosening the sealing sleeve nut of the pipeline. As soon as the third circle was released, the oil sprayed everywhere. The debugging personnel, while ensuring safety, disregarded the fact that their entire body was covered in hydraulic oil and immediately controlled the hydraulic oil pipe. The ultimate cause was found to be the blockage of the narrow valve core, which resulted in poor oil return. The problem was promptly resolved.
In the end, the project team overcame numerous difficulties and successfully completed the one-time full load pressure test of the 100MN standard force measuring machine, buying valuable time for the subsequent implementation and application of the project.
Breaking through bottlenecks, key core technologies have obtained multiple foreign invention patents!
Ziyi Academy fully leverages the experience and advantages of the transformed research institute, and the project development team focuses on tackling key core technical challenges, gradually breaking through multiple bottlenecks such as material development difficulties, traditional heat treatment processes, and sensor structure optimization. Among them, "Precision Detection Method Technology" has obtained multiple international invention patents in the United States, European Union, Japan, and South Korea.
In June 2020, the performance test results of the newly developed metal material prototype force sensor were not satisfactory. The project team started analyzing and discussing all night long, and finally found out that the problem was that the heat treatment system adopted could not meet the requirements of the sensor. The analysis results indicate the direction of efforts. After arduous research and development, the performance of the final force sensor has been greatly improved, which means a big step forward in sensor materials and heat treatment processes.
Since 2019, the project has taken 4 years to successfully develop a 70MN ultra-high force sensor and the world's first 100MN force standard force measuring machine device. The comprehensive technology has reached the leading domestic and international advanced level.
Source: Sensor Expert Network