I. Requirements Analysis and Planning Phase

1. Clarify Production Objectives

• Define production cycle time (output per unit time), product specifications, process flow, and future scalability needs to avoid over-engineering or under-design.

• Example: For multi-model compatibility, design adjustable workstations or quick-change tooling structures.

2. Optimize Spatial Layout

• Plan equipment layout based on workshop dimensions to minimize material handling paths and ensure sufficient operational space while avoiding cross-interference.

• Consider ergonomics (e.g., workstation height, ease of operation) to reduce operator fatigue.

3. Modular Design

• Divide equipment into independent functional modules (e.g., conveying, sorting, inspection) for easier maintenance, upgrades, or reconfiguration.

• Example: Use standardized interfaces to enable rapid replacement of faulty modules.

II. Equipment Design and Manufacturing Phase

1. Material Selection and Durability

• Choose materials (e.g., stainless steel, aluminum alloy, engineering plastics) based on load, environment (humidity, temperature, corrosion), and fatigue resistance.

• Select high-wear, anti-fatigue components (e.g., bearings, chains) for critical parts to extend service life.

2. Transmission System Design

• Ensure smooth power transmission without vibration or slippage.

• Example: Calculate tension for synchronous belt drives and lubricate chain drives regularly.

3. Precision Control

• Achieve micron-level accuracy for positioning/sorting workstations using high-precision guides, servo motors, etc.

• Example: Calibrate coordinate mapping between vision systems and robotic arms for precise grasping.

4. Safety Protection Design

• Install guardrails, light curtains, emergency stop buttons, etc., to prevent accidental entry into hazardous zones.

• Example: Add protective covers for rotating components and warning signs for high-temperature areas.

5. Energy Efficiency and Environmental Compliance

• Optimize motor power matching and adopt variable frequency drives to reduce energy consumption.

• Equip exhaust/wastewater treatment systems to meet environmental regulations.

III. Electrical and Control Systems

1. PLC Programming and Logic Optimization

• Write clear, scalable PLC programs with reserved I/O points for future expansion.

• Example: Use HMI interfaces for dynamic parameter adjustments to minimize downtime.

2. Sensor and Inspection Systems

• Select appropriate sensors (photoelectric, pressure, displacement) based on detection requirements to ensure data accuracy.

• Example: Use dual-redundant sensors for material shortage detection to avoid false alarms.

3. Communication Protocol Compatibility

• Ensure seamless integration with upper-level systems (e.g., MES, ERP) using protocols like Modbus or Profinet.

• Example: Implement OPC UA for cross-platform data exchange.

4. Anti-Interference Design

• Apply shielded cables and filters in electromagnetic interference-prone areas (e.g., near inverters).

IV. Installation and Commissioning Phase

1. Leveling and Alignment Calibration

• Use laser levels or dial indicators to adjust equipment foundations for stable operation.

• Example: Keep conveyor belts level to prevent material misalignment or jamming.

2. No-Load and Load Testing

• Conduct no-load trials to verify mechanical motion and electrical signals.

• Gradually increase load to rated capacity while monitoring vibration, noise, and temperature rise.

3. Integrated Commissioning

• Simulate actual production flows to validate inter-station coordination and optimize cycle time matching.

• Example: Adjust robotic arm grasping speed to align with conveyor belt timing.

V. Maintenance and Optimization Phase

1. Preventive Maintenance Plan

• Develop a scheduled maintenance checklist (e.g., lubrication, fastening, cleaning) and log equipment data.

• Example: Check chain tension monthly and replace gearbox lubricant quarterly.

2. Rapid Fault Response Mechanism

• Maintain a spare parts inventory and train maintenance personnel in common troubleshooting (e.g., PLC alarm code analysis).

• Example: Use remote monitoring systems for real-time equipment status tracking and early issue detection.

3. Continuous Improvement and Upgrades

• Optimize equipment parameters (e.g., sorting mechanism speed) based on production feedback.

• Example: Replace manual quality inspection with AI vision systems for higher efficiency and accuracy.

VI. Compliance and Standardization

1. Adhere to Industry Standards

• Ensure design and manufacturing comply with GB/T, ISO, or other standards (e.g., safety standard GB 5226.1).

• Example: Meet hygienic design requirements (e.g., stainless steel, cleanable surfaces) for food industry equipment.

2. Documentation Management

• Archive design drawings, operation manuals, and maintenance records for traceability and audits.