“This is a steel skeleton production line independently developed by the company, which is more than 10 million yuan cheaper than buying it outside; this is a PE pipe production line transformed from an abandoned production line; this sealing machine that has undergone electromagnetic heating energy-saving transformation, plus power distribution The filter and energy-saving device supporting the system can save 1.9 million yuan in electricity bills every year..." In the production workshop of Anyuan Pipeline Company, Zhong Qiuming, director of the R&D and Technology Department, is a treasure.

From small parts to large production lines, you can see the works of the R&D technical department almost everywhere. The "blooming everywhere" of research and development results not only saves a lot of money, but also lays a solid foundation for the company to develop a broader market. And these results are inseparable from the "soul figure" of the R&D technical team-Jiangtou Group and Pingkuang Group's 2019 model worker Zhong Qiuming. From the workshop maintenance team leader and deputy director, until he became the director of the R&D technology department in 2013, everyone had a common comment on him: "Professional and courageous, it is a bit too awkward."

"Professionalism"——

Lead the team to achieve a "zero" breakthrough in the independent research and development production line

Zhong Qiuming is 49 years old this year. When he talks about R&D, he feels like a teenager with endless enthusiasm. When he introduces the results of R&D, his eyes shine. And what excites him most is the steel frame production line independently developed and put into production for the first time in 2014.

The traditional FG600 steel frame production line can only be compatible with DN500 and DN600 steel frames. In order to increase production capacity, it is necessary to break through the restriction so that the production line can be compatible with the production of pipes of various specifications. At the beginning of 2014, two leading steel skeleton pipe production enterprises in China successively started the development of the FG600 steel skeleton polyethylene plastic composite pipe production line, but they failed to overcome the difficulties of the electronic control system.

At this time, the research and development of the FG600 steel skeleton composite pipe production line of Anyuan Pipeline Company has just been approved, and the R&D technical team is facing tremendous pressure.

"R&D is a process from scratch. You must first have a good idea, and then the team work together. This requires not only the leader to be professional, but also the ability to lead the team. Director Zhong has served as such an excellent leader 'The role.' said Xu Zhou, an engineer in the R&D and Technology Department. The research and development of the production line is extremely complicated, and the design drawings add up to several thousand. Zhong Qiuming needs to divide the labor according to the specialties of each person in the team, and finally integrate all the content and ensure that all parts are perfectly matched.

Zhong Qiuming is very proficient in electricity. In the research and development of electronic control systems, he led the research and development team to repeatedly confirm and in-depth discussion of the production line process and various details, and put forward precise technical requirements, so that the development of electronic control systems can be carried out smoothly. In less than half a year, they overcame many difficulties such as incomplete materials and insufficient manpower, combined with the brainstorming of production, technology, maintenance and other departments, and finally broke through the key technical problems in the electronic control system in one fell swoop, and the production line was successfully put into operation.

This production line breaks through the previous limitation of only compatible with 2 specifications of pipes, and can be compatible with 7 specifications, which not only doubles the production capacity, but also meets a variety of market needs. The successful research and development of the production line has saved the company 12 million yuan in funds and provided valuable experience for the independent research and development of the production line in the future.

brave"--

Dare to carry out a number of energy-saving transformations for others, and build new equipment in 3 days

From the maintenance department to the R&D technical department, although there are similarities in the profession, the scope is more extensive after all. Liu Hong, chief engineer of Anyuan Pipeline Company, confessed to reporters that he was actually not optimistic about Zhong Qiuming at the beginning, but he did not expect that this "newcomer" had a very strong learning ability and execution ability. The continuous improvement of professional ability also made some outsiders think about him. The decision that is not “insurable” provides strong support.

Anyuan Pipeline Company is a plastic pipe manufacturer. Most of the equipment is equipped with heating system, which is a large electricity consumer. How to do something about power saving and reduce costs is an important topic for technicians. In 2018, Zhong Qiuming did two tasks: introducing filtering energy-saving devices and using electromagnetic heating to save energy. Equipped with a filter energy-saving system in the power consumption system, it can reduce the harmonics in the power grid, improve the power factor, and reduce the reactive power consumption. At that time, filtering energy-saving devices were not popular in Pingxiang area. After investigating the experience of several companies outside the province and combining the actual conditions of the company's equipment, he boldly tried to introduce filtering energy-saving devices and matching them with the power distribution system. The heating system of the injection molding machine in the steel skeleton workshop was originally a traditional stainless steel heater, which has high energy consumption and low utilization rate. After reading a lot of technical materials, he carried out electromagnetic heating energy-saving transformation of the heating system, and then heating this block can save energy by 30%, and the equipment maintenance rate has dropped, and the equipment use efficiency has improved. These two alone can save 1.9 million yuan in energy for the company every year.

In addition, the 24-hour uninterrupted oil pump of the injection molding machine in the steel frame workshop is also an "electric tiger", with high energy consumption, high oil temperature, and high failure rate. How to "tame" it is also a big problem. In 2019, Zhong Qiuming and technical consultant Chen Jianyun successively transformed the injection molding machine oil pump and motor into a servo control system, which reduced the power consumption of the oil pump by 70%, the oil temperature and the equipment failure rate. After the project is promoted, it is expected to save more than 1.8 million yuan in energy for the company every year.

Although he is bold, Zhong Qiuming does not fight unprepared. In 2019, the company received a batch of orders for sponge city infiltration pipes. Because it is the first time to produce this kind of pipe, the company lacks suitable punching equipment. If it is processed outside, it will not only delay delivery time but also high cost.

Seeing that the delivery time is getting closer, Zhong Qiuming volunteered to make a military order on September 24: design and manufacture a new set of punching equipment within 3 days to ensure the smooth delivery of the infiltration pipe. Of course, this is also his decision based on his knowledge of the equipment. Immediately after consulting the information, proceeding with the design, arranging the parts procurement plan, on-site instructor production, on-site installation, Zhong Qiuming led the team to work overtime until late at night. In order to save costs, he also tried every means to improve some of the company's idle materials and make full use of the equipment. The set of perforating equipment was finally put into use at 12 o'clock in the evening on the 26th, and the seepage pipe was delivered on schedule, meeting the market demand.

"It's very picky"——

Repair the old, profit and waste "reform" a production line

Not only did he make great efforts to save energy and reduce consumption, Zhong Qiuming took his "stingy" to the extreme, and even discarded equipment and materials.

The new PE pipe production line invested by Anyuan Pipeline Company in 2019 will require the assistance of the R&D technical department from the project bidding to the official commissioning in May. Liu Hong recalled that in order to install the PE pipe equipment as soon as possible after it was in place, the pipe trench was dug in advance according to the equipment factory's standards.

In line with the principle of “saving if you can save”, Zhong Qiuming used waste pipes from the factory to lay the pipes. Unexpectedly, the size of the waste pipes was larger than that of the trench and could not be installed smoothly. "There are too many departments involved in pipeline installation, there are also outsourced construction teams, and coupled with the tight schedule, everyone is afraid that the progress will be affected." Liu Hong said that there was inevitably a voice of criticism at the time, but Zhong Qiuming admitted himself I swallowed my grievances, and then withstood the pressure, communicated with the manufacturer’s technicians to adjust the size of the ditch, and coordinated with the various departments to work overtime to get back the lost time. "The installation of the production line was completed on schedule, and various departments also reported that it was doing very well, indicating that he did think of many ways."

After the PE pipe production line was successfully put into operation, as the understanding of the production line deepened, Zhong Qiuming came up with the idea of transforming the abandoned production line into a PE pipe production line.

After many discussions with Liu Hong and various demonstrations, Zhong Qiuming began to prepare-the original production line configuration and circuit must be adjusted to be modified; the production line assembly has also changed, some equipment has been removed, and a gravity packing system has been added. Wait. In September 2019, at a cost of only more than 100,000 yuan, Zhong Qiuming's team used the abandoned steel wire mesh production line to successfully transform a PE pipe production line that required more than 500,000 yuan to purchase.

As a R&D technical department, it is not only a technology department, but also needs to respond to the needs of quality inspection, installation, production, sales and other departments in a timely manner to develop products that the market needs, and adjust the direction of research and development according to market development. Because of his production foundation, Zhong Qiuming understands the needs and difficulties in production. In order to make up for the shortcomings in professional knowledge, he does not know how many books he has read and how many industry technical exchange meetings he ran.

At the technical work meeting at the beginning of each year, the R&D Technical Department will summarize the problems of the Marketing Department, Logistics Department, Installation Department and Workshop, and establish and solve the problems one by one. "Every problem that everyone raises is related to the "open source" and "throttling" of the enterprise. Technology is updated every day, and we must maintain a fast enough speed to gain a foothold in the market." Based on this, Zhong Qiuming's Learning never stops, and the technology is becoming more and more sophisticated, leading the team to continuously meet new challenges.

Contribution: Wang Jiani

Editor: Li Qing