CN110782141A - Single piece tracing data forming method for aluminum alloy wheel forging production line - Google Patents
Single piece tracing data forming method for aluminum alloy wheel forging production line Download PDFInfo
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Abstract
The invention discloses a method for forming single piece tracing data of a forging aluminum alloy wheel production line, which comprises the following steps: arranging a code engraving machine on a code engraving station at the off-line position of the process so as to form a front and back consistent unique identification code on the off-line workpiece to be coded through laser coding; arranging a code reader on a code reading station at the on-line position of the process, reading a unique identification code on a coded workpiece to be on-line, and associating the unique identification code with the tracing data; and automatically triggering to number the ID of the workpiece in a virtual coding mode at a preset position before spinning offline after the workpiece is sawed offline, associating the ID with the unique identification code to realize association with tracing data, and automatically triggering to place the workpiece number and the bound data into a quality database called by OPC (optical proximity correction) when spinning offline. The invention can realize one-key tracing of workpieces, and greatly overcomes the defects of low production tracing efficiency and poor effect caused by the problems of incomplete production information record, information island and the like.
Description
Technical Field
The invention relates to the technical field of forging, in particular to a method for forming single-piece tracing data of a production line of a forged aluminum alloy wheel.
Background
The wheel as the automobile safety part has to keep the traceability of products in the design, manufacture, sale and service processes, the traditional manual record is used for tracing the products on site, a large amount of manpower resources are consumed, the statistics of production and processing technological parameters of the products are incomplete, the quality data can be generally counted only by taking batches as units, and the sale and after-sale service conditions of the products cannot be tracked even after the products are delivered out of a warehouse and flow into the market.
The forming process of forging the aluminum alloy wheel comprises the steps of processing the wheel in multiple passes from a raw material aluminum bar to a finished product package. In the forging production area, the temperature of a workpiece is high in the wheel forging area processing process, the tracing cannot be performed in an RFID mode, and then the metal flow is severe and the deformation amount is large in the forging forming process, so that a product tracing means based on surface identification and code reading technology cannot be realized; in the heat treatment area, the identification code on the surface of the workpiece is influenced by heat treatment processing to generate distortion, color change and the like; in a machining area, marks on the surface of a workpiece are machined, and repeated code carving is needed.
Therefore, there is a need to develop a usable single piece trace back data formation system.
Disclosure of Invention
The invention aims to provide a method for forming single-piece traceability data of a forged aluminum alloy wheel production line aiming at the technical defects in the prior art, and aims to solve the problems that in the processing process of the existing forged aluminum alloy wheel production line, the temperature of a workpiece is high, the metal flow is violent, the deformation amount is large, marks and code reading on the surface of the workpiece cannot be realized, and the traceability data cannot be comprehensively and effectively acquired in the production process.
The technical scheme adopted for realizing the purpose of the invention is as follows:
a single-piece tracing data forming method for a forged aluminum alloy wheel production line comprises the following steps:
arranging a code engraving machine on a code engraving station at the off-line position of the process so as to form a front and back consistent unique identification code on the off-line workpiece to be coded through laser coding;
arranging a code reader on a code reading station of a process on-line position, reading a unique identification code on a coded workpiece to be on-line, and associating and storing the unique identification code and the tracing data;
after the workpiece is sawed and offline and before spinning and offline, automatically triggering a forge piece numbering module and a data binding module at preset positions to carry out ID numbering on the workpiece in a virtual coding mode, and associating the ID numbering with a unique identification code and binding with tracing data; when the workpiece is spun off-line, a finished product information dump module is automatically triggered, and the workpiece number and the bound data are placed into a quality database called by OPC.
The tracing data comprises processing technological parameters of corresponding procedures, including spinning technological parameters such as spinning temperature, spindle rotating speed and feed ratio, forging press type technological parameters including pre-forging temperature, hitting power and post-finish forging temperature, hot blank data of a heating furnace offline such as discharging temperature, and raw material information such as warehousing information and ex-warehousing information of raw materials, serial numbers of manufacturers, furnace number information, blank information such as diameters and lengths of blanks and the like.
The process off-line position comprises a sawing process completion position, a punching process completion position and a turning process completion position.
The on-line position of the working procedure comprises a position before a heating furnace heats a cast rod working procedure, a position before a solid solution working procedure, a position before a turning working procedure, a position before a barreling unit working procedure, a position before a milling working procedure and a position before a polishing unit working procedure.
Further, if the material throwing happens in the production process, the material throwing tracing module is automatically triggered to directly place the finished processing station and quality data of the workpiece into a quality database called by OPC (optical proximity correction), and a material throwing mark is made for analyzing the reason of the material throwing.
The material throwing data in the quality database comprise post-heating furnace material throwing data, post-forging material throwing data and post-rotation material throwing data, and the post-heating furnace material throwing data comprise a forge piece number, a production date, material throwing time and a discharge temperature; the post-forging material throwing data comprise forging press type process parameters including pre-forging temperature, impact force and post-finish forging temperature; and the spinning material throwing data comprises spinning process parameters including spinning temperature, spindle rotating speed and feed ratio.
After the workpiece is spun, the control system sends the ID number of the workpiece to a code carving machine at the offline position of the next process, and the code carving machine at the offline position carves the unique identification code on the surface of the workpiece which is spun.
The invention can realize one-key tracing of final products, semi-finished products and even raw materials to be traced, thereby greatly improving the defects of low production tracing efficiency and poor effect caused by the problems of incomplete information record, information isolated island and the like of the current production.
The method for forming the single piece tracing data of the aluminum alloy wheel forging production line is suitable for an automatic production line which takes a hot forging piece as a blank, and records the key parameters of each key procedure of the aluminum alloy wheel forging product in the production process, so that the production efficiency of tracing records can be improved, and a product comprehensive quality report can be obtained.
Because the forged aluminum alloy hub is subjected to multi-pass processing and a longer circulation process in the production and manufacturing process, the traceability of the quality of a single product and the transparent management of quality information can be realized, the control of an enterprise on the quality of the product is improved, and the core competitiveness of the enterprise is improved. Compared with the technologies of RFID, surface code pasting and the like, the method has the characteristics of wear resistance, fastness, high processing efficiency, high processing precision, non-contact, low cost and the like, and is very suitable for workpiece tracing of a forging aluminum alloy hub production line.
Drawings
FIG. 1 is a schematic layout of a code printing station and a code reading station of the present invention;
fig. 2 is a schematic diagram showing a production flow of a wheel in a rotary forging area and a forge piece data acquisition process.
FIG. 3 is a schematic diagram showing the correspondence between pointer data and forging data blocks when the forgings are numbered;
FIG. 4 is a schematic view of the new workpiece pointer moving downward;
FIGS. 5-6 are diagrams illustrating quality data binding to a workpiece number and pointer moving down during data binding;
7-8 are schematic diagrams showing pointer clearing, throwing workpiece data, and throwing identification of throwing workpieces during throwing trace;
fig. 9 is a schematic diagram showing product quality data collected during finished product dump.
Detailed Description
The invention is described in further detail below with reference to the figures and specific examples. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
According to the full-flow production process of forging the aluminum alloy wheel, the lower line position and the upper line position of a semi-finished product are counted, and a code carving station and a code reading station are arranged at the lower line position and the upper line position; when the workpiece is in a heated hot forging state, data information is bound for the workpiece in a virtual coding mode, and therefore data of the whole-process machining technological parameters of the workpiece are recorded.
As shown in fig. 1, the off-line position includes a sawing process completion position, a punching process completion position, and a turning process completion position. And respectively arranging corresponding code engraving machines at the positions, such as a laser code engraving machine, and engraving a unique identification code, such as a two-dimensional code identification, on the surface of the workpiece.
It should be noted that, after the sawing process is offline, the data record of the production process is conveniently stored, so that the code is printed at the primary position of the production process, namely the completion position of the sawing process, and the code is used as the unique identification code of the whole production process. Since the workpiece may have a stock with the forging stock offline as a line side library after the punching process, the workpiece surface is marked with a unique identifier after the punching process. In addition, after the turning unit of the forging stock is used for processing the inner circle and the outer circle, the two-dimensional code mark on the surface of the workpiece can be processed, so that the workpiece, namely the wheel, needs to be engraved again after the turning is finished.
The on-line position of the working procedure comprises a position before a heating furnace heats a cast rod working procedure, a position before a solid solution working procedure, a position before a turning working procedure, a position before a barreling unit working procedure, a position before a milling working procedure and a position before a polishing unit working procedure. At these positions, corresponding code readers, such as two-dimensional code readers, are respectively arranged to scan and read the two-dimensional codes on the surface of the workpiece, so as to obtain workpiece information.
In the invention, the code is read by the code reader before the workpiece is on line in the cast rod heating furnace, so that the unique identifier of the workpiece is obtained for the first time; and (3) tracing by a code reader before the solid solution process (solid solution furnace) is carried out, so that the binding of the solid solution process and the aging process parameters of the workpiece is completed. Even if workpieces are subjected to mixed line production, order insertion, order supplement and the like, the system can read the quality data of the wheel in the rotary swaging area through the code reader.
After solid solution and aging treatment, the forging stock forms a finished forging stock, and the possibility of entering the warehouse by the branch line also exists as the finished forging stock sold separately, so that code reading equipment is added on the branch line after air cooling for counting the number of the products entering the warehouse and the quality data of each off-line forging stock.
Before the forging stock is turned and on-line, the code needs to be read again to distinguish different forging stock numbers. The workpiece is always off-line or on-line in the subsequent circulation process, and the two-dimensional code marked on the workpiece again after turning is used, the code reader is respectively arranged at the position before the barreling unit procedure, the position before the milling procedure and the position before the polishing unit procedure, and the unique identification code is read, so that the wheel can be always traced back in the subsequent processing and circulation processes, including the postprocessing procedures of barreling, milling, chamfering, polishing, cleaning, packaging, warehousing and the like. After the production and processing are finished, a finished product code is printed on a finished product and is associated with the unique identification code for storage, so that the single piece tracing after the product circulation is realized.
Fig. 2 is a schematic diagram of a production flow of a wheel in a rotary forging processing area and a forge piece data acquisition process. As shown in FIG. 2, at the beginning of production, after the aluminum bar is read and on-line, the information of the warehousing and ex-warehouse dates, the manufacturer number, the furnace number and other raw material information are recorded. After the saw is off-line, a workpiece unique ID is bound for the saw by the control system and associated with the raw material information. When the forge piece sequentially passes through each forming procedure, the processing data of each procedure are sequentially bound, and the pointer continuously moves downwards; if the material throwing occurs in the material circulation process, the machining stations and the quality data of the finished workpieces are directly put into a quality database, and the material throwing marks are made for analyzing the material throwing reasons.
And after the workpiece finishes all processing flows of the rotary forging area, storing the quality data of the finished product into a quality database, sending the ID of the workpiece to a laser marking machine, and marking a two-dimensional code mark on the surface of the workpiece.
After the wire is cut off and before the solid solution process, the workpiece is bound with the unique ID through the production control system to record the processing data of each process, the control system adopts a virtual code tracing program to realize, the virtual code tracing program comprises a forge piece numbering module, a data binding module, a material throwing tracing module and a finished product information dumping module, and the modules respectively have an initialization coding function, an intermediate data binding function, a function of dumping the material throwing information to a quality database and a function of dumping the finished product information to the quality database.
The sawing machine serves as the first equipment of the whole automatic production line for forging the aluminum wheels, the coding of the forge piece starts from the beginning, when a signal of the discharge of the sawing machine is received, the forge piece numbering module is triggered, the discharge information of the sawing machine is bound with the workpiece while the coding is given to the forge piece, a pointer of the forge piece is established in a PLC control system for the forge piece, the pointer points to an information data block of the forge piece, as shown in FIG. 3, the upper left diagram in FIG. 3 shows the pointer data block, the upper right diagram shows a picture after the information data block is folded, the lower left diagram shows a picture after the information data block is unfolded, and the prefix of the name in the lower left diagram is the line number in the upper right diagram.
Wherein, the initial value in the pointer data block represents the work order number of the forging forming area, No. 1 is No. 1 process; the actual value is the name of the pointer corresponding to the current process, that is, the workpiece corresponding to the pointer No. 1 is currently in the first process of the forging area, and the pointer points to the information DATA block DATA1, where DATA1 includes the serial number of the forging and the corresponding process and quality DATA such as forming temperature, robot transit time, press striking force, and the like.
And moving the pointer No. 1 downwards through the data binding module along with the transfer of the sawing machine blanking flow to the next procedure, and sequentially analogizing through the procedures of No _2 and No _ 3. When the saw finishes discharging after cutting again, the forging number module generates pointer No. 2, which points to DATA2 of the information DATA block, as shown in fig. 4.
Based on the virtual code encoding function established by the pointers and the indirect addressing function, the pointers can only correspond to the information data block of the forge piece along with the increase of the discharge quantity of the sawing machine, and therefore the operation is repeated without disorder.
In the forming process of the workpiece after being discharged from the sawing machine, the workpiece sequentially passes through a cast rod heating furnace, a forging press, a punching machine and the process of transferring materials of robots at all stations, and the material codes of all the processes correspond to the technological parameters to carry out data binding. Specifically, the forging area is divided into a plurality of stations, and each workpiece is taken as a finished product and is off-line only if all processes are needed, so that the data block pointed by the current pointer is bound by processing information each time by using the characteristics of a circular queue pointer, and a data binding module is triggered by each action signal of equipment on the basis of equipment interconnection and intercommunication realized by an FCS (data processing system).
Taking the front temperature measurement of the press as an example, when the robot sends a temperature measurement point signal before pre-forging to the master controller, the data binding module is triggered, the measured temperature, the robot carrying time and the forge piece of the current station are bound, the corresponding address is written in, the original pointer moves downwards after the binding is finished, and the next workpiece is bound again after the process, so that the process is repeated, as shown in fig. 5-6.
In the production process of a forging area, the material throwing process caused by reasons such as insufficient forming temperature of workpieces, overtime discharge waiting of a robot, equipment failure and the like occurs at all times, and the design of the material throwing module is very necessary for ensuring the accuracy of workpiece numbering. When the phenomenon occurs, the system automatically executes a material throwing tracing program, triggers a material throwing tracing module, dumps a data block pointed by a pointer of a current work sequence number into a database material throwing record called by a quality database, as shown in fig. 2, the data comprises a forging number of a forging, a production date and processing data of a station before material throwing, the data can be used for analyzing the reason of material throwing and serve as the basis of process optimization, and the work pointer is cleared and a material throwing mark is marked when the material throwing is completed, as shown in fig. 7-8.
When the workpieces finish all processing flows of the rotary swaging area, and the robot puts the workpieces into a discharging roller way, a finished product information dump module is triggered, as shown in fig. 2, the serial numbers of the forgings and all data bound with the serial numbers are put into a quality database called by OPC, as shown in fig. 9, and meanwhile, corresponding pointers are emptied to prepare for binding of the next workpiece.
The method takes the production line of the forged aluminum alloy wheel as a target object, utilizes code carving and code reading mechanisms of different processes to open the tracing bottleneck between the processes by analyzing the technological processes of the production line of the forged aluminum alloy wheel, realizes the digital acquisition and integration of each single product in the material batch, production equipment of each process, key technological parameters, quality inspection results of each pass, production accountants, storage locations and intermediate logistics processes related to the whole production process, and realizes the automatic acquisition of single and whole-process quality data of the production line of the forged aluminum alloy wheel for the first time.
In addition, aiming at the characteristic that the aluminum wheel rotary forging area is machined one piece in one pass, a virtual code tracing program is utilized, and a forge piece numbering module, a data binding module, a material throwing tracing module and a finished product information dumping binding module are designed by the program through modular programming, so that the traceability of the aluminum wheel rotary forging hot machining area is realized.
The foregoing is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, various modifications and decorations can be made without departing from the principle of the present invention, and these modifications and decorations should also be regarded as the protection scope of the present invention.
Claims (6)
1. A single piece tracing data forming method for a forging aluminum alloy wheel production line is characterized by comprising the following steps:
arranging a code engraving machine on a code engraving station at the off-line position of the process so as to form a front and back consistent unique identification code on the off-line workpiece to be coded through laser coding;
arranging a code reader on a code reading station of a process on-line position, reading a unique identification code on a coded workpiece to be on-line, and associating and storing the unique identification code and the tracing data;
after the workpiece is sawed and offline and before spinning and offline, automatically triggering a forge piece numbering module and a data binding module at preset positions to carry out ID numbering on the workpiece in a virtual coding mode, and associating the ID numbering with a unique identification code and binding with tracing data; when the workpiece is spun off-line, a finished product information dump module is automatically triggered, and the workpiece number and the bound data are placed into a quality database called by OPC.
2. The method for forming single piece traceability data of a wrought aluminum alloy wheel production line of claim 1, wherein said process offline positions comprise a sawing process completion position, a punching process completion position, and a lathing process completion position.
3. The method for forming single-piece traceability data of a forged aluminum alloy wheel production line according to claim 1, wherein the on-line positions comprise a position before a heating furnace rod-casting process, a position before a solution process, a position before a turning process, a position before a barrel-polishing unit process, a position before a milling process, and a position before a polishing unit process.
4. The single piece tracing data forming method of the forged aluminum alloy wheel production line according to claim 1, wherein if material throwing occurs in the production process, the material throwing tracing module is automatically triggered to directly place the finished processing stations and quality data of the workpiece into an OPC-called quality database and make material throwing marks for analyzing the reason of material throwing.
5. The method for forming the single-piece tracing data of the forged aluminum alloy wheel production line according to claim 4, wherein the material throwing data in the quality database comprises post-heating furnace material throwing data, post-forging material throwing data and post-rotation material throwing data, and the post-heating furnace material throwing data comprises forge piece number, production date, material throwing time and discharge temperature; the post-forging material throwing data comprise forging press type process parameters including pre-forging temperature, impact force and post-finish forging temperature; and the spinning material throwing data comprises spinning process parameters including spinning temperature, spindle rotating speed and feed ratio.
6. The method for forming the single-piece tracing data of the forged aluminum alloy wheel production line according to claim 1, wherein after the workpiece is spun, the control system sends the ID number of the workpiece to a code carving machine at the offline position of the next process, and the code carving machine at the offline position carves the unique identification code on the surface of the workpiece after the spinning is finished.
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN111580452A (en) * | 2020-04-30 | 2020-08-25 | 北京机电研究所有限公司 | Method for producing virtual identification of forge piece suitable for thermal deformation process |
| CN112712607A (en) * | 2020-12-31 | 2021-04-27 | 桂林福达重工锻造有限公司 | Forging quality tracing method |
| CN113393253A (en) * | 2021-07-09 | 2021-09-14 | 中车青岛四方机车车辆股份有限公司 | Digitalized information tracing method and system for locomotive monitoring |
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