Needle valve coupler with grinding system

The needle valve is one of the three key precision components in a diesel injector. Its manufacturing quality directly impacts the performance and output capacity of the injector, and consequently, the overall performance of the engine. 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 low integration, limited automation, and poor information sharing between different stages. This lack of coordination leads to inefficiencies, increased human involvement, and potential quality issues. To address these challenges, this paper explores an integrated matching system for needle valve components. The core of this system lies in optimizing the grinding strategy for the needle valve coupling parts. The process begins with pre-processing of the needle valve body and needle valve, followed by surface finishing. Operators receive production task lists and select materials accordingly. The middle hole and seat surface are ground using a machine equipped with automatic loading and unloading functions. After processing, the middle hole is tested, and the results are fed back to the operator for quality assessment. Qualified parts proceed to the next stage, while unqualified ones are stored separately. The outer diameter of the needle valve is then ground based on the middle hole size, with real-time inspection ensuring proper alignment and quality. The design of the needle valve fitting grinding system aims to enhance automation and information integration. Currently, the system lacks seamless communication with MES (Manufacturing Execution System) and CAPP (Computer-Aided Process Planning), leading to fragmented processes and limited control over product quality. By integrating these systems, the new solution optimizes the matching process, reduces manual intervention, and enables real-time data feedback for better process control. The system follows a three-layer architecture: presentation layer, business logic layer, and data access layer. This structure ensures scalability, security, and ease of maintenance. It includes six main modules: task management, processing management, quality control, status monitoring, BOM management, and user management. Each module plays a critical role in ensuring smooth operation and efficient data flow. The database design focuses on managing production tasks, processing parameters, and quality data. Integration with MES and CAPP allows for real-time updates and accurate data retrieval. Web services are used to connect with external systems, enabling cross-platform data exchange through XML format. Object-relational mapping is applied to simplify development and improve maintainability. The system is built using a B/S architecture, with Windows Server 2003 as the server and Windows XP as the client. SQL Server 2005 and Visual Studio 2005 are used for development, with C# as the programming language and Internet Explorer 6.0 or higher as the browser. By implementing this system, the needle valve grinding process becomes more automated, precise, and efficient. It enhances production capacity, reduces costs, and improves overall product quality, offering valuable insights for enterprises seeking to modernize their manufacturing processes.

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