In recent years, China has experienced a significant increase in demand for automatic winder metal troughs. By 2005, the annual demand had surpassed 30,000 units, and this year it is expected to exceed 40,000. However, due to limitations in domestic machining equipment, it has been challenging to produce complex grooved components. As a result, China has relied heavily on imported parts for this critical component. Although some major Chinese companies have tried using superplastic forming techniques to address the groove formation issue, they still face difficulties in manufacturing the necessary molds for inverted groove structures. This has become a major bottleneck in the localization of automatic winding machines in China, making it essential to develop an industrialized solution for the "automatic winding method of metal troughs."
Qingdao Tongchun Electromechanical Technology Co., Ltd. has taken a new approach by leveraging its existing silica sol precision casting technology. After five years of dedicated research, the company developed an innovative mold design and manufacturing process for the "overall precision casting method" of automatic winder metal troughs. This method provides an effective way to produce complex parts that are difficult to form through traditional methods, offering crucial technical support for the localization of winding machines.
The first innovation involves a mold-opening scheme that combines axial splitting, sand cores, and live blocks. This approach successfully solves the problem of inverted drafts in the vase-shaped groove portion of the metal trough, enabling precise casting of the desired shape. The second improvement focuses on optimizing the silica sol precision casting process to address the rough surface issues of the metal trough. Finally, the company employs micro-grinding flexible polishing technology, which preserves the original groove structure while achieving a high surface finish with Ra0.4.
This technology offers several advantages: it eliminates the need for complicated and costly groove processing by integrating complex groove formation during the casting stage. It also ensures smooth, round grooves that can be directly polished. Moreover, the whole-casting method significantly reduces production costs—by more than 40% compared to traditional five-axis forming methods, with costs being only one-tenth of those methods at the same production scale.
Tongchun's metal troughs have been tested in numerous large cotton mills across China. Performance metrics have not only met but exceeded those of Italian-made Savio automatic winder metal troughs. These products are currently running on Savio automatic winders at companies such as Qingdao Bayi, Dezhou Demian, Binzhou Liumian, and Shandong Beyond. They achieve winding speeds of 1200–1300 m/min, with excellent spindle formation and winding quality, as well as proper yarn unwinding. According to comprehensive performance tests conducted by the Wuxi Mashan Textile Machine Testing Center, all indicators meet or exceed usage requirements. In comparative tests of yarn guiding performance conducted by Zhengzhou Zhongyuan Textile Institute, Tongchun’s metal troughs showed a lower yarn failure rate than imported alternatives.
Currently, Qingdao Tongchun has a monthly production capacity of 2,000 to 5,000 metal troughs, supported by mature production technology and consistent product quality.
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