Needle valve coupler with grinding system

The needle valve is one of the three critical precision components in a diesel injector. Its machining quality and performance directly impact the overall efficiency and effectiveness of the injector, and consequently, the entire machine. To meet the demands of large-scale production, grinding is commonly used due to its high efficiency and precision. However, the current grinding process suffers from fragmented operations, limited integration, and low levels of automation and informatization. This leads to inefficiencies, increased human intervention, and potential inconsistencies in quality. In order to enhance productivity and ensure consistent quality, this paper presents a study on an automated matching system for needle valve couplers. **Grinding Strategy for Needle Valve Couplers** The matching strategy forms the foundation of the grinding system, ensuring that the process is well-organized and efficient. The needle valve body and the needle valve undergo preliminary surface finishing before being processed further. Operators receive a task list, select materials, and use a middle hole and surface grinding machine to process the inner hole and seat surface of the needle valve body. This machine features automatic loading and unloading. After processing, the middle hole is inspected, and the results are fed back to the operator for quality assessment. If the part meets the standards, it moves to the next stage; otherwise, it is stored in the non-conforming area. Based on test results, the grinding process is adjusted accordingly. A cylindrical grinding machine is then used to process the outer diameter of the needle valve, with real-time inspection to ensure proper matching. Each needle valve coupler is paired one by one, ensuring consistency and quality. **Design of the Needle Valve Grinding System** 1. **System Requirements Analysis** Current systems lack sufficient automation and integration, leading to isolated processes and limited interaction with MES (Manufacturing Execution System) and CAPP (Computer-Aided Process Planning). This hinders data sharing, process control, and overall efficiency. To address these issues, this paper proposes an integrated needle valve grinding system that optimizes the matching process, enhances automation, and improves quality control. 2. **Overall System Design** The goal is to create a highly automated and information-driven system. The design follows a three-layer architecture: presentation layer, business logic layer, and data access layer. This structure ensures scalability, security, and ease of maintenance. The system architecture is illustrated in Figure 1. 3. **Functional Modules of the Grinding System** The system includes six key modules: task management, processing management, quality control, status monitoring, BOM management, and user management. These modules work together to streamline the grinding process, improve data accuracy, and reduce manual intervention. Each module plays a crucial role in ensuring the smooth operation of the system. 4. **Database Design** A well-designed database is essential for managing data efficiently. It supports the automation of the grinding process, improves performance, and facilitates future upgrades. The database integrates with MES and CAPP systems, allowing for seamless data exchange and real-time updates. **Implementation of the Needle Valve Matching System** The system is built using a B/S architecture, with code separation to ensure stability and security. It runs on Windows Server 2003 and Windows XP, using SQL Server 2005 and Visual Studio 2005. Web Services are used to integrate with MES and CAPP systems, enabling cross-platform data sharing. An OR-Mapping component is also utilized to simplify data handling and improve development efficiency. **Conclusion** By integrating with existing MES and CAPP systems, the needle valve grinding system enhances automation, streamlines processes, and improves quality control. Real-time feedback and closed-loop control help maintain stable performance, reducing variability and increasing production capacity. This system not only lowers costs but also provides a valuable model for enterprises aiming to implement advanced manufacturing technologies.

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