Folding seats are widely used in daily life due to their advantages of simplicity and beauty, comfortable seating, convenient storage, and durability. As the core bearing and supporting component of the seat, the forming quality of the backrest plays a decisive role in the overall performance and structural stability of the seat.
Industry Pain Points: Traditional Processes Restrict Production Efficiency
The traditional stamping forming process of seat backs is lengthy, covering 9 processes such as stretching, blanking, straightening, pre-folding, necking, bending, and crimping. The complex mold technology and excessive processes not only seriously restrict the promotion of lean production — leading to low production efficiency, increased material turnover costs, and greater difficulty in quality control — but also make it difficult to realize the whole process of unmanned production relying on stamping manipulators and surrounding automation equipment, which is difficult to adapt to the efficient and intelligent development needs of modern manufacturing industry.
Innovative Solutions: Mold Optimization + Automation Integration
Facing the customer’s demand for automated stamping production, Kaishuo Technology fully demonstrated its technical strength in the field of one-stop turnkey projects of stamping molds and manipulators. In view of the fixed nature of the customer’s existing production line, which is mainly for single-variety mass production, we recommended the “multi-machine connected manipulator” with national invention patents — this equipment is specially designed for mass production of single-variety products and can accurately adapt to the customer’s production mode.
- Revolutionary Breakthrough in Mold Technology
On this basis, according to the specific requirements of the manipulator connection for molds in each process (such as the equal height of the lower mold product surface, avoiding product flipping, side hanging, angle rotation, and realizing smooth discharge of edge waste, etc.), a comprehensive evaluation was conducted and a plan for modifying molds in some processes was formulated, striving to simplify and optimize the production processes and avoid unnecessary investment in molds and punch presses. Taking the final flanging process as an example: in traditional processes, to ensure that the edge of the steel plate is crimped smoothly and firmly, 3 sets of engineering molds are usually used to complete the process step by step. After in-depth research by our mold technical team, under the premise of ensuring product quality, through the linkage design of upper and lower pressing blocks and side pressing blocks, the stamping and crimping processes are combined, and the same effect can be achieved with only 1 set of molds. Through this series of optimizations, the number of punch presses and molds in the production line has been reduced from 9 sets to 6 sets, which not only significantly reduces equipment investment costs but also lays a solid foundation for the efficient operation of multi-machine connected manipulators through process integration.
- Whole-Process Automated Production System
Based on the above optimization results, the automation team of Kaishuo Technology, relying on profound technical accumulation and rich project experience, further built a whole-process automated production system: the first station is equipped with a three-in-one servo feeder to realize precise feeding and cutting of raw materials; the middle link relies on 6-process multi-machine connected manipulators to complete the continuous operation of each process; the last station realizes the orderly collection of finished products through a receiving belt conveyor line. Finally, the stable production efficiency of 11-13 backrests per minute is achieved, perfectly meeting the customer’s core demand for stamping automation.
Technology Empowers Manufacturing Upgrade · Kaishuo is Trustworthy
From the customization of technical solutions to the optimization of production processes, Kaishuo Technology has proven itself to be a “partner” that customers can always trust with 17 years of technical accumulation. In the future, we will continue to break the shackles of traditional production with technological innovation, injecting strong impetus into the efficient and intelligent d
