In the first semester of 2018, the demands for Damon Industry belt rollers were far more than expected.  Starting from 2016, Damon Industry has been continuously striving to improve its manufacturing process. For example, rear track fine finishing improvement through optimization of fixture and machines, clamping that can combine two processes into one, time reduction and increase of efficiency, together with improvements in fatigue management during the rehandling process. Examples can go on and on. Through manufacturing process development, manufacturing at Damon Industry becomes more and more efficient, but as orders increase, satisfying clients’ needs in terms of time delivery becomes harder and harder. In order to further improve production efficiency, in the year of 2018, Damon Industry focuses on optimizing belt conveyor pulley production. 

As a result of several discussions and evaluations within the group responsible for developing the project, the team came up with a few ideas: for L size roller shafts / W size cylinder splitting length, drilling center holes requires two times clamping and the second processing implies changing heads after the completion of one end. Consequently, auxiliary time is long, workers put a lot of effort into the process and the two times clamping cause concentricity error, that restricts further improvements in the quality of the product. In this respect, the project team believes that products obtained as a result of one-time process would be ideal.

Having set a direction of research, Damon Industry gained knowledge regarding the special operations of the merging process:

1、 Process combination: being able to drill both of the L size roller shafts and W size cylinder shafts through one-time clamping process;

2、 Meeting L size roller shafts and W size cylinder shafts concentricity requirements, within 0.05mm;

3、 Meeting functional requirements of the machines:

1）Easy clamping of the work piece; 

2）Stability: high quality cast iron is required for the bed, the guide rail is subjected to super audio frequency quenching, with high hardness and good wear resistance;

3）Using ER clamping heads to replace center drilling;

4）Using a CNC operation system that is adapted to the national and international brand system, with friendly interface and easy to operate.

Brainstorming is the core tool of LP and our team members looked at the project from different angles and by using different ways of thinking, concluding that we need not only to fulfill orders, but to meet precision demands. We started looking for external resources, a special machine that can meet both the processing technology and machining accuracy requirements. As a result of external resources consultation and data parameter analysis, we found out that:1. If developing equipment according to our technological requirements, costs of research and risk probability are high, the manufacturing cycle is long and cannot be guaranteed. 2.Is there a special machine that can meet the needs of our existing product processing technology after the equipment is optimized or reconstructed?

Thanks to online information, we eventually got in touch with a professional equipment manufacturer, decided upon the technical requirements of the special machine manufacturing and perfected the key functions of the equipment. The advantages of the CNC machine are: it facilitates one time clamping, so that manufacturing is completed in one process and also, by combining the servo drive unit with the high precision ball screw, it improves the precision of the machine, ensuring the product’s machining accuracy.

According to the new technology, the special machine developed by Damon Industry team and external experts will enhance the product dimension accuracy by one level. The production efficiency is increased by more than 30%, the manufacturing cycle is reduced by 20%, the site is 1/3 less than that of the original, meeting the customer's requirements in terms of "high precision, excellent quality, short term" and the spirit of "continuous improvement and excellence" advocated by real crafts men.