**Abstract**
Large residual capacity, heavy load, and automatic belt grinding are commonly applied in various industrial scenarios. Examples include the grinding of automobile engine connecting rod ends, boiler pipeline polishing, and nuclear power high-pressure vessel surface treatment. These applications require robust and efficient grinding systems capable of handling significant material removal and maintaining high precision.
**Key Features of the Grinding Equipment:**
1. Due to the large grinding allowance (typically 1mm or more), the equipment is designed with multiple stations, combining abrasive belt polishing with grinding wheel operations or allowing for their interchange.
2. The workpieces involved are often bulky, leading to the development of large-scale, heavy-duty grinding machines.
3. The equipment operates for extended periods in challenging environments, requiring high durability and reliability.
4. Automation is a key feature, ensuring consistent quality and reducing manual labor.
**1. High-Efficiency Belt Grinding for Automobile Engine Connecting Rod Ends**
This technology represents the world’s first high-efficiency machine tool that uses abrasive belt grinding to achieve a 4.5mm margin on a constant-thickness rod end. The grinding process ensures a stable precision of ±0.03mm on the end face, with a CPK value of 2.33—exceeding the standard requirement of CPK ≥ 1.67. This system was first implemented at the Shenlong Automobile Xiangfan factory and later adopted by Shanghai Diesel Engine Factory and Nanyang Hongyang Machinery Factory as their primary equipment.
**2. Abrasive Belt Grinding for Boiler Pipelines**
The system includes five grinding heads: the first two use grinding wheels to remove oxide scale and reduce the remaining material, while the last three are abrasive belt heads. The abrasive belts have grit sizes of 36#, 80#, and 120#, achieving a surface roughness of Ra ≤ 1.65μm. After polishing, the pass rate of the pipelines increases from 60%–70% to over 90%.
**3. Strong and Efficient Belt Grinding for Spiral Steel Pipe Welds in the West-East Gas Transmission Project**
This solution eliminated the need for manual weld grinding, meeting the demands of the domestic West-East Gas Pipeline Project. It was recognized as one of the top three innovation technologies in 2003 by the petrochemical industry. The technology has been widely adopted by major steel pipe manufacturers, including Ziyang Steel Pipe Plant, Baosteel, and others. The maximum error in seam height and base metal after grinding is ≤0.05mm, with a surface roughness of Ra ≤ 0.2–0.4μm.
**4. High-Efficiency Precision Belt Grinding for Nuclear Power High-Pressure Vessel Welds**
This system was first officially used at the Deyang Factory of Dongyang Boiler Factory in June 2008. The intelligent and efficient grinding equipment developed based on this technology has been deployed by companies such as Dongfang Headquarters, Shanghai Lingang, Wuhan Alstom, Japan Sensong, and India Laesen & Toubro. The system can clean up to a root depth of 170mm, with a grinding line speed of 82m/s. It allows for a single grinding depth of up to 15mm, a material removal of up to 100 × 5mm, and a minimum surfacing layer thickness of 0.5mm per pass. The grinding efficiency reaches 10–20m²/h, with a surface roughness of Ra ≤ 6.3–0.2μm.
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